20 Most Important Machine Used in Denim Washing Plant is Describe Easy way

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Introduction

When we talk about washing, we usually mean cleaning something. But in the textile world, the word washing was associated with a wide range of meanings. Nowadays, garment washing is a very popular technology that is used to clean garments. Usually, garments made from solid color-dyed or pigment-printed fabric are washed in a washing machine. It has been found that washing garments brings out some of the colors of the garments, and it also changes the appearance of the garments. Therefore, new outlooks and appearances are produced in the garments as a result of this. The concept of washing can be described in a nutshell as a process by which we can change the look, appearance, comfort-ability, and design of clothing made from solid color dyed or pigment printed fabric to achieve a desired look, appearance, comfort, and design. In the washing of garments, many types of machines are used. As part of this article, we will learn about different types of machines used in the garment-washing.

List of Machine Used in Denim Washing Plant

It is well known that washing technology is continuously being enriched with the addition of new technology and modern machines. Here are some of them that are mentioned as follows:

1. Front loading washing machine11. Boiler
2. Side loading washing machine12. 3-D Crinkle
3. Sample washing machine13. Gas dryer
4. Whisker & hand scraping dummy14. Steam dryer
5. Pen destroy machine15. Pressing Machine
6. Grinding machine16. Sand blasting machine
7. Laser machine17. Compressor
8. PP spray cabin18. Ozone machine
9. PP spray gun19. Hydro-extractor
10. Tagging machine20. Oven  

The following is a description of all the machines mentioned above:

1. Front Loading Washing Machine

The term “front loading machine” refers to a machine that is loaded from the front side of the machine. The front loading machine is a computerized machine. Among the many advantages it has is that it is computerized, has a good operating system, is automatically controlled, and has excellent dyeing facilities. Despite the fact that it has many advantages, it does have some disadvantages as well. There is a lack of skilled operators in the industry due to the fact that the machine is computerized.

Front loading garments dyeing and washing machine
Figure 01: Front loading garments dyeing and washing machine

2. Side Loading Washing Machine

This type of machine is known as a side loading washing machine because it loads from the side of the machine instead of the front. This type of machine is also known as a belly machine. There is a manual operation involved in the operation of this machine. In this type of machine, the back stain is less likely to occur and the machine is easy to handle. But in this type of machine, all parameters of the dyeing process are difficult to control, making it unsuitable for dying garments.

Figure 02: Side loading garments dyeing and washing or bally machine

3. Sample Washing Machine

There is no doubt that the sample washing machine is an important piece of equipment in any washing plant. Before bulk washing, samples are washed following a fixed wash recipe with the buyer’s approval before bulk washing takes place. There is a small quantity of samples that are being washed here.

Figure 03: Sample Washing Machine

4. Whisker and Hand Scraping Dummy

Among all the dry processes that can be applied to denim, whiskering is the most crucial. Making whiskers is done by making patterns that look like whiskers. In some cases, designers make their own whiskers according to their own creations. The jeans are mounted on the dummy in their raw state. Dummy is made up of rubber balloons which are used as a mechanism.  The jeans are mounted on the dummy, and then air is supplied to the dummy by an air compressor after the jeans are mounted on the dummy. Now whiskers are being done by sand paper in a careful manner. A hand scraper or a hand brush can also be used on jeans locally by using this type of dummy.

Figure 04: Whisker and Hand Scraping Dummy

5. Pen Destroy Machine

In order to destroy jeans, a pen destroy machine is used. A pneumatic signal or an electric signal can be used to operate this machine. In most factories, pen destroy machines are operated using pneumatic systems. In order to use this type of machine, one stone is attached to it at the front of the machine. There is a high speed of movement of the stone, and a specific area of the jeans is damaged as a result.

Figure 05: Pen Types Destroy Machine

6. Grinding Machine

A grinding process is done on jeans to give them an old look and a vintage look. Specifically, this machine is used to grind the edges of jeans, especially the hum and pocket edges. A machine such as this one has two wheels. Powered by electrical energy, these wheels move at high speeds with a high degree of efficiency. The edges of the garments are being compressed by the wheel and this is causing slight damage to the garments.

Figure 06: Grinding Machine

7. Laser Machine

Day by day, there is an increasing amount of new technology being introduced to the denim washing sector. One of these technologies is the laser technology. It is a laser machine used for destroying whiskers and whiskers on jeans using lasers. The term “laser” refers to the amplification of light by stimulating the emission of radiation by stimulating the emission of light. Through the use of a light emitting system, laser machines are able to burn specific areas of jeans in accordance with their design. To begin with, the design of the whiskers or destroys is created in Photoshop or Illustrator. After that, the design is input into the laser machine for cutting. As soon as the jeans have been designed, a laser light is imposed on them according to the design.

Figure 07: Laser Machine

8. PP Spray Cabin

PP stands for “Potassium permanganate.” Potassium permanganate is sprayed on specific area of the body, usually the thigh of a pair of jeans. There is a risk of health problems associated with potassium permanganate. Therefore, PP is sprayed in a cabin that is called the PP spray cabin and is known as a PP spray cabin. There is a spray gun and a rubber dummy contained in this cabin. There is also an exhaust fan located in this cabin. In the cabin, this fan is responsible for exhausting dust, pp, and other small particles. As a first step, jeans are put on a dummy, and then the PP is sprayed onto the dummy. In the cabin, PP solution is hung by buckets on the wall. When workers are started to spray then the solution is come from the bucket with the help of the air pressure.

Figure 08: PP Spray Cabin

9. PP Spray Gun

In order to spray specific areas of garments with PP, a PP spray gun is used. The PP solution is kept in a small pot in which it is kept. With the help of the air pressure, the PP solution is pumped out of the gun pot by the air pressure. There are buttons that can be used to control the system. The amount of spray that is sprayed on jeans can be increased or decreased by moving the control button on the device.

Figure 09: PP Spray Gun

10. Tagging Machine

The purpose of this machine is to tack in the jeans with the help of a needle. The tagging process is carried out before fast washing is carried out. Initially, the place where the tag will be attached is marked with a marker. In this machine, there are two needles with plastic pins that are attached to them. With the help of an electric motor, workers are able to move a needle with a plastic pin inside the jeans by pressing the paddle of the machine. When the jeans are washed fast, the tags are removed and the jeans are then dried.

Figure 10: Tagging Machine

11. Boiler

A boiler is one of the most important machines in a washing plant. Jeans need to be washed in hot water in order to be clean. The latest type of garment washing machines use steam to heat the water so that all types of garments can be washed. It is necessary to steam the 3-D crinkle so that the 3-D can be dimensionally stable. An ironing machine that is used to iron jeans is called a pressing machine. The heat produced by a pressing machine is produced by steam.

Figure 11: Boiler

12. 3D-Crickle

It is important to note that there are two types of crinkle. One type of crinkle is the normal or two-dimensional crinkle, and the other type is the three-dimensional crinkle. A 3D crinkle machine is used to produce three dimensional crinkles on items. First of all, resin is sprayed on the area of jeans where 3-D will be done in order to prepare it for the printing process. Jeans are placed into the handle of the machine after they have been sprayed. As of now, 3-D designs are created manually by the customer based on the requirements they provide. Afterwards, a heat source is applied to the 3-D area for a period of one minute. As soon as the jeans have been made in 3-D, they are sent to the oven to cure so that the reaction will be permanent.

Figure 12: 3-D Crickle Machine

13. Gas Dryer

After the garments have been washed, they are usually dried using a machine known as a dryer. It is important to note that there are two types of dryers. The gas dryer is one of those types of dryers. The gas is directly used in the production of heat in this type of dryer. A dryer of this type applies heat from the upper part of the dryer, which is the part where the heat is applied.

Figure 13: Gas Dryer

14. Steam Dryer

Steam is used in steam dryers in order to produce heat. A condenser is a device that converts steam into heat via the process of condensation. Steam dryers are now available for sale in used condition. Using a steam dryer will not affect the shade of the garments in any way.

Figure 14: Steam Dryer

15. Pressing Machine

In order to iron the garment, a pressing machine is used. There are also pressing machines that are used for pressing garments by heat in order to create permanent palettes. Steam is used to generate heat in the press machine so that it can press the material.

Figure 15: Iron or Pressing Machine

16. Sand Blasting Chamber

The sand blasting machine is used in order to remove the color from the garment in order to restore the garment to its old look. In this machine, sand is directly hit onto the surface of the garment by means of air pressure applied to the machine. The result of this is that some of the color has come out of the surface. As well as being hazardous to the health, it is also harmful to the environment. As of today, sand blasting machines are not used because buyers do not approve of the process of sand blasting.

Figure 16: Sand Blasting Machine

17. Compressor

The compressor is one of the most important machines in the washing sector. There is a pneumatic system used in the majority of machines. In order to operate this system, compressed air is required. There is a compressor that applies compressed air to the machine, such as a pen type destroy machine, a whisker or hand scraping dummy, a PP spray guy, etc.

Figure 17: Compressor

18. Ozone Machine

The use of ozone gas in denim washing is a new technology that has been developed in recent years. In order to produce ozone gas, oxygen is used as a fuel. The purpose of this machine is to change the color of garments after they have been washed. A buyer may request a blue tone from the seller at times. Sometimes a reddish tone can be seen on the fabric due to the chemical or washing process. The ozone machine is used in order to remove the reddish tone within a short period of time. A washing machine like this is a kind of machine that is used for washing clothes. It is different from other washing machines in the sense that here there is no water used in the process. There is no use of water or chemicals in an ozone machine. As a result, it is possible to use the ozone machine as a sustainable means of washing.

Figure 18: Ozone Machine

19. Hydro-extractor

There is a device called a hydro-extractor that is used to remove excess water from the garments. Using the centrifugal force, a hydro-extractor works on the principle of a centrifugal force. The garments should be placed in the washing machine after they have been washed. In the event that the machine is moving at a high speed, a lot of water will drain from the garments as it moves. As soon as the garments have been unloaded from the machine, they will be sent to the section of the dryer for drying. With the help of the hydro-extractor, about 70-80% of the water is removed from the process.

Figure 19: Hydro-extractor

20. Oven

It is necessary to cure 3D printed garments after they have been made in order for it to remain stable for a long time. For the purpose of curing garments, ovens are used in garment washing plants. There are two types of ovens used in the washing plant, and each one is used in a different way. You can choose between an oven with a close door and a conveyor belt or an oven with an open door. Closed door ovens are used to bake garments that are hung with a hanger before they are placed in the oven. After the garments have been placed inside the curing room, the door will be closed for a certain time at the curing temperature. Previously, the time and temperature of the room have been set. Upon completion of the curing process, an alarm will ring. Once the garment has been baked, it will come out of the oven. The production of ovens with a closer door is less than those with a wider door. The conveyor belt oven has the advantage of being able to produce continuously, on the other hand. Due to the conveyor belt moving within the door, the main door of the oven will never be able to close. It is more than just a close door oven that determines productivity.

Figure 20: Close Door Oven
Figure 21: Open Door Oven

Conclusion:

Denim washing is the process of washing, treating, and finishing denim fabric or garments to achieve specific aesthetic effects such as faded, distressed, or vintage look. Denim washing is an essential part of the denim manufacturing process and plays a significant role in determining the final look and feel of the denim fabric or garments. In this article, we came to learn different washing machine used in denim washing plant.

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