Different Types of Dry Process for Denim Washing

Posted by Firoz Kabir on Sunday, December 15, 2013 0

Dry process in case of denim washing is now very common, buyers frequently ask for it because of new trend of fashion. To create an old-vintage look on denim pants, jackets or trousers different types of dry processes apply before basic washing. The common dry processes are mentioned as below.

  • HAND BRUSH
  • WHISKER
  • 3D WHISKER
  • CRINKLE
  • 3D WRINKLE
  • CHEVRON
  • PATCH GRINDING
  • HEM GRINDING
  • TACKING
  • NICKING
  • PP SPRAY
  • HIGHLIGHTING
  • RESIN
  • CURING

PP(KMnO4) spray

Potassium permanganate spray is done on jeans to take a bright effect on sand blast area. One important thing about the potassium permanganate spray is, this is usually a sporting process to increase the effect of sand blast. Potassium permanganate solution is sprayed on the blasted area of jeans garment with the help of a normal spray gun. This potassium permanganate spray appears pink on the garment when fresh and turns to muddy brown on drying. The garment is hanged in open to dry after potassium permanganate spray and when the potassium permanganate turns its colors completely then it is considered to ready for the next process.

It is always followed by neutralization process. Sodium Meta bi-sulphate is most commonly used neutralizer. A number of products are available in the market for the neutralization process like sodium meta bi-sulphate selected on the bases of effect required on blasted area.

Sand Blast

Sand blasting is the process of scrubbing off the garment by blowing high speed air mixed with very fine particles of sand. This is a very successful and most widely used process for fashion articles. When the surface area of the garment is blasted, white cotton appears beneath the blasted area and the affected appears are very similar to the worn out jeans.
Sand blast provides a very uniform result which cannot be achieved with its alternates. Its specialty is the merging effect that is blended with such a beauty that it has no difference with natural effects.




Destroy & Grinding

distressing or grinding is the process of destruction on jeans form edges of the garment. When we look at old jeans we find it destroyed from the edges of pockets, fly area, belt and bottom. This used effect can be created on jeans by grinding and is of key importance in high fashion garments.
Grinding is done of garments by pen type of stone tools. It can be done in mid of the wash process. In many workshops it is done before any wash process as a first process after stitching. Stone tools similar to grinders used in wood and stone industry are utilized to work on garments with a few amendments to their design.

Tacking/Tagging

Tacking or more commonly tag pinning is a very in fashion style in denim garment in these days. In this process the effect is created by swift tag machines with the help of plastic or nylon tag pins in rigid form of garment to get contrast.
Usually tag pin machines are used to attach tag pins to garment. The procedure is very simple and proceeds as; garment is folded on required area and tacked through folds.


Hand Sand

Sand ballasting with paper, commonly known as scrapping is the most widely used process for creating the blasting effect. It is usually done by mounting the garment on rubber balloons. After mounting the garment air balloon is filled with air to expose the area to operate. It is important to fill the pressure.
Hand sand is the step which is generally being done in rigid form of garments to get the distressed look. Locations can be front thigh & back seat or its can be overall / global application as per the Standard. Emery paper is being used to scrape the garments in particular placement & design. Emery paper comes in different number generally start from 40 till 600 and above , higher the number finer the emery paper, lower the coarseness of the paper. In the garment industry from 220 , 320 & 400 number papers are most popular & widely used.

Ripping, Pilling & Cuts

These effects are created where to copy a real worn out and roughly used jeans. These are created by using sharp edge tool line clippers, blades and knives.
Warp yarn is cut by a knife and the white weft yarn is left in place to create a beautiful worn out effect. The garment with cuts is then washed in washers to reveal the white the white thread. This makes the horizontal white lines of weft and if some dye is added to wash bath it will add more beauty to the garment. The secret is the cuts are always kept weft wise i.e. in horizontal to the garment. This will keep the weft in place and warp will be removed in the washing process. If it lets the warp is cut then the only thing you get after wash is a big hole.

3D Whiskers

Resin ( Formaldehyde free ) being used for achieving 3D effect ( 3 Dimensional ), Rigid Look etc. This process can be done by spraying or dipping the garments in to Resin, Catalyst, Silicone & PU solution in right combination according to the fabric strength & desired effect needed.
After application of resin solution in right proportion, make manual designing as needed on the thigh, hip & back knee area to get 3Dimentional effect. After making it , it should be manually dried with hot press or hair dryer & then must
be cured in oven at right temperature, time as mentioned in resin product manual.

About the Author

Md. Firoz Kabir(M.Sc in Textile Engineering)

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