Process Flow Chart of Denim Manufacturing:
In this fashionable era, the young generation is highly dependent on denim based garments. It’s seen that their wardrobes are full of different types of garments which are made by using denim fabric. Normally denim is a twill weave is woven and 100% cotton fabric that contains dyed warp yarn and grey weft yarn. During denim fabric manufacturing, a process flow-chart should maintain to facilitate the fabric manufacturing process which is discussed in this article.
Flowchart of Denim Manufacturing Process:
Yarn collection from a spinning factory
↓
Warping
↓
Yarn dyeing
↓
Weaving
↓
Singeing
↓
Equalizing or Heat setting
↓
Finishing
↓
Inspection
↓
Folding & Packing
↓
Delivery
All the above processes are discussed in the following table:
|
SL/No.
|
Process
|
Procedure
|
|
01
|
Yarn collection from a spinning factory
|
According to the required types of denim fabric, the yarn should collect from the spinning factory. Denim fabric can be crushed denim, vintage denim and reverse denim, etc.
|
|
02
|
Warping
|
Here, warping is done to arrange a convenient number of warp yarns of related length so that can be collected on a single warp beam as a continuous sheet of yarns that can be used for the next processes.
|
|
03
|
Yarn dyeing
|
In this process, scouring, washing, dyeing, and drying is done. It should be noted that only warp yarns have needed to dye.
|
|
04
|
Weaving
|
Weaving is done here by using warp yarn (dyed yarn) and weft yarn (grey yarn). Here different types of weave design have followed such as 2/1 twill weave, broken twill, reverse twill, zig-zag twill, etc. sometimes fancy design is also used for producing fashionable fabric.
|
|
05
|
Singeing
|
Singeing is done here to obtain a clean fabric surface which allows the structure of the fabric to be clearly seen.
|
|
06
|
Equalizing or Heat setting
|
Equalizing or heat setting is done here to control fabric shrinkage percentage. Special types of weft yarn are heated here so that it can’t create high shrinkage during the garments manufacturing process.
|
|
07
|
Finishing
|
In the case of denim finishing, the sanforizing process is used.
|
|
08
|
Inspection
|
Finally, inspection is done here, if found any problem, taken the necessary steps to solve that.
|
|
09
|
Folding &
Packing |
After inspecting denim fabrics, folding and packing are done here to deliver the goods.
|
|
10
|
Delivery
|
Finally, all the goods are sent to the buyer.
|
Mayedul Islam is a Founder and Editor of Garments Merchandising. He is an Expert in Garments Merchandising. Writing is his passion. He loves to write articles about Apparel, Textile and Garment Washing specially on Merchandising. Mail him at mayedul.islam66@gmail.com
In rapier looms any possibility that core spun yarn spandex will break and create the patta in weft
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