Are you searching recipe of enzyme stone wash of denim garments? Yes, this article is for you. This article will be discuss stone enzyme wash process in detail. Enzymes are proteins which is consist of amino acid and these amino acid produced by living organisms. In denim garments washing, stone is used with enzyme which is create more fading effect on denim garments.
What is Stone Wash?
Stone wash is a process where denim garments are washed with enzyme and stone to create an old-looking or fading effect on denim garments. In the stone wash process of denim garments, pumice stone is used which surface is rough. Consequently, more fading is produced on surface of denim garments due to the frication between the surface of pumice stone and fabric surface.
Figure 1: Pumice stone for stone enzyme wash process
Objectives of Stone Enzyme Wash Process
Objectives of stone enzyme wash process is given below.
The main objectives of stone enzyme wash process is to create irregular fading effect on denim garments.
To improve the softness of denim garments.
To remove the size material from the garments. Hence, it is easy to do subsequence process.
To improve anti-pilling properties of denim garments.
Moreover, to cleaned of dust, darts, oil spots, and impurities from the garments.
How to Form Pumice Stone?
In enzyme stone wash, pumice stone is used. Now, we will learn how to form pumice stone?. The pumice stone is formed by contact lava with water. Mainly, It occurs most frequently near water or underwater volcanoes. Pumice stone is a result of the rapid ejection of highly heated, highly pressurized rock from a volcano. The uneven and foamy configuration is created of pumice stone due to rapid cooling and rapid depressurization. By lowering the solubility of gases dissolved in the lava, depressurization creates bubbles that cause them to rapidly dissolve. By cooling and depressurizing simultaneously, the bubbles freeze. Due to bubbles, pumice stones float on water. Mainly, Indonesia and Turkey are main supplier of pumice stone. The color of Indonesia stone is slightly brown while Turkey stone is white. Generally, every bag contains 22-25 kg stone.
Chemical Composition of Pumice Stone
Chemical composition of pumice stone is given below.
S/N
Elements
Amount (%)
1.
Silicon dioxide (SiO2)
71.91%
2.
Aluminium (Al2O3)
12.66%
3.
Calcification loss
4.53%
4.
Potassium Oxide (K2O)
4.30%
5.
Sodium Oxide (Na2O)
3.45%
6.
Ferric oxide (Fe2O3)
1.13%
7.
Calcium Oxide (CaO)
1.46%
8.
Magnesium Oxide (MgO)
0.32%
9.
Sulphur Trioxide (SO3)
0.03%
10.
Indefinable content
0.21%
Total
100.00%
Table 1: Chemical composition of pumice stone
Physical Properties of Pumice Stone
Physical properties of pumice stone is given below
S/N
Properties
Value
1.
pH value
8.0
2.
Hardness (Mohs scale)
6.0
3.
Refractive index
1.5
4.
Melting point
150000 C
5.
Density
2.313 (gm/cm3)
Table 2: Physical properties of pumice stone
Grain Size of Pumice Stone and Brand Name
Grain size of pumice stone and brand name is given below:
S/N
Grain size (mm)
Brand
1.
0-3
Special besser
2.
0-8
Besser
3.
2-10
Ricc
4.
0-16
German
5.
16-40
Stone wash
Table 3: Grain size of pumice stone
Learn More About Pumice Stone
Flow chart of Enzyme Stone Wash
Figure 2: Flow chart of Enzyme Stone Wash
Recipe of Enzyme Stone Wash
Recipe of enzyme stone wash is collected from a famous denim washing factory. This recipe is for 100 pcs denim garments whose total weight is 70 kg . However, recipe of enzyme stone wash is given below.
Process
Water (L)
Time (min)
Temperature (0 C)
Chemical name
Chemical qty
De-sizing
500
15-20
70
Soda ash
1 kg
L.P-30
300 gm
Rinse
1000
3 min 2 times
Cold
Enzyme stone wash
500
20-25 min ( but the time depends on the desired effect. The Machine will be running until the desired effect is found)
50
Enzyme
600 gm
Acetic acid
100 gm
L.P-30
300 gm
Stone
1 bag (every bag contain 22-25 kg stone)
Rinse
1000
3 min 2 times
Cold
Clean up
700
10
70
Soda ash
1 kg
Detergent
300 gm
Rinse
1000
3 min 2 times
Cold
Softener
700
10-15
Cold
Mesoft-CCS Flakes (Cationic)
4 kg
Solosoft-MHJ
300 gm
Hot dry
30
70-80
Cool dry
10
cold
Table 4: Recipe of enzyme stone wash
Enzyme Stone Wash Process of Denim Garments
Enzyme Stone wash process of denim garments is given below with step by step description.
Step1 : De-sizing
Working procedure of de-sizing process is given below.
Initially, Selected lot is weighted by using electric balance.( weighted 100 pcs garments whose weight is about 70 kg)
Then, loaded the garments into the washing machine for de-sizing process.
Takes 500 L water in the washing machine.
Now, running the washing machine and set the parameter ( temperature 700 C for 15 min)
Next, added soda ash 1kg and L.P-30 300 gm
After 15 min, drop the liquor and rinse the garments 3 min 2 times by cold water and drain the water.
Step 2: Stone Enzyme Wash Process
Working procedure of stone enzyme wash process of denim garments is given below
At the beginning , take 500 L water in the washing machine.
Added Enzyme 600 gm, acetic acid 100 gm, L.P-30 300 gm and pumice stone 1 bag( 22kg).
Next, set the parameter of the washing machine and run the machine. ( Temperature 500 C for 20 min. Enzyme time is not fixed. After 10 min, check the enzyme effect under water bath. Running the machine until get desired enzyme effect)
Subsequently, when found desired enzyme effect, rise the temperature 900 C for enzyme killing.
Next, drop the liquor and rinse 2 times for 3 min.
Now, unload the garments and stone. Subsequently, separated denim garments from stone.
After separating, again load the garments for subsequence process.
Step 3: Clean up
Initially, takes 500 L water in the washing machine.
Added soda ash 1 kg, and detergent 300 gm.
Run the machine at temperature 700 C for 10 min.
After 10 min, drop the liquor and rinse 2 times for 3 min.
Step 4: Softening
Takes 500 L water in the washing bath.
Added softener.
Run the machine for 10 min at room temperature.
After 10 min, drain the wash bath and unloaded the garments for subsequence process.
Step 5: Hydro-extractor
After softening process, unloaded the garments from the washing machine and send to the hydro-extractor section. Hydro-extractor remove the excess water from the garments.
Step 6: Dryer
Load the garments in the steam dryer.
Set the temperature 700 C for 30 min.
After 30 min, run the machine for 10 min in cold dryer.
Check and unloaded the denim garments.
Step 7: Inspection
Finally, garments is send to the quality control section for check quality. If ok, then, garments is ready for shipment.
Enzyme Stone Wash Sample
Figure 3:Enzyme stone wash of denim garments
Problem Caused by Stones
Some problems are arise due to the stone wash. Problem caused by stone is given below.
Stone wash result in wear and tear of the denim garments.
Increase water pollution.
Due to the abrasion between washing machine and stone lead to the damage of washing machine.
Due to the frication between fabric surface and stone, color comes out from the garments and increase back staining and re-deposition.
Labor cost is increased because dust from finished garments have to remove.
Limitations of Stone Wash Process of Denim Garments
Limitations of stone wash process or the disadvantage of stone wash process of denim garments are given below.
Stone wash may lead the damage the washing machine parts.
It is difficult to control quality of the abrasion of stone with garments. Hence, it is not possible to get uniform enzyme effect.
Stone wash provides rougher feel than normal enzyme wash.
Stone enzyme wash process increase the production cost.
Enzyme stone wash process is non-selective.
Conclusion
In summary, the stone enzyme wash process for denim garments combines wash of enzyme and stone. By combing, pumice stone and enzymes, the enzyme stone wash gives more enzyme effect on denim garments. Additionally, the flow chart of stone wash is give a you a short view from loading denim garments to final inspection. Though, stone enzyme wash process has lots benefits, but there are limitations of stone washing regarding strength loss of fabric, cost issue, and environmental concerns
Reference
Hossain, M. F. (2015). Practice of Textile Coloration, Volume-I. Dhaka: Books Fair Publications.
Jalil, P. D. (2018). Denim and Washing Technology. Dhaka: Granthanir Prokashoni.
Kabir, D. S. (2016). Chemistry of Dyes & Pigments. Dhaka: Books Fair Publications.
Rahman, E. M. (n.d.). Practical Hand Book of Washing and Dyeing. University campus.
