Recycled Cotton | Benefits and Challenges of Cotton Recycling

In the sustainability context, recycle cotton is a popular topic with high interest of manufacturers, brands and retailers. For the entire supply chain of textile, recycled cotton can play a vital role to fulfill the goal of sustainability. Cotton is the most popular and comfortable fiber that is used around 56% of total fiber uses across the world. It has reliable quality performance as it is versatile, breathable and very comfortable to wear off.

Conventional cotton harvesting involves use of large scale pesticides,, herbicides and fertilizers that cause to harm the whole environment. In addition, cotton harvesting and processing requires huge amount of water that is left as wastewater cause harm for aquatic lives. 

For sustainable cotton harvesting there are some concept already exists like Organic Cotton( GOTS of OCS Certified cotton), Fairtrade cotton and Better Cotton (BCI). Besides the organic, Fairtrade and BCI cotton the new concept is recycled or regenerated cotton. It is not that much new as it was initiated in the beginning of 21st century and still continues with more and more research. 

Recycled cotton prevents unnecessary wastage and can be a more sustainable alternative to disposal. It can come from secondhand clothing or from textile waste or leftovers which are eventually spun into new yarns and then fabric. It is also commonly referred to as regenerated cotton or reclaimed cotton. Basically the sources of cotton recycling are two types: Pre-consumer cotton and Post-consumer cotton.

 

Pre-consumer cotton: Includes wastage in yarn production, fabric, garments cutting room or so on that are not used for any clothing

Post-consumer Cotton: Includes used garments, upholstery, towels, household items.

In fact, the largest share of the source is pre-consumer waste.

Process of Cotton Recycling: It is all together mechanical recycling method. The wastes are collected and then sorted into colors as they are already dyed. After sorting, the fabrics or other kind of pre consumer wastages are run through  a machine that shreds them into yarn and further into raw fiber. This is a critical process and puts a great deal of strain on the fiber thus it becomes weaken and entangled during shredding.  

The raw fibers is then spun into yarns for reuse in the other products. Since the quality will not be the same as original cotton thus it is spun with other fibers as blend. Most common blend happens with virgin cotton and polyester. The fiber length and uniformity will be impacted which leads to limit of the end use application.

Use of Recycled Cotton:
It is frequently blended with some other fibers to make fabric or other textiles, creating sustainable environmental friendly product. Recycled cotton can be used in industrial settings for polishing. It is popular to be made high quality paper with recycled cotton. The papers used for high command official purposes are mostly made of recycled cotton. It is also used for seat stuffing and automotive insulation in the industry of automobiles. Now Denim fabric mills are using recycle poly as a new concept under sustainable umbrella for the high interest of Brands and Retailers.

Benefits of Cotton Recycling:

• It can be used for insulation, rags of stuffing where it appears with new life cycle.
• Recycling process prevent unwanted wastage that can divert many products from landfills. According to the Council for Textile Recycling, annual textile waste is estimated about 25 billion pounds.
• Since it is already colored so after recycling further coloring is not required
• The amount of energy, water and dyestuff use is reduced since recycled cotton yarns most commonly are sourced from pre-consumer textiles that are sorted by color.
• Reduce the emission of CO2 and other fossil fuel.

Challenges of Cotton Recycling:

• Since Cotton becomes weaken during recycling it must be blended with other fibers to be produced new yarn with required strength and durability and therefore it can not recycled further.
• Any amount of recycled product will impact the yarn and fabric properties such as length, strength, evenness and uniformity.
• Cost is generally higher than the standard cotton processing
• Test results are not that much good.
• In a product not more than 30% recycled cotton can be used.
• Consumer interest to buy recycled cotton product with higher price is less.

After all, Cotton is a fiber that is naturally biodegradable, based on a study of North Carlina State University of USA, more that 75% cotton decomposed in soil within 273 days of dumping. So it is naturally a sustainable fiber all together. 

You May Also Like:

• Better Cotton Initiative (BCI) | Sustainable Cotton Production Standard
• Global Organic Textile Standard (GOTS) | Certification Steps and Requirements
• Organic Content Standard (OCS) Certification | OCS 100 Standard
• EcoVero™ Fiber The Alternative to Viscose is a Sustainable Innovation 
• Nano Bubble Technology Reduces 95% Water in Denim Washing
• Basic Procedures of Denim Fabric Srinkage and Shade Checking
• Different Types of Enzymes That are Used in Denim Washing
• Different Types of Dry Process for Denim Washing
• Sustainable Denim Washing 

Recycled Cotton | Benefits and Challenges of Cotton Recycling

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In the sustainability context, recycle cotton is a popular topic with high interest of manufacturers, brands and retailers. For the entire supply chain of textile, recycled cotton can play a vital role to fulfill the goal of sustainability. Cotton is the most popular and comfortable fiber that is used around 56% of total fiber uses across the world. It has reliable quality performance as it is versatile, breathable and very comfortable to wear off.

Conventional cotton harvesting involves use of large scale pesticides,, herbicides and fertilizers that cause to harm the whole environment. In addition, cotton harvesting and processing requires huge amount of water that is left as wastewater cause harm for aquatic lives. 

For sustainable cotton harvesting there are some concept already exists like Organic Cotton( GOTS of OCS Certified cotton), Fairtrade cotton and Better Cotton (BCI). Besides the organic, Fairtrade and BCI cotton the new concept is recycled or regenerated cotton. It is not that much new as it was initiated in the beginning of 21st century and still continues with more and more research. 

Recycled cotton prevents unnecessary wastage and can be a more sustainable alternative to disposal. It can come from secondhand clothing or from textile waste or leftovers which are eventually spun into new yarns and then fabric. It is also commonly referred to as regenerated cotton or reclaimed cotton. Basically the sources of cotton recycling are two types: Pre-consumer cotton and Post-consumer cotton.

 

Pre-consumer cotton: Includes wastage in yarn production, fabric, garments cutting room or so on that are not used for any clothing

Post-consumer Cotton: Includes used garments, upholstery, towels, household items.

In fact, the largest share of the source is pre-consumer waste.

Process of Cotton Recycling: It is all together mechanical recycling method. The wastes are collected and then sorted into colors as they are already dyed. After sorting, the fabrics or other kind of pre consumer wastages are run through  a machine that shreds them into yarn and further into raw fiber. This is a critical process and puts a great deal of strain on the fiber thus it becomes weaken and entangled during shredding.  

The raw fibers is then spun into yarns for reuse in the other products. Since the quality will not be the same as original cotton thus it is spun with other fibers as blend. Most common blend happens with virgin cotton and polyester. The fiber length and uniformity will be impacted which leads to limit of the end use application.

Use of Recycled Cotton:
It is frequently blended with some other fibers to make fabric or other textiles, creating sustainable environmental friendly product. Recycled cotton can be used in industrial settings for polishing. It is popular to be made high quality paper with recycled cotton. The papers used for high command official purposes are mostly made of recycled cotton. It is also used for seat stuffing and automotive insulation in the industry of automobiles. Now Denim fabric mills are using recycle poly as a new concept under sustainable umbrella for the high interest of Brands and Retailers.

Benefits of Cotton Recycling:

• It can be used for insulation, rags of stuffing where it appears with new life cycle.
• Recycling process prevent unwanted wastage that can divert many products from landfills. According to the Council for Textile Recycling, annual textile waste is estimated about 25 billion pounds.
• Since it is already colored so after recycling further coloring is not required
• The amount of energy, water and dyestuff use is reduced since recycled cotton yarns most commonly are sourced from pre-consumer textiles that are sorted by color.
• Reduce the emission of CO2 and other fossil fuel.

Challenges of Cotton Recycling:

• Since Cotton becomes weaken during recycling it must be blended with other fibers to be produced new yarn with required strength and durability and therefore it can not recycled further.
• Any amount of recycled product will impact the yarn and fabric properties such as length, strength, evenness and uniformity.
• Cost is generally higher than the standard cotton processing
• Test results are not that much good.
• In a product not more than 30% recycled cotton can be used.
• Consumer interest to buy recycled cotton product with higher price is less.

After all, Cotton is a fiber that is naturally biodegradable, based on a study of North Carlina State University of USA, more that 75% cotton decomposed in soil within 273 days of dumping. So it is naturally a sustainable fiber all together. 

You May Also Like:

• Better Cotton Initiative (BCI) | Sustainable Cotton Production Standard
• Global Organic Textile Standard (GOTS) | Certification Steps and Requirements
• Organic Content Standard (OCS) Certification | OCS 100 Standard
• EcoVero™ Fiber The Alternative to Viscose is a Sustainable Innovation 
• Nano Bubble Technology Reduces 95% Water in Denim Washing
• Basic Procedures of Denim Fabric Srinkage and Shade Checking
• Different Types of Enzymes That are Used in Denim Washing
• Different Types of Dry Process for Denim Washing
• Sustainable Denim Washing 

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Better Cotton Initiative (BCI) | Sustainable Cotton Production Standard

Better Cotton Initiative (BCI) is a non-profit organizations aims to make global cotton production better for the people who produce it, better for the environment and better for the sectors future. Goal of BCI is aligned to the goals of SDGs as it embraces the SDGs and is inspired to be part of a global community working to make the world a better place. The Better Cotton Standard System covers the main three elements of sustainability : Environmental, social and economic. Each of the elements from the principles and criteria to the monitoring mechanisms which show results and impact - work together to support the better cotton standard system.

BCI standard was initiated in the year 2005 and was recognized by GAP INC, Organic Exchange(Textile Exchange), H&M, ICCO, IFAP, IFC, IKEA, Oxfam, PAN UK and WWF.

BCI is the largest cotton sustainability programme in the globe. It has 1.3 millions licensed farmers in 21 countries to whom BCI and its partners provide training on more sustainable agricultural practices.








BCI supports the farmers to improve the poor environmental management and working conditions to produce cotton.Licensed BCI Farmers produce cotton in a way that care for the environment, minimizing the negative effects of fertilizers and pesticides and caring for water, soil health and natural habitats. BCI farmers also commit to decent work principles - conditions that support workers safety and well being.

BCI Farmers produced 3.3 million metric tonnes of BCI cotton in the 2016-17 which is enough to make 2.5 billion pairs of Jeans. Currently Better cotton accounts for 14% of global cotton production which is included the three BCI recognized equivalent Standards: CmiA(Africa), MyBMP(Australia) and ABR(Brazil).

SO far BCI has 1197 members spanning the cotton supply chain, 85 brands and retailers, 1039 suppliers and manufacturers, 32 producers organizations, 31 civil society member and 12 associate members.

Besides BCI, organic (GOTS & OCS) Fairtrade, myBMP(Australia), ABR(Brazil), Aid by Trade Foundation and some others work towards ensuring sustainable cotton production.

Principles and Criteria:

Betters cotton standard works based on seven important principles what their licensed farmers responsible to do:

• minimize the harmful impact of crop protection practices
• promote water stewardship
• care for the health of the soil
• enhance biodiversity and use land responsibly
• care for and preserve fibre quality
• promote decent work
• operate an effective management system

Assurance Programme:

The Better Cotton Assurance Programme is a key component of the Better Cotton Standard System. It involves farmers participating in a continuous cycle of learning and improvement, and is the central mechanism for assessing whether farmers can grow and sell Better Cotton.

Chain of Custody(CoC):

The Better Cotton Chain of Custody (CoC) is the key framework that connects demand with supply of Better Cotton and helps to incentivize cotton farmers to adopt more sustainable practices.

The CoC refers to the chronological documentation, paper trail and electronic evidence that relates to the movement of Better Cotton products through the supply chain. This ensures the volume of Better Cotton claimed by BCI Retailer and Brand Members does not exceed the volume of Better Cotton produced by licensed BCI Farmers in any given time period, accounting for conversion rates.

Better Cotton Claims Framework:

It provides support to BCI members to make credible and positive claims about Better Cotton. This Claims Framework is is governed by the BCI Code of Practice, BCI Terms of Membership, and BCI Monitoring Protocol.

Outcome and Impact:

BCI standard is stringent to their commitments to measuring sustainability improvements everywhere of the cotton production. It has a aim of achieving 30% cotton will be produced in the way of BCI whereas currently it upholds 14% of the total amount produced. BCI standard works based on result indicator date which measure quantitatively differences between incensed BCI Farmers and non BCI Farmers in the same Geographical area.



Funding:
BCI Organization receives funding from three sources: earned income for services delivered; grants and donations from private and public funders; and volume-based fees and funding from brands. \

You May Also Like:

• Global Organic Textile Standard (GOTS) | Certification Steps and Requirements 
• Organic Content Standard (OCS) Certification | OCS 100 Standard

Better Cotton Initiative (BCI) | Sustainable Cotton Production Standard

No comments

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Better Cotton Initiative (BCI) is a non-profit organizations aims to make global cotton production better for the people who produce it, better for the environment and better for the sectors future. Goal of BCI is aligned to the goals of SDGs as it embraces the SDGs and is inspired to be part of a global community working to make the world a better place. The Better Cotton Standard System covers the main three elements of sustainability : Environmental, social and economic. Each of the elements from the principles and criteria to the monitoring mechanisms which show results and impact - work together to support the better cotton standard system.

BCI standard was initiated in the year 2005 and was recognized by GAP INC, Organic Exchange(Textile Exchange), H&M, ICCO, IFAP, IFC, IKEA, Oxfam, PAN UK and WWF.

BCI is the largest cotton sustainability programme in the globe. It has 1.3 millions licensed farmers in 21 countries to whom BCI and its partners provide training on more sustainable agricultural practices.








BCI supports the farmers to improve the poor environmental management and working conditions to produce cotton.Licensed BCI Farmers produce cotton in a way that care for the environment, minimizing the negative effects of fertilizers and pesticides and caring for water, soil health and natural habitats. BCI farmers also commit to decent work principles - conditions that support workers safety and well being.

BCI Farmers produced 3.3 million metric tonnes of BCI cotton in the 2016-17 which is enough to make 2.5 billion pairs of Jeans. Currently Better cotton accounts for 14% of global cotton production which is included the three BCI recognized equivalent Standards: CmiA(Africa), MyBMP(Australia) and ABR(Brazil).

SO far BCI has 1197 members spanning the cotton supply chain, 85 brands and retailers, 1039 suppliers and manufacturers, 32 producers organizations, 31 civil society member and 12 associate members.

Besides BCI, organic (GOTS & OCS) Fairtrade, myBMP(Australia), ABR(Brazil), Aid by Trade Foundation and some others work towards ensuring sustainable cotton production.

Principles and Criteria:

Betters cotton standard works based on seven important principles what their licensed farmers responsible to do:

• minimize the harmful impact of crop protection practices
• promote water stewardship
• care for the health of the soil
• enhance biodiversity and use land responsibly
• care for and preserve fibre quality
• promote decent work
• operate an effective management system

Assurance Programme:

The Better Cotton Assurance Programme is a key component of the Better Cotton Standard System. It involves farmers participating in a continuous cycle of learning and improvement, and is the central mechanism for assessing whether farmers can grow and sell Better Cotton.

Chain of Custody(CoC):

The Better Cotton Chain of Custody (CoC) is the key framework that connects demand with supply of Better Cotton and helps to incentivize cotton farmers to adopt more sustainable practices.

The CoC refers to the chronological documentation, paper trail and electronic evidence that relates to the movement of Better Cotton products through the supply chain. This ensures the volume of Better Cotton claimed by BCI Retailer and Brand Members does not exceed the volume of Better Cotton produced by licensed BCI Farmers in any given time period, accounting for conversion rates.

Better Cotton Claims Framework:

It provides support to BCI members to make credible and positive claims about Better Cotton. This Claims Framework is is governed by the BCI Code of Practice, BCI Terms of Membership, and BCI Monitoring Protocol.

Outcome and Impact:

BCI standard is stringent to their commitments to measuring sustainability improvements everywhere of the cotton production. It has a aim of achieving 30% cotton will be produced in the way of BCI whereas currently it upholds 14% of the total amount produced. BCI standard works based on result indicator date which measure quantitatively differences between incensed BCI Farmers and non BCI Farmers in the same Geographical area.



Funding:
BCI Organization receives funding from three sources: earned income for services delivered; grants and donations from private and public funders; and volume-based fees and funding from brands. \

You May Also Like:

• Global Organic Textile Standard (GOTS) | Certification Steps and Requirements 
• Organic Content Standard (OCS) Certification | OCS 100 Standard

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Short Staple Spinning Flow Chart | Carded and Combed Yarn Manufacturing Processes

 In short staple spinning three types of spinning systems are available in a wide range. In ring spinning carded and combed yarn are produced according to the requirement of yarn quality, price as well as time consumption. Carded yarns are highly used for medium quality and average count, used for all kinds of fabrics.

Flow Chart for Carded Yarn Manufacturing Process:

Fiber → Blow Room   →     Lap

↓

                Lap   →        Carding   →   Card Sliver

↓

Card Sliver →   1st Drawing Frame →   Drawn Sliver

↓

  Drawn Sliver    →     2nd Drawing Frame   → Drawn Sliver

↓

Drawn Sliver →    Simplex   →   Roving

↓

Roving    →   Ring Frame   →   Yarn

↓

Winding

↓

Reeling

↓

Bundling

↓

Bailing

 Comb yarn is very much high quality yarns in comparison with card yarn cause of here more short fiber and naps as well as impurities are removed through the combing action. Superior quality yarns can produce in using combing machine to the machine sequence. In cotton count, higher the number finer the yarns will be. Combed yarns have high count number with best quality in using fabric making.

 

Combed cotton yarn manufacturing process:

Fiber → Blow Room   →     Lap

↓

                Lap   →        Carding   →   Card Sliver

↓

Card Sliver →   Pre-Comb Drawing Frame →   Sliver (Pre-Drawing)

↓

Sliver    →   Lap Former →   Lap

↓

    Lap     →     Comber →       Comb Sliver

↓

Comb Sliver   →     Post-Comb Drawing Frame   → Drawn Sliver (Post-Drawing)

↓

Drawn Sliver →    Simplex   →   Roving

↓

Roving    →   Ring Frame   →   Yarn

↓

Winding

↓

Reeling

↓

Bundling

↓

Bailing

 For high quality fabric making combed yarns are frequently used as to make luxurious garments. Comfort as well as handling appeal is much higher in the case of garments made of combed yarns.

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Short Staple Spinning Flow Chart | Carded and Combed Yarn Manufacturing Processes

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 In short staple spinning three types of spinning systems are available in a wide range. In ring spinning carded and combed yarn are produced according to the requirement of yarn quality, price as well as time consumption. Carded yarns are highly used for medium quality and average count, used for all kinds of fabrics.

Flow Chart for Carded Yarn Manufacturing Process:

Fiber → Blow Room   →     Lap

↓

                Lap   →        Carding   →   Card Sliver

↓

Card Sliver →   1st Drawing Frame →   Drawn Sliver

↓

  Drawn Sliver    →     2nd Drawing Frame   → Drawn Sliver

↓

Drawn Sliver →    Simplex   →   Roving

↓

Roving    →   Ring Frame   →   Yarn

↓

Winding

↓

Reeling

↓

Bundling

↓

Bailing

 Comb yarn is very much high quality yarns in comparison with card yarn cause of here more short fiber and naps as well as impurities are removed through the combing action. Superior quality yarns can produce in using combing machine to the machine sequence. In cotton count, higher the number finer the yarns will be. Combed yarns have high count number with best quality in using fabric making.

 

Combed cotton yarn manufacturing process:

Fiber → Blow Room   →     Lap

↓

                Lap   →        Carding   →   Card Sliver

↓

Card Sliver →   Pre-Comb Drawing Frame →   Sliver (Pre-Drawing)

↓

Sliver    →   Lap Former →   Lap

↓

    Lap     →     Comber →       Comb Sliver

↓

Comb Sliver   →     Post-Comb Drawing Frame   → Drawn Sliver (Post-Drawing)

↓

Drawn Sliver →    Simplex   →   Roving

↓

Roving    →   Ring Frame   →   Yarn

↓

Winding

↓

Reeling

↓

Bundling

↓

Bailing

 For high quality fabric making combed yarns are frequently used as to make luxurious garments. Comfort as well as handling appeal is much higher in the case of garments made of combed yarns.

Remove t

Original text

Contribute a better translation

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Rotor Spinning | Open End (OE) Spinning | Flowchart of Rotor Yarn

Open ended (OE) or break spinning is referred to as rotor spinning where process sequence is less than combed as well as carded yarn. Roving formation in simplex machine is not required to rotor spinning where drawn slivers are fed to the machine directly. Production rate of OE spinning system is higher than ring spinning where coarse yarns are made within a range of 5 to 40 cotton count. Medium to low quality yarns are produced here used for making denim, dungaree, twill, chino as well as any heavy fabric. Local use of rotor yarn is sometimes higher than ring spun yarns. Rotor spinning is much popular in use due to the high production rate, less wastage percentage as well as highly usable in denim to make blue jeans.

OE or Rotor Spinning flow chart is given below:

Fiber/Bale →    Blow Room →     Lap

↓

Lap    →   Carding   →   Sliver (Carded)

↓

Carded Sliver →  1^st Drawing frame   →   Drawn Sliver

↓

Drawn Sliver   →   2^nd Drawing frame →   Drawn Sliver

↓

Drawn Sliver   →   Rotor Spinning   → Rotor Yarn

↓

Winding

↓

Reeling

↓

Bundling

↓

Bailing

Now a day’s chute feed system is very much popular than conventional lap feed system in case of blow room lap feeding.

Rotor Spinning | Open End (OE) Spinning | Flowchart of Rotor Yarn

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Open ended (OE) or break spinning is referred to as rotor spinning where process sequence is less than combed as well as carded yarn. Roving formation in simplex machine is not required to rotor spinning where drawn slivers are fed to the machine directly. Production rate of OE spinning system is higher than ring spinning where coarse yarns are made within a range of 5 to 40 cotton count. Medium to low quality yarns are produced here used for making denim, dungaree, twill, chino as well as any heavy fabric. Local use of rotor yarn is sometimes higher than ring spun yarns. Rotor spinning is much popular in use due to the high production rate, less wastage percentage as well as highly usable in denim to make blue jeans.

OE or Rotor Spinning flow chart is given below:

Fiber/Bale →    Blow Room →     Lap

↓

Lap    →   Carding   →   Sliver (Carded)

↓

Carded Sliver →  1^st Drawing frame   →   Drawn Sliver

↓

Drawn Sliver   →   2^nd Drawing frame →   Drawn Sliver

↓

Drawn Sliver   →   Rotor Spinning   → Rotor Yarn

↓

Winding

↓

Reeling

↓

Bundling

↓

Bailing

Now a day’s chute feed system is very much popular than conventional lap feed system in case of blow room lap feeding.

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Moisture Regain and Moisture Content of Different Fibers

Moisture Regain: It is the ratio between the weight of water with the oven dry weight of the material express in percentage.

Moisture Content: It is the ratio between the weight of water with the total weight of the material express in percentage.

Fiber  -  MR%  -  MC%

Cotton   - 8.5      -  7.34
Jute      -  13.75    -  12.1
Viscose - 11.0    -   9.91
Silk       - 11.0    -   9.91
Wool     - 16.0    -  13.8
Acrylic   - 1.5     -  0
Flax       - 12.4    -  10.4
Hemp    - 12.4   -   10.4
Nylon     - 4.0    -   3.1
Polyester  - 0.4   -  0
Acetate    - 6.0    -  0


Olefin, Polypropylene, Carbon, Graphite, Glass fiber has no Moisture Regain or Moisture Content.

Moisture Regain and Moisture Content of Different Fibers

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Moisture Regain: It is the ratio between the weight of water with the oven dry weight of the material express in percentage.

Moisture Content: It is the ratio between the weight of water with the total weight of the material express in percentage.

Fiber  -  MR%  -  MC%

Cotton   - 8.5      -  7.34
Jute      -  13.75    -  12.1
Viscose - 11.0    -   9.91
Silk       - 11.0    -   9.91
Wool     - 16.0    -  13.8
Acrylic   - 1.5     -  0
Flax       - 12.4    -  10.4
Hemp    - 12.4   -   10.4
Nylon     - 4.0    -   3.1
Polyester  - 0.4   -  0
Acetate    - 6.0    -  0


Olefin, Polypropylene, Carbon, Graphite, Glass fiber has no Moisture Regain or Moisture Content.

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Spandex Fiber | Properties of Lycra | Elastane Fiber

Spandex Fiber

FTC (Federal Trade Commission) Definition-A manufactured fiber in which the fiber forming substance is a long-chain synthetic polymer comprised of at least 85% of a segmented polyurethane. Dupont Company first produced spandex as Lycra in 1959. Lycra is a trade name of spandex fiber was given by "Dupont" The others trade name of spandex is Elastane, Elaspan, Linel, ROICA and ESPA according to the manufacturers. Now Spandex is widely used for producing stretch fabrics such as knit fabrics, denim, twill, canvas, etc.

Available fiber formation

• Spandex Textile Filament Fiber

Raw Materials of Spandex

• Polyurethane
• Natural latex

Properties of Spandex fiber

• Outstanding stretch and recovery.
• Extensibility is maximum 700%
• Stronger, more durable and higher retractive force than rubber
• Lightweight, soft, smooth, supple
• Widely use in garments for comfort and fit.
• Heat-settable — facilitates transforming puckered fabrics into flat fabrics, or flat fabrics into permanent rounded shapes
• Easily Dye-able
• Resistant to deterioration by body oils, perspiration, lotions or detergents
• Abrasion resistant
• Available in fiber diameters ranging from 10 denier to 2500 denier
• Available in clear and opaque lustrous
• Easily sew-able with no needle breakage

End Uses:

• Most of the apparels where requires stretch and fit.

 

Spandex Fiber | Properties of Lycra | Elastane Fiber

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Spandex Fiber

FTC (Federal Trade Commission) Definition-A manufactured fiber in which the fiber forming substance is a long-chain synthetic polymer comprised of at least 85% of a segmented polyurethane. Dupont Company first produced spandex as Lycra in 1959. Lycra is a trade name of spandex fiber was given by "Dupont" The others trade name of spandex is Elastane, Elaspan, Linel, ROICA and ESPA according to the manufacturers. Now Spandex is widely used for producing stretch fabrics such as knit fabrics, denim, twill, canvas, etc.

Available fiber formation

• Spandex Textile Filament Fiber

Raw Materials of Spandex

• Polyurethane
• Natural latex

Properties of Spandex fiber

• Outstanding stretch and recovery.
• Extensibility is maximum 700%
• Stronger, more durable and higher retractive force than rubber
• Lightweight, soft, smooth, supple
• Widely use in garments for comfort and fit.
• Heat-settable — facilitates transforming puckered fabrics into flat fabrics, or flat fabrics into permanent rounded shapes
• Easily Dye-able
• Resistant to deterioration by body oils, perspiration, lotions or detergents
• Abrasion resistant
• Available in fiber diameters ranging from 10 denier to 2500 denier
• Available in clear and opaque lustrous
• Easily sew-able with no needle breakage

End Uses:

• Most of the apparels where requires stretch and fit.

 

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Olefin/Polypropylene fiber | Manufactured fiber Olefin

Olefin or Polypropylene Fiber

FTC (Federal Trade Commission) Definition-A manufactured fiber in which the fiber forming substance is any long-chain synthetic polymer composed of at least 85% by weight of ethylene, propylene, or other olefin units, except amorphous (non-crystalline) polyolefins. Commercially it was first produced by Hercules Incorporated(A chemical manufacturing company).




Raw Materials of Olefin

• Ethylene
• Propylene
• Other olefin units

Available Fiber Formation

• Olefin Staple Fiber
• Olefin Filament Fiber
• Olefin Carpet BCF Filament Fiber
• Olefin Film Fiber
• Polyethylene Fiber

Properties of Olefin Fiber

• Excellent abrasion resistant
• Highly strong
• Outstanding color fastness
• Quick drying
• Low static
• Resistant to deterioration from chemicals, mildew, perspiration, rot and weather
• Thermally bond-able
• Stain and soil resistant
• Sunlight resistant
• Very comfortable
• Very lightweight (This fibers have the lowest specific gravity of all fibers)

End Uses:

• Apparel
• Automotive
• Home Furnishings
• Industrial

Olefin/Polypropylene fiber | Manufactured fiber Olefin

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Olefin or Polypropylene Fiber

FTC (Federal Trade Commission) Definition-A manufactured fiber in which the fiber forming substance is any long-chain synthetic polymer composed of at least 85% by weight of ethylene, propylene, or other olefin units, except amorphous (non-crystalline) polyolefins. Commercially it was first produced by Hercules Incorporated(A chemical manufacturing company).




Raw Materials of Olefin

• Ethylene
• Propylene
• Other olefin units

Available Fiber Formation

• Olefin Staple Fiber
• Olefin Filament Fiber
• Olefin Carpet BCF Filament Fiber
• Olefin Film Fiber
• Polyethylene Fiber

Properties of Olefin Fiber

• Excellent abrasion resistant
• Highly strong
• Outstanding color fastness
• Quick drying
• Low static
• Resistant to deterioration from chemicals, mildew, perspiration, rot and weather
• Thermally bond-able
• Stain and soil resistant
• Sunlight resistant
• Very comfortable
• Very lightweight (This fibers have the lowest specific gravity of all fibers)

End Uses:

• Apparel
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Dip dyeing is becoming more popular in Garments dyeing

Garments Dyeing: Garment dyeing is a process of imparting color materials to fully fashioned garments like as shirts, pants, twill garments, jackets, pullover, T-shirt, Polo shirt, sweaters etc. The garments are usually dyed before finishing with various trimmings or accessories. In textile coloration it is not so far initiated in our country but it is more popular outside our country like as France, Italy, Spain, Germany, Canada, North America, turkey, Israel, Japan, USA, Uk, China etc.

Garment dyeing is an opposition of the conventional method of making garments from previously dyed fabrics. Knitted fabrics, twill weave fabrics and/or other woven fabrics made from cotton yarns are subjected to garment dyeing.  Garments made of cotton material are easy to dye up but besides cotton several other fabrics can be found in whole or partially made of wool, silk, nylon, polyester or acrylic are subjected to garment dyeing.

Dip Dyeing: In garments dyeing, dip dyeing is becoming more popular day by day as the fashion trend and customer demand. Due to cheap and easy process it is as popular to the manufacturers.  It is also as called gradient dyeing. It is the process, the fully fashioned garments are arranged to dip into a dye bath (vessel, bucket, bowl etc) accordingly a pre-determined area or height. This process runs again and again. According to demand, garments are to be soaked into dye bath up to a certain limit for enough time. To dye up the garment as deeper shade to light shade from bottom to top the gradient time will be maintained for certain area of the garment.


Process flowchart for DIP Dyeing

•  Scouring (80°C)
• Neutralization (With Acetic Acid)
• Enzyme (At 45°C Temp and PH-4.5-5.5)
• Dyeing (90°C Temp for 3-5 Minutes)
• After Treatment (Fixing Agent)
• Softener (Commercial Softening Agent)
• Bath Drop

Normally garment dyeing runs with two types dyestuffs available in the market.

    1. Direct Dyes
    2. Reactive Dyes
    a) Hot Brad
    b) Cold Brand

For dip dyeing we use direct dye though it has low color fastness property, moreover it takes less time for color fixation

 Necessary Items:

•     Dye Bath ( Vessel, bucket, bowl or any other container)
•     Hanger
•     Washing Machine
•     Stirrer
•     Rubber gloves

Pretreatment: As the fabric is not ready for dyeing after making cloths, it is treated with caustic soda and peroxide solution to perform pretreatment process which helps to make it more absorbent and free from natural color as well as other impurities.






Recipe:

• Caustic Soda (NaOH)-2gm/l
• Per-Oxide (H2O2)-4gm/l
• Detergent-1gm/l
• Temp-80°C
• Time-15min

Working Procedure: A lot of garments are now taken into the dyeing machine for easy performing the pretreatment process (Good to know that, scouring, dyeing or any normal wash can also be done into a washing machine). Now add Caustic Soda, Hydrogen peroxide and Detergents according to the above recipe. Now maintain the liquor ratio at 1:10 at 80°C. Now perform this treatment for 15 minutes. Well scoured garments are treated as more absorbent, where color permanency will be high. In this process the garments are to be more absorbent, removing the natural or unwanted colors to make genuine white, oils as well as other impurities. Good scouring plays an important role during dyeing, color fastness and appearance. The whole materials are now subjected to rinse wash to remove the caustic and other chemicals. Now the garments are neutralized with Acetic Acid so that any of the caustic soda does not exist with the material. The PH of Acetic acid should be kept into 4.5 to 5.

Note: If the garments are made with zipper of cotton tape frequently be torn during the scouring process, so nylon or polyester tape is recommended to use here.

Enzyme: After scouring process the full quantity of garment needs to treat with enzyme which will help to remove the hairiness and projectile fibers as well as make the garments ready for dyeing. You can use Acid enzyme as 2gm/l at 45-55°C for 15 minutes. After enzymatic treatment one or two rinse wash to be done for washing it properly. (PH during enzymatic treatment keeps in 4.5 to 5)

Recipe: We have used this for dyeing 380 Pcs baby girls shorts.

• Direct Dye-355gm
• Salt (Glubar Salt)-10gm/l
• Labeling & Wetting Agent-1gm/l
• Water-2500L
• Temp-95°C
• Time-5min

Working Procedure:  Make the dye bath ready with direct dye as normal dyeing procedure. At first we will be sure the garment is made from scoured and bleached fabric, otherwise scouring or pre treatment will have to complete. After adding dyes, salt and wetting agents it needs to stir to make the dye bath properly. For getting more color fastness and reduce fixation hours we can use some binding agents as we need. The temperature of dye bath remains around 90-95°C.

The garment which is used to dyeing need to attach with hanger or something else to hang it from, then water uses to wet the garment properly before taking it underneath the dye bath. Now start to place the garment into the dye bath as desired height. You may require helps in doing this so as not to spill the dye everywhere. Once the garment has been soaking in the dye bath for long enough time then remove it carefully so that color spot does not transfer to the non-dyed portion. If so, run the garment, from non-dyed section to dyed section, under warm water until water runs clear. This will remove any excess dye from the garment. Continue the process till your desired shade is developed and maintain the shade at different areas of the garment. To get as deeper to lighter shade at bottom to top you can soak the garment into dye bath as long enough time. The process of dip dyeing is not so crucial but it takes extra precautions, care and many more times. During dyeing it will take spraying some water to the garment to wet it and helps to absorb colors by the material.


Once your desired shade produced it needs to take it into a washing machine.

After Treatment: It is the process usually doing after dyeing for color fixation and color permanency as well as improving the color fastness. This is a chemical treatment so as for this a typical recipe is given below.

Recipe:

• Commercial Fixer-0.5gm/l
• Softener (Cationic)-0.5 gm/l
• Temp-40°C
• Time-3-5 minutes
• M:L ratio- 1:10

Working Procedure: After completing the dyeing it will be required some process to have sufficient dye molecules penetration to the most inner part of the fibers. In the dye bath now adds the fixing agent (Commercial Fixer) according to the recipe. Temperature in this bath will keep at 40°C and treatment time is 3-5 minutes. By this treatment the material will be treated as finally colored. Most of the dye particles will finally enter into the core of fibers and the fiber will swell at some extent so that the pores of fibers will be reduced and dye materials cannot come out from the innermost part. It will increase the color fastness of the materials. Before this treatment is started a rinse wash will be done to remove extra dyes which adhere with the materials and after this process also another rinse will be done to remove unfixable dyes or sediment dyes at the bottom of the dye bath. Now softener is added to the bath to make the material softer, improving hand feel and brightness.

Now just hanging up the garments for 20 minutes to squeeze extra water (Do not use hydro extractor to reduce staining or uneven color adhering). You can use oven to dry the garments as well, you can get prominence color performance without staining or shade variation. Now the garments are cured at curing chamber at 150-200°C to dry finally and properly. You can use dryer for a while at the final stage.

Over Dyeing in Garments: When a fully fashioned garment is dyed for another color though it can be used as wearing dress, this technique is so called over dyeing. Usually coloration is performed over a consisting color on to a garment is referred as garments over dyeing. As an example when a purple colored fully ready garments are supposed to be subjected for red color it may call as over dyeing. There is a common concept among the garments trade peoples, when a garment is dyed with its whole area is known as garments dyeing but when color imparts fully or partially over garments can be defined as garments over dyeing, because it could be used as wearing dress before this coloration.  In garments dyeing normally two types of dyestuffs are used such as Direct Dye and Reactive Dye. The garments which are required to dye up should be made of cotton fiber though many of them are now produced with combination of other fibers as blends. Dyeing procedure of over dyeing is as like as other normal dyeing arrangements but here some extra precautions and care must be taken. At present the garments washing plants are capable to make the garments over dyeing. If the garments which are white in color and can use as dress are subjected for dyeing is also known as over dyeing.

Garments Tie Dyeing: Tie means make a knot to garments different places as if they cannot come in contact with dyes or chemicals during dyeing. It is as like as batik printing method. A garment is tied at different places prior to dyeing; as a result whole garments will be colorful remaining the tied places un-dyed. Indeed this technique is known as garments tie dyeing and now is becoming so popular in the world garments trade.

Dip dyeing is becoming more popular in Garments dyeing

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Garments Dyeing: Garment dyeing is a process of imparting color materials to fully fashioned garments like as shirts, pants, twill garments, jackets, pullover, T-shirt, Polo shirt, sweaters etc. The garments are usually dyed before finishing with various trimmings or accessories. In textile coloration it is not so far initiated in our country but it is more popular outside our country like as France, Italy, Spain, Germany, Canada, North America, turkey, Israel, Japan, USA, Uk, China etc.

Garment dyeing is an opposition of the conventional method of making garments from previously dyed fabrics. Knitted fabrics, twill weave fabrics and/or other woven fabrics made from cotton yarns are subjected to garment dyeing.  Garments made of cotton material are easy to dye up but besides cotton several other fabrics can be found in whole or partially made of wool, silk, nylon, polyester or acrylic are subjected to garment dyeing.

Dip Dyeing: In garments dyeing, dip dyeing is becoming more popular day by day as the fashion trend and customer demand. Due to cheap and easy process it is as popular to the manufacturers.  It is also as called gradient dyeing. It is the process, the fully fashioned garments are arranged to dip into a dye bath (vessel, bucket, bowl etc) accordingly a pre-determined area or height. This process runs again and again. According to demand, garments are to be soaked into dye bath up to a certain limit for enough time. To dye up the garment as deeper shade to light shade from bottom to top the gradient time will be maintained for certain area of the garment.


Process flowchart for DIP Dyeing

•  Scouring (80°C)
• Neutralization (With Acetic Acid)
• Enzyme (At 45°C Temp and PH-4.5-5.5)
• Dyeing (90°C Temp for 3-5 Minutes)
• After Treatment (Fixing Agent)
• Softener (Commercial Softening Agent)
• Bath Drop

Normally garment dyeing runs with two types dyestuffs available in the market.

    1. Direct Dyes
    2. Reactive Dyes
    a) Hot Brad
    b) Cold Brand

For dip dyeing we use direct dye though it has low color fastness property, moreover it takes less time for color fixation

 Necessary Items:

•     Dye Bath ( Vessel, bucket, bowl or any other container)
•     Hanger
•     Washing Machine
•     Stirrer
•     Rubber gloves

Pretreatment: As the fabric is not ready for dyeing after making cloths, it is treated with caustic soda and peroxide solution to perform pretreatment process which helps to make it more absorbent and free from natural color as well as other impurities.






Recipe:

• Caustic Soda (NaOH)-2gm/l
• Per-Oxide (H2O2)-4gm/l
• Detergent-1gm/l
• Temp-80°C
• Time-15min

Working Procedure: A lot of garments are now taken into the dyeing machine for easy performing the pretreatment process (Good to know that, scouring, dyeing or any normal wash can also be done into a washing machine). Now add Caustic Soda, Hydrogen peroxide and Detergents according to the above recipe. Now maintain the liquor ratio at 1:10 at 80°C. Now perform this treatment for 15 minutes. Well scoured garments are treated as more absorbent, where color permanency will be high. In this process the garments are to be more absorbent, removing the natural or unwanted colors to make genuine white, oils as well as other impurities. Good scouring plays an important role during dyeing, color fastness and appearance. The whole materials are now subjected to rinse wash to remove the caustic and other chemicals. Now the garments are neutralized with Acetic Acid so that any of the caustic soda does not exist with the material. The PH of Acetic acid should be kept into 4.5 to 5.

Note: If the garments are made with zipper of cotton tape frequently be torn during the scouring process, so nylon or polyester tape is recommended to use here.

Enzyme: After scouring process the full quantity of garment needs to treat with enzyme which will help to remove the hairiness and projectile fibers as well as make the garments ready for dyeing. You can use Acid enzyme as 2gm/l at 45-55°C for 15 minutes. After enzymatic treatment one or two rinse wash to be done for washing it properly. (PH during enzymatic treatment keeps in 4.5 to 5)

Recipe: We have used this for dyeing 380 Pcs baby girls shorts.

• Direct Dye-355gm
• Salt (Glubar Salt)-10gm/l
• Labeling & Wetting Agent-1gm/l
• Water-2500L
• Temp-95°C
• Time-5min

Working Procedure:  Make the dye bath ready with direct dye as normal dyeing procedure. At first we will be sure the garment is made from scoured and bleached fabric, otherwise scouring or pre treatment will have to complete. After adding dyes, salt and wetting agents it needs to stir to make the dye bath properly. For getting more color fastness and reduce fixation hours we can use some binding agents as we need. The temperature of dye bath remains around 90-95°C.

The garment which is used to dyeing need to attach with hanger or something else to hang it from, then water uses to wet the garment properly before taking it underneath the dye bath. Now start to place the garment into the dye bath as desired height. You may require helps in doing this so as not to spill the dye everywhere. Once the garment has been soaking in the dye bath for long enough time then remove it carefully so that color spot does not transfer to the non-dyed portion. If so, run the garment, from non-dyed section to dyed section, under warm water until water runs clear. This will remove any excess dye from the garment. Continue the process till your desired shade is developed and maintain the shade at different areas of the garment. To get as deeper to lighter shade at bottom to top you can soak the garment into dye bath as long enough time. The process of dip dyeing is not so crucial but it takes extra precautions, care and many more times. During dyeing it will take spraying some water to the garment to wet it and helps to absorb colors by the material.


Once your desired shade produced it needs to take it into a washing machine.

After Treatment: It is the process usually doing after dyeing for color fixation and color permanency as well as improving the color fastness. This is a chemical treatment so as for this a typical recipe is given below.

Recipe:

• Commercial Fixer-0.5gm/l
• Softener (Cationic)-0.5 gm/l
• Temp-40°C
• Time-3-5 minutes
• M:L ratio- 1:10

Working Procedure: After completing the dyeing it will be required some process to have sufficient dye molecules penetration to the most inner part of the fibers. In the dye bath now adds the fixing agent (Commercial Fixer) according to the recipe. Temperature in this bath will keep at 40°C and treatment time is 3-5 minutes. By this treatment the material will be treated as finally colored. Most of the dye particles will finally enter into the core of fibers and the fiber will swell at some extent so that the pores of fibers will be reduced and dye materials cannot come out from the innermost part. It will increase the color fastness of the materials. Before this treatment is started a rinse wash will be done to remove extra dyes which adhere with the materials and after this process also another rinse will be done to remove unfixable dyes or sediment dyes at the bottom of the dye bath. Now softener is added to the bath to make the material softer, improving hand feel and brightness.

Now just hanging up the garments for 20 minutes to squeeze extra water (Do not use hydro extractor to reduce staining or uneven color adhering). You can use oven to dry the garments as well, you can get prominence color performance without staining or shade variation. Now the garments are cured at curing chamber at 150-200°C to dry finally and properly. You can use dryer for a while at the final stage.

Over Dyeing in Garments: When a fully fashioned garment is dyed for another color though it can be used as wearing dress, this technique is so called over dyeing. Usually coloration is performed over a consisting color on to a garment is referred as garments over dyeing. As an example when a purple colored fully ready garments are supposed to be subjected for red color it may call as over dyeing. There is a common concept among the garments trade peoples, when a garment is dyed with its whole area is known as garments dyeing but when color imparts fully or partially over garments can be defined as garments over dyeing, because it could be used as wearing dress before this coloration.  In garments dyeing normally two types of dyestuffs are used such as Direct Dye and Reactive Dye. The garments which are required to dye up should be made of cotton fiber though many of them are now produced with combination of other fibers as blends. Dyeing procedure of over dyeing is as like as other normal dyeing arrangements but here some extra precautions and care must be taken. At present the garments washing plants are capable to make the garments over dyeing. If the garments which are white in color and can use as dress are subjected for dyeing is also known as over dyeing.

Garments Tie Dyeing: Tie means make a knot to garments different places as if they cannot come in contact with dyes or chemicals during dyeing. It is as like as batik printing method. A garment is tied at different places prior to dyeing; as a result whole garments will be colorful remaining the tied places un-dyed. Indeed this technique is known as garments tie dyeing and now is becoming so popular in the world garments trade.

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