In countries like India Sheet Dyeing Method is commonly used for manufacture of its Denim Fabrics, which has following advantages over Rope Dyeing Method: The technology is less capital intensive. The made- up Denim fabric is then thoroughly checked for defects such as weaving defects, uneven dyeing, bleaching and dyeing defects, oil stains, or patches. The term "Denim" has originated from the city of Nimes in France where "serge de Nimes" was manufactured. Even today Denim Fabric without Indigo Dyeing is not called authentic Denim. The warp is dyed, oxidized, dried and sized at a one go. Brushing and singeing should eliminate impurities and help to even the surface of the fabric. We are racing in Denim global market. In this process, back beams are processed on the dyeing/ sizing machine instead of ropes. (i) Threads from several back beams are combined to form a warp sheet and dyed and sized on the same machine. Yarn is then spun through Open-End Spinning or Ring Spinning. At warping, the individual cones are put into the creel (the number of cones depends upon fabric construction) and yarn from individual cones is pulled together in sheet form, wound on a barrel called warping beams (for Direct warping) or on weaving beams (for Sectional Warping). The major functions of Carding are to remove foreign matter and short fibers, form the cotton into a web and convert the web into a rope-like form known as a sliver. The weft thread is inserted between two layers of warp sheets by means of a suitable carrier, such as Shuttle, Projectile, Rapier, Air current, Water current, etc. It is typically used to make jeans, overalls, and other clothing. The final woven fabric, wound on a cloth roll, is taken out from weaving machines at particular intervals and checked on inspection machines so that any possible weaving fault can be detected. This improvement in strength and frictional resistance characteristic of warp yarn is essential because during weaving, yarn has to undergo severe strain & stress as well as frictional operations. The fault less fabrics are sent to the packaging department while the defective ones are sent for further corrections. The size and quality of each yarn end are monitored by the Barco Profile System to ensure uniformity. ACG also has the capacity to produce Amsler Open-End yarn, also known as Faux Ring Spun yarn. Denim is woven through Shuttle less Weaving System by using 96 ZAX-e Type Tsodakoma Corporation’s Airjet looms or rapier looms or projectile looms. Dyeing and sizing is done in two stages in this method. Generally there are two most popular methods of dyeing Denim Fabric. One set is called warp thread which is in sheet form, the other one is called weft thread which is inserted between two layers of warp sheet by means of a suitable carrier i.e. In this process, the fabric is cut into the desired width according to the size required. Normally if warp sheet is with patterns of different coloured yarns it is processed on sectional warping machine. Flowchart of Denim Manufacturing Process: Yarn collection from spinning factory ↓ Warping ↓ Yarn dyeing ↓ Weaving ↓ Singeing ↓ Equalizing or Heat setting ↓ Finishing ↓ Inspection ↓ Folding & Packing ↓ Delivery. Initially when Denim Fabric entered the fashion market, Denim manufacturers were using Natural Indigo Dye, which was costly and giving a natural finish. The woven Denim Fabrics then goes through various finishing processes, such as brushing, singeing, washing, impregnation for dressing and drying. There are two methods for glass fiber manufacturing, Continuous Filament Process and Staple Fiber Process. The technology is a proven one. Normally dyed and Grey ring or open- end yarns are used in warp and weft respectively. The selection of carrier depends upon the type of weaving machinery used. Individual fibers are laid down in the groove of a fast spinning rotor and twisted into yarn. Spinning of Cotton. As far as manufacturing process of denim is concerned, it is similar to that of Grey fabric up to the process of weaving with the only difference that in case of Denim Fabric, it is dyed at the stage of sizing where as in case of Grey Fabric, the decision regarding dyeing stage depends upon the … b. Denim Fabric Denim Fabrics woven of 100% cotton would be very strong and durable. Dressing regulates the hand and rigidity of the fabric while compressive shrinking manages its dimensional stability. Manufacturing of Denim The term “Denim” has originated from the city of Nimes in France where “serge de Nimes” was manufactured. In the past, herringbone weaves, Bedford cords, seersucker, and combinations of 3 by 1 (3/1) and 1 by 3 (1/3) twill weaves have been produced as non-conventional denim variants, along with plain-weave chambray.
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