Latest Denim Processing Technologies

The denim sector has become popular in the garment industry and it turns into the largest sector in the fashion industry. There are many newly invented technologies that are a major part of denim processing. You can’t think about special effects on denim fabric without techniques and technologies. Now it becomes an enormous sector for some machines, technologies, techniques, and human contribution.

Denim is a strong and long-lasting fabric that is made of fine cotton. It’s a long process to make denim fiber into the fabric. When you want to get the final fabric, you must follow the step-by-step process. With the latest machines and environmental technologies, it can be possible to get high-quality fabric. In this article, we will share with you all denim processing technologies.

What is Denim?

There are different types of fabrics and Denim is one of them. It is a kind of woven fabric used to make different kinds of dresses. Generally, denim fabric is made of cotton yarn. It was produced with 100% cotton fibers in the past, but it is currently found in blended fibers.

Normally denim fabric consists of two types of yarns: weft and warp. The yarn set across is known as weft, and the yarn that goes under or over the yarns is known as warp. The unique feature of denim fabrics is that it is a form of diagonal ribbing pattern on the back of the fabric that makes it dissimilar from cotton fabric.

In “white and blue color,” denim represents the two sides of fabric: indigo dyed and undyed. The dyed indigo part indicates the weaving section warp yarn, and another part indicates keeping the yarns undyed. Denim fabric is used for making jeans, pants, hats, jackets, shirts, bags, boots, belts, skirts, scarves, etc.

Denim Processing Technologies:

There are four types of popular technologies for making denim fabrics in the apparel industry. Here are they.

Denim Processing Using Water-free Laser Technology: 

Right now, water-free laser technology uses on other modern jeans, pants, and other clothing. It is used for surface modification. This technology requires UV action for surface modification. There are common uses of natural and lab fibers.

Huge types of lasers are capable of controlling the various wavelength. You will find different modes for surface modification for any substrates like textiles. To make a great surface modification requires a laser.

For the huge customizations, conventional technologies are beneficial from a different point of view. Using the conventional process requires much water whenever you want to discolor the jeans. The drawback of this process is that it discharges while mixed with chemicals that can’t control the intensity of the water.

On the other hand, a laser means a source of energy, and it is possible to understand the expected object. It helps to control the intensity. But how can it be possible? It’s a computer control-based technology where it is easy to alternate the utilization of water, stones, and chemicals. It is a short process that can add some customization effect to denim fabrics. It is very costly, which is the principal disadvantage of this process.

Denim Processing with Plasma Technology

Plasma Denim Processing Technologies

In the textile industry, the use of plasma technology is available. It played an important role in the last decades. Plasma technology is regarded as the implemented technology, and for that, it is developing now. This technology indicates the textile industry as an eco-friendly and inexpensive process compared to the traditional denim fading method.

Denim processing with plasma technology indicates the use of polymerizing to non-polymerizing gaseous molecules with the help of electrical discharge. The use of natural gases is the principal advantage of this method. When you use conventional technology, your fabric will be torn and faded-looking. Running this process requires a large number of chemicals and water that cause environmental pollution. To solve this problem, dry processing is the potential solution.

It is a fact that plasma and laser technology are similar. They effectively create a surface effect in the fabric where it is not necessary to use many chemicals and water. Denim washing causes environmental pollution. If you use plasma technology, it minimizes pollution. At present, sulfur and indigo is the potential component to explore the process of denim fabrics. However, cold oxygen plasma works for designing and color fading. Again, atmospheric pressure plasma is a less costly and environmental process.

Ozone Fading of Denim:

Ozone Denim Processing Technologies

Ozone fading of denim is low water-consuming denim processing. It works on the power of sunlight with the help of oxides of nitrogen, hydrocarbon, oxygen, and another chemical. Indigo-dyed fabric is turned into yellow color by the ozone reaction when it is explored. Finishing the denim fabric reduces the consumption of chemicals, water, energy, stones, and enzymes. The fading rate of indigo dye works on a certain amount of dye on fiber and its solubility. That is the complexity of ozone fading of denim. When the fabric absorbs the ozone on its surface, it starts fading.

Denim washing in ozone indicates the fabric washing by dissolving ozone in water in the machine. In the closed chamber, it fades on using ozone. However, the techno-environmental advantages of ozone denim processing are as follows:

  • Minimum loss of the fabric’s strength
  • It is an easy process
  • Contribution of low water and chemical
  • Cost-effective process

 Ozone fading complies with plasma processing. At the time of action, it emits high-energy electrons to cause moisture in the air, generating radicals’ admixture. Here, you will find the combination of charged particles’, UV light, and free radicals. However, UV- light in the plasma creates % Oh radicals. It is the most oxidative radicals in the radical generation in the plasma technology. And it is liable for the degradation of indigo dye in textile.

Ozone treated and plasma-assisted denim fabric explores the paler shade instead of enzyme-design denim fabric. Plasma oxidizes the indigo dye represented on the fabric’s surface. All enzymes react to the sizing material on fibers at the time of enzyme designing. However, it has no effect based on indigo dye molecules. There is no sign of the shade of the fabric. For the cellulose enzyme action, it may infiltrate efficiently on the denim fabric based on an aqueous medium. Here enzymatic hydrolysis indicates that ozone-treated cellulose in plasma-assisted denim is bitterer than in the enzyme-designed denim clothing.

Sandblast of Denim:

For the special look of the denim fabric, the sandblast process is one of them. It is a simple process where you have to face fewer difficulties. The Sandblast process is a modern technology that offers a certain portion of indigo-dyed denim, and for that, you have to use a special kind of sand. It is a widely used process in the garment industry for worn vintage effects. It’s a technical process that works for making important fabrics such as denim, canvas, twill, etc. Completing the action requires hard aluminum and refined granular powder.

The Sandblast process indicates that aluminum oxide sand is mixed with dry air and thrown to the nozzle at high speed. Here the sand drives away the color on a certain fabric portion. In this way, you will get a fashionable effect on denim fabric.

After completing the sandblast, it requires washing with enzymes and silicon to improve the softness of the fabric. It is for the abrasion or damage, the increasing or decreasing the fabric density. Here seam strength fabric and tensile strength fabric work for decreasing enzyme washing during sandblasting.

After silicon washing, the stiffness of denim is also decreasing, which ensures the total softness of the clothing. However, the flow angle of the sandblast is a vital parameter (10 to 20 degrees). A well-plan blowing angle is important because it gives a higher fading effect to damage the higher fabric. When the machine-based sandblasting of the denim is complete, a combination of chemical wash and other wash like stonewash fixes the denim quality.

Final Thought: 

Denim processing is similar to the art of culture. It’s a part of the fashion. It leads the garment industry to make branded clothing. However, special effect brings special value to the fabric or canvas. Here we represent four types of denim processing, all of which grow the significant effects. To create such valuable denim, the four processes require by the garment industry.

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