Effect: To give certain areas a fade-out look. Same effect as sandblast (A1), but you get a different appearance on denim. The faded area will look less flat, and the slubs in the fabric will become more visible then when sandblasting is done.
Process: By hand scraping on the garment with sand paper.
Advantages: Better contrast than sandblast (see above under effect).
Disadvantages: There is a bigger risk of getting broken stitches at for example back pockets compared to sand blasting.
Service Skill Ness:
Hear I Responsible For I handled hear how to increase the Strength of different weight denim (tearing & tensile) How to perfectly , Washing, dyeing and tinting, toping, toning, with reactive dye direct dye, pigment dye, etc.
Washing Job Responsibility
Making Recipe For all type of Garment dyeing, including various Wet Process.
Costing for all type of Wet, Dry Process& Garment Dyeing.
Able to Solve Critical Testing using Like Color Fastness to crooking, Color fastness to light, Color fastness to actual laundering, Tearing Strength Formal- dehydrates, Azo free, flammability, P.H etc.
Able To handle & Satisfy customer by achieving critical wash as Required by the customer
Production planning
Shade checking & Make Decision
Look after the admin & management section.
Observe the different kinds chemical.
Admin & Social compliance.
To motivate the worker & handle workers & stuffs
DRY PROCESS
Sand blasting & Hand brushing
Wrinkle free & Crinkle
Pressing & Tagging.
Pigment spray.
Grinding & Scraping
I can also handled Color fastness to crocking color fastness to ozone, over different fabrics like as Denim, Canvas, herringbone, Bedford Cord, twill, I have also handled different test like Formaldehaydred,flammability, azo free dimensional stability test et
I am working above different type of chemicals like as Sandopan dtc, bio-de, Anti -stain Pc, Sand clear, Sando Fix, Pocket clear BelpasinNOF etc.
I have Experience to work with different type of enzyme (acid & neutral) like as BactosolCA, G-ZymeHel, NutrexNBL, Enzyme, SWGR, Denimax-Lt-35, Denimax-1000-L, Bio-polish, Enzyme–SL. Genzyme-200 etc.
I have also work with different type of softener (Cationic& Nonionic)work with ant ozone Leomna,fk,P-soft Zylon, NS Ceranine HCS, N-soft, Velvetol-8 , OZK, Micro emulsion.
Extra duties to have done
Office management, Staff management, keeping overall control top to bottom of the washing operation report to the management Compliance with labors law.
Effect: To get an all over faded, worn look and hairy surface on the garments. Process: A chemical is added in the washing machine, and wash is done in high temperature. Though the name is sand wash, no sand is used in this process.
Advantages: You will get little hairy surface for softer hand feel and for look.
Disadvantages: The result will be too hairy on some fabrics. Hand Scraping and Sand Brushing Machine is used in washing factory
Laser machine is used for whisker by burning the Garments. First time have to make a design for whisker by using Photoshop illustrator then it will impose on garments after selecting the intensity of burn.
Effect: Used for making whiskers (artificial creases by for example crotch) and other designs on garments (also see 5A Whiskers)
Process: A computerized laser machine is used to burn the design on the garment. The laser destroys the colour so they area burned will look lighter than the base color.
Advantages: Any kind of design can be made. Since it is computerized, the result will look the same from piece to piece. Easy to control in production.
Disadvantages: Expensive. The result can look unnatural since all the garments will look identical.
Info: Not commonly used in Bangladesh and few suppliers have this facility.
Laser whisker
This whisker is done by laser machine. First time we have to make design in the Photoshop illustrator then it insert into laser machine and fix the intensity and impose on the garments according to marking and burn the indigo. After wash the burned indigo will remove and whisker will see. This whisker production is more but the tint absorb is uneven.
Experience of Laser Technologist in Washing Factory
I am an enthusiastic garment washing & dyeing technologist with amazing management abilities. I have 18 years plus experience in the Textile (garment Processing) field. I am good at Wet & Dry processing which is the demand of the day in garment processing. I am exposed to international culture and has most of the time been a team leader to attain growth of the company.
I have worked on various kinds of fabrics / substrates woven, knitted, Denims, Silks etc.
I have excellent communication skills with ability to teach fundamentals to my juniors to create a team to produce consistent results in shortest period. I am known to handle multi task and ensure discipline in my plant with congenial atmosphere for best output.
I look forward to take up a challenging career at your esteemed organisation as a Plant head. I am herewith enclosing my details; if you would need any further clarifications please do not hesitate to contact me on my cell phone or by email. .
EXPERIENCE DETAILS
Durgeshwari Garment Processors Pvt. Ltd.
Gaziabad.
(Delhi NCR.)
Plant Head
Working
Heading a washing plant with dry and wet processing capacity of 10000 denim garments per day.
Sonu Enterpreises(Sonipat)
Delhi NCR.
Plant Head
Feb. 2009-May 2011
Heading a washing plant with dry and wet processing capacity of 10000 denim garments per day.
Spykar Lifestyles Pvt. Ltd. Mumbai,
India
Plant Manager-Washing
August 2006-
January 2009
Heading a washing plant including development facility having dry pocess, washing and dyeing capacity of 5000-10000 adult jeans/shirts/cargos per day
Columbia Washing Plant Ltd., Dhaka, Bangladesh.
Washing Manager
October 2003
July 2005
Was in charge of a big washing unit with daily production of 20,000 Garments of different fabrics materials. Handling both wet / Dry Process. Had laser machines from GFK(Spain).
ARVIND MILLS,
Ahmedabad, INDIA
Manager
Manufacturing
(development & new technology group)
January 2003
October 2003
Looking after all kinds of developments on d
COMPANY
DESIGNATION
TENURE
DETAILS
TCNS LIMTED,
Noida, India
Manager
Central services
October 1999
December 2002
Managing an integrated washing plant of 10,000 garments per day includes Dyeing, washing, and Dry processing.
Executive Garment Processors Pvt. Ltd.
Mumbai,India.
.
Production Controller
Sep.’95
Oct’99
Handling washing of 35000 pcs in the biggest commercial laundry for 70 different exporters.
Sampling activity of 400 pcs.
Dupont Sportswear Ltd. GOA
(WRANGLER PLANT IN INDIA)
Process assistant
November 1993
March 1995
Supervising washing of Denims/ cottons garments. Setting up of Recipes. Preparing Over dyes recipes.
Baking Machine : This is the machine which is used for 3D baking. This baking slightly different from normal baking. One is two dimensions and another is three dimensions. This machine has some pattern which put inside the garments and heating at oven. Before inside pattern we used resin at specific area.
Common problems and difficulties in washing
Wash can be a complicated process, with a lot of factors involved which effects the end result. For instance different chemicals and machines are use, time and temperature are important factors. Also some processes are manual and result will vary from person to person.
This means that the end result can sometimes be difficult to predict; chemicals can react with each other, many effects of one treatment will not be seen until the final wash is done etc. Therefore many tries may be need before we know what the best treatment is to get your requested look on your chosen fabric and color.
And for example if the color is changed, we might need to use a different wash to get the same result as on the color you first wanted.
The easiest way to get the good result quickly is to give us a reference cutting of the look you want.
Then we and the supplier can choose which wash will be suitable to achieve that result on your colors and fabric.
Difficulties to get the effect to stay after customer wash, for example tint.
Colour bleeding
Heavy treatments makes fabric weaker so it can break
Sharp edges at scraping/blasting areas
Dry rubbing problems
Contrast fabrics or trims changes colour due to bleeding from the shell fabric colour
Fabric breaks due to resin
Hole marks after tagging
Over blasting over scraping to hard blasting scraping
Patch mark after applying raisin
Shade variation
To sharp whiskers, un natural look
AFTER TREATMENT (WASH)/WRINKLE FREE-
• Review if Shade Mat for washed product (denims, piece dyed fabric) were done prior to cutting, while Shade Band has been established by factory or with involvement of PEI QA. Ensure that shade band is not too wide and close to approved standard. • Ensure that bulk garment Color is within shade band/standard. • Review if Hand feel and appearance is matching to original standard. • For all product with Wrinkle Free, No Iron, Wrinkle Resistant etc call outs, send garments from every 2000 pcs per color to local approved lab for DP rating by filling the TEST REQUEST FORM • Review seam smoothness on bulk garments if product is acceptable to standard. (Use AATCC replicas for comparison) • Review fabric smoothness on bulk garments is acceptable when compared to standard.(Use AATCC replicas for comparison) • In the case of bottoms with crease, ensure crease retention is acceptable on bulk garments when compared to standard. (Use AATCC replicas for comparison). • QCs must keep records of GES (Garment Evaluation Sheet) of each color.
Wet Processes
There are different types of wet processing procedures for ready made garments:
B1. Garments wash, for denim this is referred to as rinse wash B2. Sand Wash B3. Silicon Wash B4. Stone Wash B5. Enzyme Wash B6. Acid Wash / Salt Wash B7. Bleach Wash
The wet processes are commonly used together, for example enzyme + stone wash. Last in this chapter you will get an explanation on common combinations and the result they will give.
In the following pages you will get a short description on each of these washes, and some videos showing how the process is done.
Conclusion
Please remember the conditions for wash is constantly changing due to new developments and technique. Feel free to contact your wash technician or product developer for the latest information, advise and problem solving. Baking Machine is used in rmg factory
This is cabin that contain spray gun and rubber dummy. Garments are wearing on dummy then spray pp by gun. This cabin has two or three exhaust fan. This fan exhausts the dust or pp smell from cabin. Now the exhaust remove by water following.
PP spray :
That means potassium per manganate spray on the garments at specific area. We sprayed these chemicals to reduce the color from garments. First we have to put the garments into dummy then take air then we spray pp with the help of pp gun by air pressure. This spray is done on the scraping area and after neutralize we got a white look on the spray area.
Potassium permanganate spray (PP spray) Feature
Effect: A type of bleach used to give a fade-out look. Used alone or on top of sandblasted or sand brushed areas to enhance the contrast and make it more white. Can be used on denim and sulpher dyed fabrics, but not on reactive dyed fabrics.
Process: A chemical is hand sprayed on the garments. It reacts with the garment color and bleaches it. The same chemical is used for acid wash (See B6).
Advantages: More natural look, and better contrast than with pigment spray.
Disadvantages: It is a fading agent, so the color can react differently on for example reactive dyed fabric. Instead of giving a whitish faded look it can discolor the garment. Usually it looks red- or brownish.
Tagging :
Tagging in the process which is done at unwashed condition of garments. After wash we will get it effect. Maximum time we will do it at edge area by folding the garments. This process can be done by the tag gun, plastic staple machine or manually. Sometimes this process damages the garments by creating hole.
PP rubbing:
Sometime according to development requirements we used pp rubbing process to get the effect. By this process we get more high low effect. But pp spray not get more high low. This process is difficult to handle.
Pigment spray :
Pigment spray is the process by which we will get uneven color look at garments surface. First we complete the wash process then we spray the pigment on the garments surface. We make the pigment solution by pigment dye, binder and liquid. After spray we send the garments to oven for curing. After oven color will fix and we get a good look.
Effect: Used to make fade-out look on for example corduroy, twill, canvas or light weight denim where sandblasting/scraping can not be done.
Process: A colour is hand sprayed on the garments. It is applied on top of the fabric, and is not reacting with the fiber.
Advantages: Can be used on light weight fabrics where the fabric would break if sandblasting were done, and on cord where pile loss would be a problem if scraping/sandblasting was used.
Disadvantages: On denim it will look artificial, and sometimes on other fabrics too. Can be difficult to control in production.
Pigment spray
Towel bleach:
It is one kind of bleaching process by which that give us the uneven look on the garments .In this process first we take some small piece of towel then dipping on bleaching solution then dry these piece slightly. After that we put into machine and give the original garments which need to be uneven wash then complete the process.
PP spot / Bleach spot:
This process is done by making pp solution or bleach solution then make some spot on the garments according to required. After neutralization we will get the nice spot. But there is a difference between pp spot & bleach spot. By pp spot we get look white spot and bleach spot we get slightly yellow spot.
PP spot or Bleach spot
Resin application & Problems: Resin is the chemicals by which we make the crinkle & 3D crinkle in washing plant. We also used this chemicals to hard the fabrics. Resin is directly used on the garments then curing. Resin application is very critical because of nature. If the application is more that time we have to face very big problems. So we should apply resin at optimum level. Resin should be apply according to fabrics strength & construction. Resin should be formaldehyde free. *If the resin application is more on specific area that garments will tear.
This is the machine is which curing is done. After crinkle done we put the garments in the oven for a specific time we maintain temperature at 150c because at this temperature curing reaction is happened. At curing reaction resin is react with cellulose .This oven may be gas, electric or other fuel based. Gas oven is easy to operate. In this oven we used trolley garments are hanging with trolley then put in the oven.
Conveyer oven / chain oven :
This is the machine Which is curing is done after crinkle done we put the garments on the oven for a specific time. We maintain temperature at 150c because this oven may be gas, electric or other fuel based. Gas oven is easy to operate. In this type oven the garments are running on the two or three times circle.
Prologue
It is important to preserve goals & setup planning in order to achieve professionalism & efficiency, so that we can by pass any imminent disaster while approaching to destination. Therefore, below report is made to illustrate goals for up coming year on basis of year following 2007-08. Brief reports of year 2007-08 have given below for reference. Usually our production target for each month is at least 10000,000.00 US$ & this will be our base to calculate brief report.
Machine controlled by inverter, either it is made by china or Bangladesh; there is no reliable system of controlling water of the dye bath, operators taking & measuring water with their eyes, operators & helpers mix the chemical with stick in a bucket as they have no such computerized controlled facilities. But we all know how important this is to control water ratio in the dye bath as it is controlling dyes & chemical consumption also calculating garment color shade. To minimize the problem we have made steering machine but it is not enough.
So we need –
Computer (PLS) controlled garment dye machine.
Pressing M/C for Crinkle.
Oven M/C for Crinkle.
Lesser M/C for Whiskered.
Lab
In AWL we need a well equipped lab in order to keep better quality production, thus we already merged our washing lab with textile lab, so that we can obtain better quality training & production for our associate person.
Outsourcing
We need to concentrate our capability to erect a strong marketing department for AWL to enable continuous outsourcing, rather than depending upon any one person, as it will also effectively support production department which will alleviate pressure from concerned person. From long time we are noticing that other concern factories of Auto garments have plenty work to finish while AWL engaged to finish some normal wash.
This is our request to affiliate merchandising department to make contact & introduce to our respectable buyers on behalf of Auto Washing ltd.
However, to create our own marketing department we need some smart & energetic employee, who will conduct marketing in the field & ensure continuous flow of work.
Grinding machine is used for grinding of garments edges. This has two wheel .This wheels are moving very high speed by an electric motors. This garments edges are contract with the wheels and making slig. Grinding Machine is washing process by which we will get the used effect of garments. This process is completely done at edge area
Destroy
Destroy is a process which is done by pen grinding machine. First we have to mark the garments then slightly attach this machine with the garments then slowly remove the cellulose. After wash we can get a good destroy look of garments.
Grinding Machine
Laundry
An initial investment of US $ 2 million has equipped our finishing and laundry facilities with the best technology in process control, dyeing and color kitchen and the best washing machines currently available, plus a finishing unit with techniques such as scraping; brushing; grinding; sand blasting and spray booths; and laser patterning and finishing. We also have a joint venture with a specialist European development industry to ensure that our chemicals, equipment and processes are leading edge at all times. Investment in state-of-the-art equipment is just one part of our customer orientation. It is our people that make the difference. Our young and energetic team boasts the best technical
talent in the industry, who work together with worldwide exports in design and technology to ensure that we endeavor to consistently deliver the quality and value expectations of the most discerning customers. There are several ways in which tearing can be done. The machines available for bringing out the effects are grinding machine and pumice stone machine. With help of these machines effects the desired effects are achieved. These machines are user friendly and take very little time to produce the effect.
Pen grinding
This machine are used for destroy the garments. This machine are operated by electric signals. One stone is attached with this machine at front. When this stone is moving with high speed that it will with pacific area of garments and garments will damage at desire area.
Grinding Machine
Grinding machine safety
Before mounting a new wheel test it for soundness and inspect for cracks. Ensure the wheel is the correct RPM rating for the machine, this must be marked on the wheel and the machine, for all disks over 55mm in diameter. Ensure the wheel is mounted correctly by a qualified user.
All guards and protective hoods are to be in place and tightly secured. Guards, so far as is reasonably practical, should be so made that they can contain a wheel if it fractures. With the power source disconnected/ isolated turn the wheel by hand to check for clearance.
The grinding machine must be fitted with efficient stopping and starting devices conveniently situated.
Before switching on the machine ensure the table is secured and adjusted as close as practicable to the wheel. Ensure the work piece is rigidly supported and firmly clamped.
Allow the wheel to test run at full speed for at least a minute before starting actual grinding.
Never place your hands near revolving wheel or use them or any other device to stop the wheel after switching off.
Avoid grinding on the sides of straight – sided wheels and the use of warped cut- off wheels.
Abrasive wheels should be stored in an area, which does not become excessively hot or excessively cold and the area should always be kept dry.
Dust masks must be worn when grinding unless the machine is fitted with an adequate dust extractor.
Sate of Use of Grinding Wheels
Proper mounting of grinding wheel is very important for its safe running afterwards, therefore follow the instructions for mounting given below:
Tighten the nut enough only to hold the wheel firm and ensure it is balanced.
Replace the wheel guard.
Adjust the tool rest so that it is not more than 3mm from the wheel, square to it and at axle height.
Stand aside and let the wheel run for minute before grinding.
Use eye protection
Check that the tool rest is not more than 3mm from the wheel and square to it.
Before you start grinding stand aside and let the wheel run free.
True the wheel, using a dressing tool if the surface is uneven.
Place the object against the wheel without bumping or jarring.
Grind only against the face of the wheel not its side.
Never force grinding so as to stall or slow the motor excessively.
Do not grind material like lead, aluminum and brass as clogging of the wheel causes poor cutting and overheating.
Select the correct type of wheel for the intended operation
Look for cracks and apply the Ring test by tapping.
Make sure that the manufacturer’s recommended wheel speed is not exceeded.
Do not alter the hole in the wheel or force the wheel on to the spindle.
Use clean, recessed matching flanges at least one-third of the wheel diameter.
Use a clean, smooth spacer pad on each side of the wheel under each flange.
