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The Caustic washing process of batch of 80 kg Twill/Canvas garments are described below
First step: DETERZENT WASH
ü Lot weight(80pes)———— 80 kg denim long pant
ü Add water @L: R=1:8———– 640 liters.
ü Machine running
ü Add Caustic soda(NaOH)@ 1.6 gm/liter ————- 1024 gm
ü Add Detergent @ 0.8 gm/liter —————– 512 gm
ü Temperature ———————— 50⁰c to 60⁰c
ü Time(depend upon the shade) ———————–20 to 60 mts
ü Drop the liquor.
ü Wash cold water for 3 mts.
Second step: NEUTRAL WASH
ü Add water @L: R=1:5———–400 liters.
ü Machine running.
ü Add Acetic acid @ 1gm/liter ——- 400 gm.
ü Time ————– 5 mts.
Here acetic acid is used to neutralize the garments from alkaline medium.
Third step:
ü Add water @L: R=1:6———– 480 liters.
ü Machine running
ü Add acetic acid @ 0.5 gm/liter ————- 240 gm
ü Add Flax softener @ 0.6 gm/liter —————- 288 gm
ü If more soft use silicon @ 0.4 gm/liter ———– 192 gm
ü Time ——————– 10 to 20mts
ü Drop the liquor.
ü Unload the garments on trolley.
Fourth step: HYDROEXTRACTOR MACHINE After unloading the garments from the washing machine then they are sent to hydro extractor machine to remove excess water from the washed garments.
Fifth step: STEAM DRYER/GAS DRYER
ü Load 50 kg garments to steam dryer.
ü Temperature set ——— 60⁰c to 70⁰c.
ü Run about 40-50 mts for dry.
ü Run about 10-15mts for cold dry.
OR
ü Load 50 kg garments to gas dryer.
ü Temperature set ——— 70⁰c to 85⁰c.
ü Run about 40-50 mts for dry.
ü Run about 10-15mts for cold dry.
Sixth step: Delivery After dryer, garments go to quality section for quality checking and good one is delivered garments unit.
Results:
After caustic washing, we get following points
No color change
A little bit GSM, decrease.
Increase softness
Strength becomes less weak.
So, one thing is finding that pigment wash is not a hazardous process, it is suitable for environment. Basically, it is a denim wash to remove pigment from the garments and to create old looking affect.
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