Part 1 :
Process Flow Chart of Solid Dyed Fabric:
Grey Fabric Receive From Weaving
Fabric Inspection, Laying & Sewing
Singeing & Desizing
Scouring & Bleaching & Washing
Softening & Batching
Washing-1 & Washing-2
Inspection, Packing & Shade Grouping
Delivery to Garments
Remarks: 01. If the fabric is non-peach that case Peach or Washing no need. 02. If fabric is both side peach, then need two-time Batching & Peaching. 03. If fabric is yarn-dyed that case fabric transfer after washing to Stenter finish.
Process Summary of Solid Dyed Fabric:
What is Singeing :
Hairy (Protruding) fiber removing process.
The function of Singeing:
To remove hairy fiber from fabric surface by fire or very hot plate. It creates a smooth and clean surface.
What is Desizing :
Sizing chemical removing process.
The function of Desizing:
To remove size material (Starch) / PVA from the fabric surface. If we do not remove the Sizing material Subsequent process not possible.
What is Scouring:
Impurities removing process
The function of Scouring:
To remove natural impurities plus impurities added during the process of Ginning, Spinning, Weaving like Oil, Wax, Gum, Fat, etc.
To remove the hydrophobic character of fiber.
What is Bleaching:
Natural color removing process.
The function of Bleaching:
To remove or destruct natural color (Grey color) from fabric.
To get sufficiently high & uniform degree of whiteness.
To get high & uniform absorbency in the fabric.
What is Mercerize :
Luster, Dye up takes & Dimension Stability improving process.
The function of Mercerize:
To improve the luster of the fabric.
To increase dye absorbing capacity.
To improve Dimension Stability.
To improve the strength of the fabric.
What is Peach :
Mechanically softening & energizing process.
The function of Peach:
To improve the softness of the fabric by Emery paper / Diamond paper / Silica Brush friction.
What Is Dying :
Coloring process Fabric / Yarn / Garments.
The function of Dyeing:
To adding dyes in the fabric & make it permanent.
Cotton, Viscose, & Rayon can be dyed by reactive dyes, vat dyes, pigment dyes & indigo dyes
Disperse dyes can dye polyester
Silk & Wool can be dyed by direct dyes.
CPB (Cold Pad Batch) Process
Pad Dye Pad Steam Process
Pad Dry Cure Process
Ready for dye fabric pad with dye liquor, Caustic soda, Soda ash, Wetting agent at low temperature (18-22 ˚C) in CPB m/c.
Rotating batcher during 8-12 hours.
Washing the fabric at a high temperature with Soaping Agent.
Pad dye pad steam process:
Ready for dye fabric pad with dye liquor, wetting agent, & anti-migrating agent then pass hot flue of air chamber for dry the fabric in pad Thermosol m/c.
Pad dye complete fabric pad with Salt, Caustic Soda, Soda Ash then pass with a steamer at high temperature then wash in wash box with Soaping Agent then dry.
Vat dyeing process:
In respect of color Stability & Luster, this dyeing quality is very high.
All types of cellulosic fiber can be dyeing this process.
Ready for dye fabric pad with dye liquor, wetting agent, the anti-migrating agent then dry by hot flue of air in pad Thermosol m/c.
Then pad the fabric with Hydrose & Caustic Soda and then pass with steamer then oxidize by hydrogen peroxide & soda ash then wash in wash box with soaping agent then dry.
Polyester fabric dye by disperses dyes.
Ready for dye fabric pad with dye liquor, dispersing agent, anti-migrating agent & acid then dry & cure at a high temperature around 210˚C then wash.
When any fabric made by blended fiber (CVC or PC) at that case polyester part dye first time then reduction cleaning done by Hydrose and Caustic then cotton part dye by CPB or pad dye & pad steam.
What is Stenter Finish :
Softening & Physical parameters adjust the process.
The function of Stenter Finish:
To apply finish chemical for achieving target Softness / Hardness / Others.
To control the width for achieve target GSM & width.
To heat-set Lycra fabric for width stable.
Polyester fabric Heat setting.
Different type of finish:
01. Regular Soft Finish
02. Silky Soft Finish
03. Paper Touch Finish
04. Crispy Finish
05. Wrinkle Free Finish
06. Easy Care Finish
07. Soil Resistance Finish
08. Water Repellent Finish
09. Fire Proof Finish
10. Antimicrobial/Antifungal Finish
11. Teflon Coating Finish
13. Peach finish
14. Raising Finish
15. Diamond Peach Finish
16. Aero Finish
What is Sanforize :
Fabric Shrinkage control process.
The function of Sanforize :
To control shrinkage on the basis of buyer requirement.
To control width on the basis of buyer requirement.
To control GSM on the basis of buyer requirements.
Ironing and Shrinkage fixing of the fabric by the felt calendar.