USE OF LASER TECHNOLOGY
It is a computer controlled process for denim fading. This technique enables patterns to be created such as lines and/or dots, images, text or even pictures. In one version of this concept, a mask is used to give the desired shape that is to be applied on the fabric. The laser projects through a lens system, which expands the beam. This beam is passed through the shaped mask that comprises an aperture of the desired shape and is then deflected by a mirror to strike the textile substrate. The duration of exposure determines the final effect on the fabric.
The novelty of this system is that
• It is water free fading of denim.
• It is an ecological and economical process.
• It can create local abrasion and fabric breaks, used look effect, moustache with excellent reproducibility and higher productivity.
• Being an automatic system, chances of human error are slim.
• The design is electronically translated on the fabric, thus avoiding the need for photolites of serigraphy cleaning.
The machine is very simple and compact, therefore requires very low maintenance and cleaning, extremely safe and reliable.
OZONE FADING:
By using this technique, the garment can be bleached. Bleaching of denim garment is done in washing machine with ozone dissolved in water. Denim garments can also be bleached or faded by using ozone gas in closed chamber.The advantages associated with this process are:
- Colour removal is possible without losing strength.
- This method is very simple and environmentally friendly because after laundering, ozonized water can easily be deozonized by UV radiation.
WATERJET FADING:
Hydrojet treatment has been developed for patterning and/or enhancing the surface finish, texture, durability, and other characteristics of denim garment. Hydroject treatment generally involves exposing one or both surfaces of the garment through hydrojet
nozzles.
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The degree of colour washout, clarity of patterns, and softness of the resulting fabric are related to the type of dye in the fabric and the amount and manner of fluid impact energy applied to the fabric. Particularly good results are obtained with blue indigo dyed denim.
As this process is not involved with any chemical, it is pollution free. By using water recycling system, the technique can be used as economical and environmental friendly denim processing. Color washout of dye in the striped areas produces a faded effect without blurring, loss of fabric strength or durability, or excessive warp shrinkage.
SPRAY TECHNIQUES
This technique is based on spraying the chemicals or pigments to get different effect on the garments. This can be done by using robotic spraying gun or by manual spray and followed by curing of the garment.
- It a water free process therefore zero effluent discharge.
- Less time consuming
- Different designs are possible - Easy to use
- No adverse effect on fabric strength.
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SINGLE BATH STONE WASHING AND TINTING TECHNIQUE
Tinting of denim garment is usually done after the stone wash process. In this, garment has been lightly coloured in order to give the final denim appearance a slight shift. This is not true over dyeing but merely gives the impression of a change in overall colour of the fabric. This process consumes large quantity of water and chemical. To make this process economical and ecologically friendly, some novel colour based enzymes have been introduced in the market. By using this new technique, tinting and stone washing effect can be achieved in a single bath.
- Less process time to achieve tinted look.
- No extra chemical required therefore making process more economical.
- Less water consumption.
- Less energy consumption.
- Less chance of patches or unevenness Alternate of pumice stone
To overcome the shortcoming of pumice stones, synthetic stones have been developed.
These are made of abrasive material such as silicate, plastic, rubber or Portland cement.
The advantages of using such type of products are:
- All major problems associated with the use of volcanic grade pumice stone can be overcome.
- Durability of such product is much higher and can be used repeatedly from 50-300 cycle depending upon type of synthetic stone.
- Reproducibility of washing is manageable.
- As stone discharge of the process is very less, therefore making process is economical and ecological.
- Less damage of machine and garments.
WASTE WATER SOLUTION
As the municipal discharge criteria are restrictive and cost of water high, producers will need to reuse the waste water. Many techniques are readily available for a processor to treat waste water. The basic limitation of a garment processor is the higher installation cost associated with such technique.
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T R I M M I N G
TRIMMING:
After washing, broken threads are removed by trimming. In U S Apparel manual trimming is carried out which is mostly done by women.
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B U T T O N I N G
BUTTONING
Pressing is as important as any other process in garment development. To finish the high quality product that has come through all the stages from cutting, sewing and wet process; no expense has been spared to equip this process by using the latest technology available in the international market.
We have machines from Pessani (Italy) for laser guided accurate buttoning process.
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