Journal of Management Science & Engineering Research | Volume 05 | Issue 01 | March 2022

Journal of Management Science & Engineering Research

https://ojs.bilpublishing.com/index.php/jmser

REVIEW
The Basic Layout of a Denim Textile Industry: A Basic Review
Md. Touhidul Islam* Md. Nahid Hassan
Department of Textile Engineering, Mawlana Bhashani Science and Technology University, Tangail, Dhaka, Bangladesh

ARTICLE INFO ABSTRACT

Article history Denim was produced in the city of Nîmes in France and was originally
Received: 7 November 2021 called the serge de Nîmes. The word denim is an English colloquialism
of the French term: “denim.” Day by day Bangladesh denim sector very
Accepted: 10 December 2021 much developed and helps to increase productivity. Bangladesh have seen
Published: 29 December 2021 a significant increase in investing in denim fabric manufacturing, increasing
the country’s production performance by reducing fabric dependence on
Keywords: imports. It is important due to its aspects of durability, and not easily torn
Denim which benefited physical laborers much. The government also plays a vital
role in denim textile industry. This paper shows different section of denim
Administration textile industry such as: sewing section, cutting section, washing, IE and
Management finishing department. The main aim of this paper is how to role all the sec-
Manpower tion of denim textile industry. Textile education is insufficient without in-
dustry attachment, which bridges the gap between theoretical and practical
Washing
aspects and acclimates students to the industrial world. We can gain about
theoretical development on an industrial level from this attachment. We
can understand more about the machines used in various departments, their
technical specifications, characteristics, operating system, and so on, and
we believe that without this type of industrial connection, it is impossible
to obtain industry-based information about textile engineering adequately.
The Industrial Attachment on Denim Manufacturing Technology was used
to organize this study (sewing section, cutting, IE, washing section, CAD
Section, and finishing department. Various operating procedures for the
production of denim in the industry are presented in this paper. The tech-
nique and process of several procedures and processes are presented here
such as machine specifications, manpower, maintenance, layout of the dif-
ferent section, dye processes and wet processes.

1. Introduction mestic product (GDP) expanded from $6.29 billion to $286

billion, with $41 billion originating from exports, with a star-
By exporting these products, the textile and garment in- tling 84 percent coming from textile and garment exports [1].
dustry contributes significantly to Bangladesh’s economic Denim garments are one of the most important components
development. From 1972 to 2019, Bangladesh’s gross do- of Bangladesh’s textile industry. Denim garments are a fam-

*Corresponding Author:
Md. Touhidul Islam,
Department of Textile Engineering, Mawlana Bhashani Science and Technology University, Tangail, Dhaka, Bangladesh;
Email: [email protected]

DOI: https://doi.org/10.30564/jmser.v5i1.4068
Copyright © 2021 by the author(s). Published by Bilingual Publishing Co. This is an open access article under the Creative Commons
Attribution-NonCommercial 4.0 International (CC BY-NC 4.0) License. (https://creativecommons.org/licenses/by-nc/4.0/).

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 Journal of Management Science & Engineering Research | Volume 05 | Issue 01 | March 2022

ily-friendly outfit that may be worn by people of all ages and 3. Different Departments
have evolved into textile and apparel products [2]. Bangladesh
Departmental investigation was the focus of our
is a textile industry-based country. Denim garments (trousers)
investigation. Each and every company has it’s own
are being produced with other garments to meet its demand
departmental section. Departmental section is also
in the competitive market of world and Bangladesh earned
the most important things that categorized a company
about 76% foreign currency from ready-made garments
according to the company’s rules and regulations. There
sector [3]. The Bangladesh denim industry is currently the top
are various departments in a denim industry which are
producer of denim in the European Union and United State
discussed in the following sub-sections.
markets. The denim industry is slated to go past 64 billion
Dollar by 2020. By 2021, apparel manufacturers in Bangla- 3.1 Store and Inventory
desh will be exporting more than 7 billion Dollar worth of The stock of any item or resource utilized in a process
denim to traditional and non-traditional markets combined is referred to as inventory [7]. Fabric inventory contains a
[4]
. Two years back, Bangladesh was highly dependent on variety of fabrics and accessories, such as sewing thread,
imported denim fabrics, but now Bangladesh can meet about needles, interlining, zippers, labels, and other items. Keeping
50% of the demand locally and are also exporting to some a well-organized and well-equipped fabric inventory system
of the globally renowned buyers. In fine, Bangladesh has an is important for bulk productions in the clothing business.
enormous opportunity to grow in the RMG export markets as The following is a flow chart of the Fabric Inventory
denim products have emerged as major players in the glob- Management system in the denim textile Industry [8].
al markets. In this regard, Bangladesh government should
prioritize denim products and provide all-out support to the 3.2 Sample Section
entrepreneurs [5]. Denim garments are made from denim One of the most significant stages in the denim textile
fabrics, which are one of the world’s oldest fabric kinds and industry is sampling. Samples are a method to attract
may always seem new thanks to years of intensive product a buyer and confirming a purchase. Several types of
development. There are a huge number of denim company samples are generated and submitted to the buyer for
remained in Bangladesh. One of them “Shasha Denims Lim- approval [9]. The ability of exporters to deal with every
ited” most significant in Bangladesh [6]. This company plays given style of garment is evaluated by samples. The buyer
the most important role in denim sectors in Bangladesh. One analyses the samples for style, construction, fit, or quality,
of the most growing up Denim Garments in Bangladesh. The among other criteria. Every factory has its own sampling
“Shasha Denims Limited” company has earned a reputation department, whose duty it is to create various samples
throughout the global woven industry as one of the foremost and obtain approvals for them. The sampling department
factories in Bangladesh for their commitment to quality, produces samples based on the buyer's requirements and
timely delivery and total value. This company is located at specifications. Spite of the fact of sampling is tough and
Savar, Dhaka-Bangladesh. The present chairman of this com- time-consuming, it will help the exporter.
pany is Mr. Anisul Islam Mahmud and managing director 3.3 Cutting Section
Mr. Shams Mahmud. The present address of this company is
Plot: 184-193 & 277, DEPZ (Ext.) BD- Savar, Dhaka, Ban- Fabric cutting is the process of dividing out pattern
gladesh. In 1991, this company was established, and the fac- parts of garment elements from a fabric lay as per pattern's
tory area is 25000 square fits. The most important factor of specified specifications [11]. It's not like common cutting,
where the actual dimensions aren't taken into account. The
any factory is it’s workpeople. Most of the development of a
cutting process is the first step in the manufacturing of
company depends on it’s workpeople or labor or worker. We
clothing. Fabric is cut into components (various shapes or
have investigated that more than 4,000 workers are working
patterns) in this procedure. Front, back, sleeve, and collar
here. In this paper we discuss a principle layout of a denim
forms, for example). Multiple layers of fabrics are spread
industry of Bangladesh.
out on a table in mass production, and large amounts of
2. Methodology fabric are used. At any given time, the certain quantity of
garments are being cut. The term "lay" relates to the fabric
In this review paper, all data and information are stack that has been set out.
collected from secondary sources including previous
articles, research papers and newspapers. Besides, Several Actions in Cutting Section
mathematical calculations are collected from “Aaron There are different types of action needed in the cutting
Denim”, a denim industry in Savar-Dhaka. section. All are important in denim textile industry when

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 Journal of Management Science & Engineering Research | Volume 05 | Issue 01 | March 2022

Table 1. Objective of different types of sample [10]

Serial no. Type of sample Objective
1 Proto Sample To examine the garments design and style of the garment.
2 Fit sample To ensuring that the garment fits properly.
3 Salesman sample To show at numerous showrooms to obtain customers.
4 GPT sample To see how far the clothing functions in various physical and chemical.
5 Size set sample To assess the factory's ability to produce samples of different sizes.
6 Pre-production sample To prepare a standard sample for mass production.
7 Pilot run Sample To inform the buyer about the factory's realistic bulk industrial capacity.
8 Top sample To convince the buyer that the same quality is maintained as in the sample.

To satisfy the purchaser that the quality of the product will be maintained to until termi-
9 Shipment Sample
nation of production.

we take this kind of action we increased our production [12]. markers make them by manually with paper patterns.
All these actions shown in this paper:
Fabric cutting
Purchase fabric from the fabric store
Following the formation of the marker, apparel patterns
The production manager provides the cutting are cut and eliminated from the layer. Fabric layers are cut
department a cut order. The cutting in-charge develops a using a wide range of technologies, namely straight knife
fabric requirement sheet or requisition slip for the fabric cutting, band knife machine cutting, and a computer-
store to issue fabrics according on the cutting plan. controlled automatic cutting machine.
Relaxation of fabrics Sorting, bundling, and numbering of garment
Knitted fabrics require relaxation before cutting. After plies (parts)
receiving the fabric from the fabric store, the cutting Layers are classified by size and colour after cutting
department opens the fabric from the fabric roll and lays it the fabric. Stickers are being used to number each layer.
on the table for relaxation for some hours before cutting. Before being transferred to the next phase, bundles are
Factories also relax fabric in the fabric store overnight stored on inventory tables.
after opening the fabric rolls.
Assessment of cut components
Cut order planning
To maintain cutting quality, quality testers inspect
The cutting master plans the number of markers they
standard cutting components at random. If any faulty
need to prepare, the size combination to be set for each
components are identified, they are repaired. Its looks into
marker and the number of plies to be laid in each marker.
the specifics of cut part inspection.
Cloth spreading/layering
Sorting printed and embroidery panels
Multiple layers of fabric are cut at the same time in
Printing and embroidery were done on cut panels as
mass production. As a conclusion, spreaders arrange
according to order requirements. After receiving printed
the fabric on a cutting table in agreement with the total
and embroidered panels, size sorting is performed. The
marker length. The layer height is restricted with one inch.
cutting section regularly double-checks printed and
Planning marker embellished panels.
The cutting master plans marker ways, marker lengths Re-cutting panels
and the numbers of plies to be laid in each lay.
For garment components that need to be replaced in
Making marker bundles, re-cutting is done. The sewing department gives
This is the process of sketching out garment patterns on out re-cutting requests for faulty garment parts. Block
the lay in preparation for cutting the garment components. panels cut for the printing and embroidery operations are
The marker paper and placed on top of the layer after also re-cut. These panels are reshaped after receiving them
it has been laminated. Those companies without CAD from the printer or embroiderer.

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Fusing garments component nique [15]. Normally, the term "washing" means the act
of cleansing something. However, in the denim industry,
Fusing in garment components is done to stiffen parts of a simply cleaning clothing is not considered a garment
garment. If needed, fusing is done at the cutting section (e.g., wash. Denim washing is a technique for adjusting the
fusing of the collar and cuff components of formal shirts). appearance, comfort, and design of garments [16]. Solid
coloured clothing and solid printed fabric are subjected
3.4 Sewing Section
to denim washing. Nowadays many types and objects of
Sewing is considered as the heart of a garment in the wash used in the denim textile industry.
fashion market [13]. After receiving all of the garment parts
from the define phase, the parts are sewn together using 3.5.1 Denim Washing Objectives
a sewing machine. Sewing Section is a very important There are many washing objectives in denim textile
department in the denim textile industry because it allows industry. All are necessary for developed and increased
the maker to obtain a complete aspect of the garments. the productions. All are included in this paper such as:
This paper talks about the most important element of To remove filth, dust, and waste from clothes, To remove
denim sewing section inspection. size materials from garments, For garments wash shrink-
age occurs, so accurate measurement can be found by
3.4.1 Inspection of the Sewing Section customers, Fading effect is varied here by variation of an
We need to identify a few basic needs that are vital in amount of detergent used, processing time and process-
the denim sewing part for a smooth and perfect sewing ing temperature, To increase the brightness of garments,
operations [14]. In general, there are three phases to To increase the smoothness of garments, To change the
inspecting the manufacturing part of clothes. They are appearance of garments, To make directly wearable after
discussed in the following sub-sections. purchase, To make garments become soft and handy and
To remove harmful materials from garments [17].
3.4.2 Sewing Inspection
3.5.2 Process Flow Chart of Denim Garments
No needle holes should be seen. Only defective Washing
stitches, such as slipped stitches, staggered sewing, and
asymmetrical stitches, should be visible. It's better to Denim is essential part of garments. Garments washing
avoid puckering at the seams. has some processes. All the processes are important for
denim textile industry [18]. When washing is not good then
The density of the stitches should be comparable.
we can’t good products. Actual process flow chart for gar-
Uneven stitch length should be minimized. A spot of oil or
ments washing are mentioned in the following:
an uneven stitch length should be inspected.
3.6 Administration
3.4.3 Seaming Inspection
As companies increasingly sell services and look for
Unequal width of seam. Insecure seam. Miss matching
opportunities beyond their home markets, their supply
of stripe and checks between two components along
chains become more global [19] . Product design, for
seam line. Trapping of foreign materials inside the seam.
example, traditionally heavily global inputs, and products
When the fabric’s front and back sides aren’t the same.
are sold around the world. Because of lower labour or
Application of the improper stitch type or seam type.
material costs in other countries, some manufacturing
Variation in shade between stitches.
operations or services may be outsourced. In this section,
3.4.4 Assembling Inspection the current state of the textile industry in various nations
has been demonstrated, including Pakistan, India,
Any component that is the wrong size or shape. The Vietnam, Taiwan, Thailand, China, and Bangladesh. It is
clothing were the correct length. Any design in clothes is important of our denim sector.
ignored. Any component in a garment that is not properly
situated. Incorrect interlining placement and fusing. Management System of a Denim Industry
Variation in shade from one component to the next. Each garment is run by a management committee.
The managing director is responsible of that committee,
3.5 Denim Washing
and many executives in various positions assist him. The
In the denim sector, the garment was a new tech- higher are listed below in order of power and function.

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Journal of Management Science & Engineering Research | Volume 05 | Issue 01 | March 2022

Table 2. Schematic flow chart of denim washing

Garments receive from the sewing department
↓
Garments sent to the dry process
↓
Hand scrapping
↓
Whickering
↓
Tacking
↓
Garments sent to the wet process
↓
Garments loading into the washing machine
↓
Extracting
↓
Drying
↓
Garments sent to the dry process
↓
P.Pspray
↓
P.P sprayed garments sent to the wet process
↓
P.P sprayed garments loading into the washing machine
↓
Washing
↓
Send to the finishing department Extracting
↓
Drying
3.6 Administration ↓
As companies increasingly sell services
Garments sent toand
thelook
dry for opportunities beyond their home
process
markets, their supply chains become more global [19]. Product design, for example, traditionally
↓
heavily global inputs, and products are sold around the world. Because of lower labour or
3D operations or services may be outsourced.
material costs in other countries, some manufacturing
↓ in various nations has been demonstrated,
In this section, the current state of the textile industry
including Pakistan, India, Vietnam, Taiwan, Thailand,
Curing China, and Bangladesh. It is important of
our denim sector.
↓
Management System of a Denim Industry
Quality committee.
Each garment is run by a management check (Q.C) The managing director is responsible
of that committee, and many executives in various ↓ positions assist him. The higher are listed
below in order of power and function.
Send to the finishing department

Managing General Merchandiser Production

Merchandiser
Director Manager Manager Manager

Helper Worker Line chip Supervisor

Figure 1. Management system of a denim industry

Figure 1. Management system of a denim industry

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3.7 CAD Section 3.8 Industrial Engineering (IE)

Because the denim textile industry is the most skilled Industrial Engineering is concerned with the design,
labour-dependent industry, any cost savings through new development, and construction of system components of
Computer-Aided Design (CAD) technologies has become man, machine, and equipment, using specialized knowledge
a requirement in gaining a competitive advantage, most and skill in the technical, economics, and natural science, as
universities have included CAD pattern making systems well as the principles and methods of engineering analysis
education and training as part of their clothing technology and design to specify, predict, and evaluate the result of
courses in recent years, in response to the actual needs of the such system [20]. It also plays important role in denim
fashion world for high-skilled fashion designers and clothing textile industry. Because using IE we developed our denim
engineer [19]. CAD/CAM (Computer Aided Manufacture) production. Without IE we can’t get more products, day by
systems enable a design to be created and altered fast without day it has used more. It has some responsibility in denim
sacrificing creativity, and they improve communication and textile: Capacity measurement, Work evaluation, Time
integration across product development systems. They’ve analysis, operator performance, Verification, WIP (Work in
played a key role in reducing the cycle time, increasing ac- Progress and Line balancing.
curacy, and placing clothes products in stores significantly
closer to when customers need them. 3.9 Finishing Department
With the increasing application of open-source soft- Before to packaging garments into poly bags, finishing
ware (OSS) in a various application, it’s essential to de- activities are carried out. A finishing department's primary
termine whether existing OSS CAD software for garment duties include thread reduction, garment inspection,
prototype development can support the learning process. and ironing [21]. The wrapping division of the finishing
An objective assessment of CAD model complexity, per department is where garments are wrapped, labelled, and
the summers and Shah can be useful in assessing case stored. Without finishing department, we can’t develop
studies, evaluating the results of experiments, or evaluat- our denim sector. Finishing department is essential for
ing student projects. The probable impacts of CAD model denim sector. Without it we can’t import products that’s
complexity have been recognized by a number of other why we can’t earn money that’s why is important for
publications. Modelling technique, according to John- denim sector of textile.
son, Valverde, and Thomison, comprises the amount of It has some function of finishing in denim textile
time spent on particular learning activities. In total, two industry. All these functions is very much important of
licensed and two OSS systems were compared for their industry. Without finishing we can’t import the products
usefulness in producing ten different pattern designs for that’s why it is important of our denim textile section.
garments. The results of a day when evaluation of a col-
lection of computer systems and licensed CAD systems Thread Trimming
are provided and critically evaluated. Thread paths and thread chain stores are not neatly
trimmed in the stitching department. Helpers in the finishing
Purposes of CAD in Denim Industry
department trim uncut threads and thread tails in garments.
Textile engineering (TE) and fashion technology (FT) Defects in garments comprise uncut and loose threads.
educational and training are constantly subjected to offi-
cial evaluation by various certification agencies. Tradi- Aesthetic and measurement inspections
tional CAD and drawing courses mainly focus on geo- At the finishing stage, all garments are graphically and
metric modeling, including wireframe, surface, and solid quantitatively checked. Finishing checkers regularly check
modeling. According to Ullah and Harib, the material of the whole garment from the inside out. Garment detailing,
a CAD/CAM course should help students achieve at least such as care labels and trimmings, are checked.
the following four outcomes:
a. The ability to apply math, science, and engineering Button attach and Butting holing
knowledge. In the finishing section, products to trimming such as
b. The ability to design a system, component, or buttons, grab buttons, and eyelets are attached.
process that meets the desired needs.
c. The ability to identify, formulate, and solve
Stain removal
engineering problems; and Stains and spots can be detected on clothing. Prior to
d. The ability to use the techniques, skills, and modern pressing, spots are eliminated with a hand spot gun or a
engineering tools required for engineering practice. stain remover system. Machine washing helps eliminate

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dust and stains. As a result, the finishing department merchant whenever an order's packing is completed.
frequently washes items within the department.
Internal shipment audits
Mending and repair work Quality department performs internal shipment audit in
Stitching and fabric defects in defective garments may the finishing department. Prior to the final inspection, this
require repair. Rather than sending damaged clothing to audit is conducted.
the stitching department, all repairs are completed in the
Reporting and documentation
finishing department.
The finishing department, like the other departments,
Ironing clothing
keeps a list of manufacturing records for pressing and
Steam irons have been used to iron garments. This is packing. All these functions are important of denim sector
done to get rid of creases in the fabric. Steam pressing in textile finishing.
are used to set parameters for knitted clothes. Garment
pressing is done using vacuum pressing tables. 4. Manpower Organization
Folding and tagging Manpower planning is one of the major activities which
consumes a significant amount of time and effort of an IE
Pressed items are folded to a predetermined size. A
at a denim textile manufacturing unit. Companies struggle
Kimble gun or threads are used to attach tags such as price
tags and hang tags on the clothing. to arrange and allocate desired machines and manpower to
get the intended output, and many a times, unavailability
Packing the garments of machine and manpower is taken as an excuse to hide
Finally, the garments are folded properly and placed in poly or cover up the failures [22]. Though allocating the right
bags according to the customer's specifications. After that, the people to the right work with the proper gear is a delicate
individual poly bags are packaged into larger cartons. problem, most this do not place enough emphasis on it.
An imbalance among requirements (manpower or machin-
Packing list creation ery) and actual allocation can create massive imbalances
The shipping in-charge creates a packing list for the in the process, which can stymie the setup’s performance.
package. The finishing department notifies the concerned It is quite essential for denim sector of textile.

Table 3. Manpower organization in denim industry [23]

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5. Raw Materials Used in Denim Industry Table 4. Size of button

Ligne Millimeters Inches
Different type of raw material used in denim textile
14 8.9 0.37
industry such as fabric, button, zipper, sewing thread, 16 10.1 0.41
label, different quality yarn, fibre, Dye stuff, Chemical 18 11.4 0.38
and auxiliaries. In any production-oriented denim textile 20 12.7 0.51
sector, raw material is an object. It is necessary for contin- 21 13.3 0.53
uous productivity and increased fabric. Cotton, jute, wool, 22 14 0.57
raw silk, and synthetic goods are being used as raw mate- 23 14.6 0.59
24 15.2 0.63
rials in the denim textile industry [24]. Textile raw materials
27 17.1 0.67
are chosen based on the company’s manufacturing policy, 28 17.8 0.69
such as whether it is a composite mill or merely a spin- 30 19 0.75
ning, weaving, or dyeing / finishing operation. All of these 32 20.3 0.83
combine a good production of denim textile industry. 34 21.6 0.86
36 22.9 0.88
5.1 Fabric 40 25.4 1

Denim is a 100% cotton fabric that is woven in a twill

5.3 Zipper
weave with different colours of warp and weft yarn [25]. On
the fabric surface of denim fabric, one color dominates. A zipper is an integral element of a garment that
Denim is a common raw material used in the clothing allows it to open and close. This is a type of trimming that
industry. Denim fabrics are mostly made of cotton, while can also be used as a garment accessory. In the apparel
hemp denim is occasionally found. Denim fabrics are industry, the zipper is the most prevalent fastening device
commonly used to make jeans, work clothing, and organic [30]
. Zipper is essential raw material of denim textile sector.
futon and pillow casings. Different types of denim fabric It consists of a slider with a tab, facilitating the opening
used such as Colored denim, Bubble gum denim, Denim or closing of two interlocking teeth or coil connected to
from fox fiber, Crushed denim, Vintage denim, Ecru den- a fabric tape strip. In making trousers, shirts and jackets,
im, Marble denim, Reverse denim [26]. zip or zipper is an essential component used to open or
close the garment’s opening. Plastic zippers are not only
5.2 Button more convenient for attaching garments, and they’re also
A button is a little round disc that is generally sewn onto wind, dust, and waterproof, and they do not snag, stick, or
an article of clothing or garment to close a gap or to enhance rust. The innovation of plastic zippers also meant that they
decorative feature. Buttoning is achieved by sliding the but- could be made in any color, allowing fashion designers
ton through a stitched slit called a buttonhole or thread loop another tool in their inventory. Many zipper used in denim
in the fabric. Buttons are fashionable because they decorate textile industry such as Nylon coil zippers, Two way sep-
and improve the appearance of denim textile clothes. It is arating zippers, Closed-end zippers, Separating zippers,
mostly used for increasing the appearance of garments [27]. Continuous zipper chain, Metal teeth zippers, Molded
Different types of button used in denim textile section as plastic zippers, Pant zippers, Invisible zippers, Bag, zip-
example: Plastic Button, Metal Button ,Wooden Button, pers, Water repellant zippers, Lapped zippers.
Fabric Button, Shell Button Glass Button, Pearl Button, Or-
namental button, Animal skin button, Ceramic button [28].

Sizes of Buttons
The button's size was calculated by its application. Shirt
buttons are most often small and close together, but coat buttons
are larger and split out [29]. Buttons are usually measured in lines
(also known as lines and abbreviated L), with 40 lines surpassing
1 inch. For example, 16 lines (10.16 mm, standard buttons
for men's shirts) and 32 lines (10.16 mm, standard buttons for
female's shirts) are two most common button sizes (20.32 mm,
typical button on suit jackets). Figure 2. Main parts of a Zipper [33]

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5.4 Sewing Thread 5.5.2 Main Label

The apparel business employs a wide range of sewing The main activities specifically the buyer’s brand name
threads. Sewing thread is a trim that secures the seams or logo, such as C&A, Tom Tailor, Zara, and so on. From
and ensures the functional features of a garment or other the customer point of view, the brand name indicates
clothing product. The apparel business employs a wide emotional contentment with the product. Customers prefer
range of sewing threads [31]. Swing thread is a necessary brand labels since they are the only ones who are aware
about the brand and who consume it.
trimming that is widely used in the denim garment in-
dustry. Sewing thread is used to create clothing in the 5.5.3 Sub Label
denim textile section. Threads are made by twisted two
or more filament yarns together. Single filament is also There are five types of sub label in denim textile
section such as
used on occasion. Sewing threads can be made of natural,
I. Care Label
synthetic, or mixed fibers. When it comes to closing and
II. Size Label
top stitching seams, core spun threads are ideal since they
III. Price Label
produce high quality seams. Continuous bulk filament IV. Composition Label
threads are ideal for overlocking or cover stitch seams. V. flag Label
Natural and synthetic fiber blended core spun threads are
ideal for sealing seams on high-quality denim garments. (I) Care label
Continuous filament threads are ideal for creating optimal Garments become dirty during end-use and it natural
seam strength in leather items. Sewing threads are yarns truth. These dirty garments are re-used by cleaning and
that’ve been designed and created to pass quickly through ironing. For perfect caring of garments, some instructions
a sewing machine. During the product’s useful life, they are expressed by symbols which are called care code.
form efficient stitches without breaking or getting distort- The label in which, the care codes of a garment are
placed called care label code. There are generally five
ed. A thread’s primary objective is to provide aesthetics
types of instructions are used in a care label which are
and performance in stitches and seams. Sewing thread is
internationally recognized, called international care
essential raw material of denim textile industry. There are
labeling code.
different types of sewing thread used in denim textile sec-
tion such as: Linen thread, Silk thread, soft cotton thread, (II) Size label
Mercerized cotton thread, Glazed cotton thread, Viscose Size labels vary from country to country. The different
thread, Polyester thread, Nylon thread, Aramide thread, types of sizing for clothing include:
PTFE thread. a. 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30
b. XXS, XS, S, M, L, XL, XXL
5.5 Label c. small, medium and large
Label is another raw material to use denim fabric. d. 0, 1, 2, 3, 4, 5
Label is a part of garments which indicates the various e. One size fits all
instructions about the garments [32]. Without any label a (III) Price label
garment cannot be sold especially in export-oriented gar-
Show the price of garment in different currency
ments. The essential data like size of the garments, fiber
depending on country.
type, care data, country of origin, company name, and
Composition label
trademark etc. It has some function: Product recognition, Content labels identify the type of fabric that has been
Suggestions for clothing sizes, promotes the product, cus- used to make the garment, for example, 100% Polyester,
tomers’ information Garments are categorized [33]. Silk, 100% Cotton. It is very important that you choose
5.5.1 Types of Labels the correct content label to attach to your garment. When
buying fabric, you should always insist that the supplier
There are mainly two types of labels used in denim confirms the fabric content in writing (or with swing
textile industry such as tags). In some instances, the care and content labels are
● Main label combined into one and this will cut down on the number
● Sub label of labels used on the garment.

9
 Journal of Management Science & Engineering Research | Volume 05 | Issue 01 | March 2022

(V) Flag Label crinkles, seam puckering, hairiness, Pilling softened-hand

feel, stabilized dimension etc. Most of the denim wash ef-
Sometimes garments contain small flag of buyer’s fect vintage look.
country which is known as flag label.
6.1 Denim Dry Processes
6. Denim Washing
Dry processes are important part of denim washing.
Denim washing is an attractive finish provided to den- Day by day dry processes is much popular in denim wash-
im fabric to increase its beauty and strength. Now-a-days ing. Denim’s dry process occurs before the wet process,
denim washing is much popular both dry and wet washing and it alters the aesthetic look of the fabric through me-
process According to the fashion and appearance, there chanical abrasion without influencing its construction or
include new washing process and technology such as 3D qualities. The garment takes on a good appearance after
or laser techniques [34]. In denim washing is done to pro- drying, and it also adds value to the product. The dry pro-
duce effects like color fading with or without patchiness, cess is used to create fashionable clothes [35].

Table 5. Different types of dry processes in denim textile industry

Dry process Description Image References

Materials and ways: It requires abrasive paper or emery paper and some
various ways such as by whiskering pattern, by Manual hand scrap, and by using
Whiskering [36]
laser Machine.
Functions: It gives whiskered effect or fading effect on denim garments.

Materials and ways: After whiskering it requires abrasive paper, air dummy
(horizontal), gum tape and Hand.
Hand Scraping [37]
Functions: This process removes the color or fade specific area of the denim
garments.

Materials and ways: Tag gun, tag pin, chalk and hand gloves are required for
Tagging this process. [38]
Functions: It gives tagging effect at edge area of denim garments.

Materials and ways: It requires Grinding machine and small size of stones are
used in this process. This process is done manually.
Grinding [39]
Functions: This gives old look appearance and creates high fashion denim
garments.

Materials and ways: It requires Grinding machine, grinding wheel, different

size stones, niddle, knife, electricity, safety accessories. This process is done
Destroying manually. [40]
Functions: It creates holes and worn-out white yarns which make garments
unique and fashionable.

10
 Journal of Management Science & Engineering Research | Volume 05 | Issue 01 | March 2022

Dry process Description Image References

Materials and ways: It requires water, Potassium permanganate (.4- 15 gm/L)

(standard stock soln = .4 %) 3. Acetic acid (as per need). It also requires P. Spray
Cabin, spray gun, air dummy, water circulation system, musk’s, gloves, safety
PP Spray [41]
shoes and apron, electricity.
Functions: It gives white or yellowish and bleach spot randomly in the denim
garments.

Materials and ways: It requires resin 20% and water 80%. It also requires
Overall Crinkle washing machine, trolley, hydro extractor, curing machine, tie, rope, and thread [42]
Functions: It produces special effect on denim garments.

Materials and ways: This process is done manually or semi automatically using
resins like low formaldehyde or DMDHEU (Dimethylol Dihydroxy Ethylene
3D Crinkle Urea) type resins Various supporting auxiliaries are used for this process. [43]
Functions: It gives 3Dimensional effect on denim garments at the thigh, hip and
back knee area.

Materials and ways: It requires laser machine, leather hand gloves, goggles for
Laser safety and photoshop illustrator app. [44]
Functions: It creates whiskering or burning effect on the denim garments.

6.2 Denim Wet Processes production processes, give it a fresh look, soften it, and
make it ready for the purchaser. In this paper shown the
Following the dry process, wet processes including as denim wet processes which is used in the denim textile
desizing, enzyme washing bleach washing as well as other industry. All the wet processes are important of our denim
washes are applied to the raw garment to get the beautiful. textile industry. Without wet processes impurities are
The garment goes through multiple chemical processes included in the fabric so the products look unattractive, so
in this procedure to eliminate contaminants from various it is important in denim textile sector.

Table 6. Different types of wet processes in denim textile industry

Wet process Description Image References

Chemicals & materials: Detergents, Soda, Hydrogen peroxide,

Anti back Stainer, stone.
De-sizing [45]
Functions: This process removes size materials, increase luster
and absorbency.

11
 Journal of Management Science & Engineering Research | Volume 05 | Issue 01 | March 2022

Wet process Description Image References

Chemicals & materials: Just water and slight detergent and

Normal/Regular wash back Stainer. [46]
Functions: This removes starch, dust and dirt from garments.

Chemicals & materials: Pumice stone, perborate and optical

brightener if necessary and softener.
Stone washing [47]
Functions: This process gives vintage look, irregular color
fading and softness of the garments.

Chemicals & materials: Sodium hypo chloride, Hydrogen per

oxide, and Sodium hypo-sulphite.
Bleach washing Functions: It gives Light BLUE shade, removes the starch [48]
present on the garments, removes the size material from the
garments and achieves soft effect on the garments.

Chemicals & materials: Neutral/Acid enzyme: G.B ZYME, Bio

polish.
Enzyme washing Functions: This process removes floating fiber, smoothen surface [49]
of garments, gives high-low effect, increase luster and removes
starch, sizing material.

Chemicals & materials: Stone,

Potassium permanganate and
Acid washing Phosphoric acid. [50]
Functions: This gives Vintage/old look,
Irregular fading and Softness.

Chemicals & materials: It does not need any chemical just need
hydro jet and water.
Waterjet fading [51]
Functions: This increases the surface finish, texture, durability
and other characteristics of denim garments.

Chemicals & materials: Pigments, direct dye, bleaching agents

Dip dyeing and dip dyeing machine. [52]
Functions: It creates special effects on denim garments.

Chemicals & materials: Pigments, softener and water.

Pigment washing [53]
Functions: It gives vintage look, softness, and fading effect.

Chemicals & materials: It can be used different types of dyes

like direct dye, reactive dye, sulfur dye and pigment colors.
Tinting [54]
Functions: It gives new fashion designs and vintage or muddy
look on the garments.

12
 4) Totalweightofyarn
Total kg =
length × Total Ends × 0.0059 following
1) warp / calculation are used(%)
length shrinkage as follows:
= (Greigh pick −
Total length × Totalcount
Ends × 0.0059
Average
m
1) warp / length shrinkage
Finished Pick) × 100 ÷ Finished (%) = Pick
(Greigh pick −
Average countsspeed×shade×weightofyarn gm/mtr
5) Dossing = m sspeed×shade×weightofyarn Finished
2) Skew (%) Pick) × 100 ÷ Finished Pick
Feedsolution g/L gm/mtr
5) Dossing = Total length × Dossing
2)
A →Skew (%)
skew(C. M) ÷ 2.54 × 100 ÷ width (inch)
6) Total Dossing Journal
= ofTotal
Management
Feedsolution Science & Engineering Research
g/L
A → | Volume 05
skew(C. M)| Issue 01 | March
÷× 2.54 2022 width (inch)
length × Dossing
M/c speed × 100 B → skew(inch) 100 × ÷ 100
width÷(inch)
6) Total Dossing = shade% B Meter
3) → skew(inch)
to Yards × 100 ÷ width (inch)
speed××Total
100 volume
7) Box dye amount = M/c or,
7) Wet process shade% × Total
M/c speed volume
× 1000Description
or, 3)
A Meter
→ to Yards Image
length(meter) × 1.0936 = yards References
g/LBox
× bothdye amount =
volume M/c speed × 1000
BA→ → length(yards)
length(meter) ÷× 1.09361.0936 == meter
yards
g/L × both
1000volume
Chemicals
shade% × pick B → length(yards)
4) After
up% & materials: It can be used direct dye, pigments ÷ 1.0936 =
andwash fabric shrinkage meter
warp/length
8) Dye 1000= shade% × pick up% bleaching agents for tie dyeing. 4) After wash fabric shrinkage warp/length
8) Dye =
Tie dyeing
stock solution = (Finished Pack − after wash pack)[55]× 100
Function: Box g/L × Totalpatterns
bath volume
and bleaching effect=on (Finished
9) Volume of stock Black bath =It makes
solution different the Pack
÷ − after
after wash wash
pack pack) × 100
Box g/L × Feed
Totalg/L
bath volume
9) Volume of Black bath = garments.
** All mathematical ÷ calculations
after wash pack are collected from
10) Pick up% (sre chemical) = Feed g/L
10) Pick
Total weightup% (sre
of sizing chemical)
chemical = **
“Aaron Denim” (Savar-Dhaka). are collected from
All mathematical calculations
Total weight of sizing chemical
× 100% “Aaron Denim” (Savar-Dhaka).
Tie dyeing Total weight of yarn
Chemicals & materials:
×100100%It can be used direct
7.11)Mathematical
Total weight
RF% =dye,Total
Total
of yarn
pigmentsCalculations
chemical
and1.8bleachinginagents
× Differentfor tie Indirect
N = L ×w
system
L ×w
chemical
of water××100
Sections
11)
12) RF%
viscosity
volume
=dyeing.
= RFof ×
volume water1.54× 1.8 N = l ×W [55]
l ×W
12) Weaving
viscosity = RF × 1.54
7.17.3Warping & LCB (Long
Function: It makes Chain Beamer)
different patterns and Direct
Direct System System
Research in Ecology | Volume 03 | Issue
7.3 Weaving The process of weaving the warp and weft Research in E
The bleaching effect on the garments.
process Directw System ×l Research in
Research in Ecology
Ecology ||VolumeVolume 03 03 ||Issue
Issue
threads
Warpinginto the
is the actualofselvedge
process weaving
of preparing the yarn
denim warpfabricandweaving.
for weft
takes N = w×l Research in Ecology | Volume 03 | Issue 04 | Dec
threads
It place
is the on into
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a shuttle loom.selvedge
moving Themany denim
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creel of 2) = L count = r1r1+r2+r3
N Average r3 ; Here c1, c2, c3 r1+r2+r3 are Cloth
L + r2 2)c3Average count = r1 r2 r3 ; Here c1, c
place
in the on
past,a shuttle
although loom.it The
has now shuttle
been loom
largely was popular c2 + factor
single packages to a beam. The yarns will be placed onto 2) Average
2) Average count
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r1+r2+r3Research ; Here
Here
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c1, c2,
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c3 are
| c1 +
are
Volume +
c2 c303 | Issue
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cover
in the past,
superseded although
by modern it has nowyarn
weaving been
machines. largelySelvedge count
2)
2) Averagewith their
count
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= = r1r1 : r2
+ r2 :; r3
+ r3 ;
Research
Here c1, c1,
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| Volume 03 | Issue
7.4 Fin
the beam in a parallel sheet. The arrangement in the
r1 r1 + +r2
+c1r2 count
c2r3+ r3
c3 with their ratio r1 : r2 : factor r3 factor factor -
7. Mathematical
superseded
denim, on the Calculations
by other
modern hand, weaving
is still in
wovenDifferent
machines. on shuttleSections
Selvedge count
3)
count
countweight
with
count with with
their
withtheir their
ofyarn ratio
theirratio ratio
r1
c1 c1 c2 c2c3 c3 Total Ends × 0.59
gm/mtr
: r1
r2
ratior1r1: r2: r2 :: r2
r3
: r3 :
=
: r3r3
-
7.4
{(war
Total Ends × 0
Fin
dyed rope is transformed from a rope to a sheet shape in 3) weight
Average ofyarn
count gm/mtr =7.4 Finishing 7.4 Fin
7.1 Warping
denim,toon
looms &produce
LCB
the other(Long
aThehand,Chain
genuine stillBeamer)
is and woven on shuttle
high-quality fabric. 3)2) weight ofyarn r1+r2+r3
gm/mtr Total Total
=; Here EndsEnds
Total
Ends
× 0.59 × 0.59
× 0.59 manuf
Average
Cloth
coun
cov
Long ChainisBeamer. rope pull from theforcan is moved 2)
3)
3) Average
weight
weight
Average count
ofyarn
ofyarn count =
gm/mtr
gm/mtr
r1+r2+r3
=r1 +r1 r2Or = == Total
r3 ; Average
Here
Ends
c1, c1, c2,c2,c3c3 areare Total ClothFabr
Ends c
Warping
looms the
to produce
The following process of
a genuineare
calculation preparing
and used yarn
high-quality weaving.
in weavingfabric. It
section. is the process of moving many +r2 r3 Average count count Or = factorproduc - {(
c1 c1 c2 + c2c3 + c3countAverage
Total × count
1.6933
Ends manuf
manufacturin
countfactor
manufa
× 1.6933 -
yarnsupward
from
The a to a guiding
creel
following of single device
calculationpackages in
aretheto aLong
used beam. Chain
The yarns
in weaving Beamer.will be placed
section. count
count onto
withwiththe their beam
their ratio inr1
ratio a r1 : r2
Or :Or
=r2
Total
=: r3Total
: =r3
Ends Ends
7.47.4 on
Finishhowa
parallel1)sheet.
Reed The Space
Total
=is Total
yarn arrangement
Ends Or count count × 1.6933
× 1.6933 products produc
produc are
Fini
The guiding device EPIEndsin positioned
probably the dyed rope in isthetransformed
ceiling from3) 4) a rope to
Totalweightofyarn
weight
a
ofyarn
sheet shape
gm/mtr kg ==
4) Total
count Ends
×
Totalweightofyarn
Total Ends × 0.59
1.6933 × 0.59 kg = on how follow
the Fcl
in Long 1) ReedBeamer.Space = rope a3) weight ofyarn gm/mtr Total =Average onon how how
2)Chain The pull from
Reed Count × No.
EPIof yarn pass the
into can
reed iseyemoved upward toTotal guiding
length ×device in the ×count
above EPIthe=can. The following calculations are used in 4)
4) Totalweightofyarn
Totalweightofyarn
Total Ends × 0.0059
kg kg = =
length
Average
Total Ends
Total
count Ends × 0.0059
following 1)
manufactu
manufac war
follow cal
Long Chain
2) Beamer. ReedThe guiding
Count × No. ofdevice
yarn
2 pass is probably
into reed eye 4)
positioned in the ceiling above
Totalweightofyarn the Ends can.×The kg
OrOr === Total Ends count
Average followi
3) EPI of=LCB
warping & Average Totalcount
warpsection. 1) products a
Total
Totallength ××Total 0.0059
No. inused
yarninselvedge length Ends
m ××0.0059 0.0059 warp 1) /war
Finish
products len
following calculations are warping
2 &=LCB section. Total length × Total
Average countEnds countcount × 1.6933 m sspeed×shade×weightofyarn
× 1.6933
1) war g
3) No.
selvedgeof warp
width in cm in ×yarn
5905 selvedge =
EPI 5) Dossing Average = count 5) Dossing = gm/mtr Feedsolution
sspeed×shade×weightofyarn onon
Finished how
2) Ske
how th
Pic
1) yarn tension = ÷× 0.075 Average m
count m
sspeed×shade×weightofyarn g/Lgm/mtr
Finish
g/L
Finish
selvedge width2.54in cm × EPI count 4)
5)4)Totalweightofyarn
Dossing kgkg
= m sspeed×shade×weightofyarn
Totalweightofyarn ==
Feedsolution
sspeed×shade×weightofyarn gm/mtrTotal length 2) ×following
Skewfollowin
A
Dossing → (%)s
÷ 5) Dossing = Total 6)
length
Feedsolution Total
×g/L
DossingDossing gm/mtr = 2)2) Ske
Skew
No.core
2) of yarn 2.54pass
length
Bag weight
= into reed eye
(gm)
× *selvedge
count × 1.6933 width = for 5)
Total
6) Dossing
length
Total
Total length × ×=
Total
Dossing Ends
Total Ends =× 0.0059
× 0.0059
Total lengthFeedsolution
× Dossingg/L g/L M/c A
speed →
1)
× skew(C
warp
1)B
100
→ /ss
warp
No.yards
of 1.50
yarn pass intoNo. of core
reed eye *selvedge width = for 6) Total Dossing
Average count = Feedsolution
M/c speed××Dossing 100 shade%B → × A
Askew(i
Total →
→ sk
volum
cotton =& for 1.70 6) Total
Average count Total Total length
7)×Box dyevolume amount = Finished
3) Totaldye Dossing M/c speedFinishe
meter × 1.09361 m m= M/c speed length
shade% 100
××Dossing
Total 3) Met
cotton 1.50 & for 1.70 6)
7) Box Dossing amount =sspeed×shade×weightofyarn
=
sspeed×shade×weightofyarn
shade%
M/c speed × Total volumegm/mtr
× 100 or, 3) Meter
2) B B
Skew →→
× 1000
to Y ss
→(%
motor PPM ×length
moto × pully diameter
4)
4) Loom
operator Speed
production= motor = PPM
warp No. of ball warped 5)
7)5)Dossing
Box dye amount
Dossing = = = Feedsolution
M/c speed
M/c speed
g/L × ×
both100 × 1000
volume gm/mtr
or, 2) A Skew
loom×pullymoto pully
diameter diameter
Total no of ball 7) Box
g/L Box
× bothdye volume amount =
shade%
M/c speed
= length × Dossing
shade%
Feedsolution ×
×× Total
g/L
1000
Total g/L volume
volume or, A →
AA → 3) Met
length
3)→skewMete
4) Loom Speed = 7) × bothdye amount 1000 or,pick up% B → B
sk
5) Loom
5) Estimated yarn kg
efficiency percentage
warp length (mtr)
= loom pully =
× Total
Actually
diameter prodEnds
× 100
g/L
6) Total
6) Total
volume
1000DossingDossing
Total
= = Total length M/c speed
M/c
8)
× Dossing
speed
Dye =
× 1000
× 1000 shade% ×
B → A→
length(
A →→l
skew
1.6933 ×calculated
count ×1000
Actually prod
prodn g/L × both
1000 volume shade% × pick M/c
up% M/cspeedspeed × 100
× 100 B 4) → Afte sk
5) Loom efficiency Total percentage
break × 1000000= × 100 g/L
8)
8)
×
Dye
both
=
volumeshade% × pick up%shade% × Total volume stock solution 4) After
3) B× →
Meter
B → tll
wash
6) Moisture
6) Break % =regain% = calculated prodn 7)7) Dye
Box 1000
Box
1000
=
dye dye amountamount
stock
shade%
= =up% 9) Volume of Black
solution
× Total volume or,or,bath = Box 3)
g/L Meter
Total
=
Set length × Total Ends stock
shade% solution
×
shade% × pick up%M/c
pick speed ×Total
1000 A=A 4)4)
(Finis
→ Afte
lenleg
Afte
Feed
6)yarn
Moisture
Lbsweight − Driedregain% yarn = kg ××2.2046
Totalweight
yarn
100 8)
9)
8)
g/L Dye
Volume
Dye
Volume
× both ==
volumeof of Black
Black bath
bath = =
M/c
Box speed
Box
g/L ×g/L ××1000
Total bath volume
bath volume →
7) = g/L × both volume stock solution 10) PickFeed up% g/L (sre chemical) =B → leng =le
break
yarn weight
Dried −yarn
Dried yarn weight
weight Total break
× productionn
100
stock solution Box g/L ×of Feed
Total g/L
bath volume ** All →=
B mathe
9)
10)
1000
Volume
Pick
10)Volume 1000
Pick up% up% of Black
(sre bath
chemical)
(sre ×chemical) = Total
= Boxweight
g/L × Total sizing chemical
bath volume
4)4) ** All
7)
8) Moisture
Dried yarn
Operator content%
weight = =
Efficiency
Total (length mtr)
9)
8)Total
Dye == ofshade%
shade% Black × bath
pick up%
pick up% = =Total weight Feed g/L × 100%
“Aaron
AfterAfter
Denim
w
7)yarn
Moisture
weight − Driedcontent%yarn weight =RPM×× 100 Total mun − (break × 2 8)
Total Dye
weight
weight ofofsizing
sizing
stock chemical
chemical
solution ×× 100%
Feed of yarn
g/L “Aaron
**
== All
(Fin
7.2 Dyeing & yarn
Sizing 10)
10) Pick up% (sre
stock chemical)
solution 100%= Total chemical × 100 ** All (F
Pick up% = =11)Box
Total weight of(sre
yarn chemical) Box= RF%
g/Lg/L ×=Total
× Total bath volume
yarn weight − Dried
weight yarn weight
× 100 9)Total
Volume
9) Total
Volume
weight of
weight
of of Black
of
sizing
Total
yarn
Black bath
bath
chemical
chemical × 100
bath volume
volume of water × 1.8 “Aaron
“Aaron
L ×w
Dyeing Total weight of sizing chemical ×× 100% Feed g/L
7.28) Clothiscover
Dyeing the
yarn process
& weight factor,of incorporating yarn with color. It's done 11)
Sizing by soaking
11) RF%
RF%Totalup%
== the yarn
weight of yarn
in a
Total chemical
×100
12) 100% viscosity Feed= g/LRF × 1.54 N =
**** All
Nl ×W =mam
All
Indigo is theEPImost frequent dye for denim. 10) Pick volume
(sre of water × 1.8
chemical) =Weaving
dyestuff-containing
8) Cloth cover liquid.
factor, 12)10)
Because Pick
Total
viscosity up%
only
weight
=
of(sre
the
volume
RF warp
yarn chemical)
of
× water
1.54 ×7.3
1.8 =
Total chemical × 100 “Aaron De
arewarp
dyed,iscover factor =incorporating 11)Total
12) RF%
viscosity =on = RF
Total × 1.54
chemical × 100 “Aaron
Total weight of sizing chemical
threads Dyeing
warp
the
the weft
cover
process yarns
factor
of are
=
left
warp natural
EPIcount yarn undyed with or color.
bleached, denim
11) is blue
RF%
7.3 Weaving
weight
= the
of sizing
volume front
chemical
of water × ××100% 1.8100%The process of weaving theN Nwarp== a
and It’s
whitedoneon theby back.
soaking Onthe the other PPIhand, sizing is used to improve 7.3
12)the
Total
Weaving weight
characteristics
of
volume
Total weight of yarnof
viscosity
yarn
=Total RF
of water
× 1.54 1.54
× 1.8
threads into the actual selvedge Direct
denimSyst fabr
weft cover factor =yarn in acount
warp dyestuff-containing
PPIcount to avoid yarn breakage7.3 12) viscosityThe process =
Total RF of
chemical×weaving× × 100the warp and weft
100 Direc
w ×Ll ×w
surfaces. weft
Sizingcoverthe warp factor yarn is necessary
weft Weaving
11)
and,
7.311)
threads
RF%
as a
RF%
Weaving The= =process
result,
into the weaving
actual
chemical
of
of selvedge weaving place
denim the
onfabric warp
a shuttle and
takes weft
loom. The shuttle N N
= N= loom
=
L
w
liquid. Indigo is the most= frequent dye for denim. Because 7.3 Weaving volume water × 1.8
machine production stops. The following calculations are used in dyeing 12)
weft count & 12)
Sizing
threads
place viscosity
on a section.
into shuttle
The
viscosity the ==
volume
processactual
RFRF×of
loom.
of water
selvedge
1.54
The
×
× 1.8
in thedenim
shuttle
weaving
1.54 past,warp
loom
the fabric
although
was takes
popular
and it has now been
weft NDirec
L
Direct = l
largel
×W l ×
only
1) Count the warp threads are dyed, the weft yarns are left The processThe process
of weaving of weaving
the warp the warp
and and
weft weft
threads
7.3
place
in Weaving
the
7.3
threads oninto
past,
Weaving a although
shuttle
the actual loom.
actualit has nowsuperseded
The
selvedge shuttle
been loom
largely
denim by modern
fabricwastakes weaving machines.
popular N= =Sw
natural undyed or bleached, denim is blue on the front into threads
in the
the
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it
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athe now other
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Total Ends
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looms thepast,
machines.
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Selvedge it
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has now used
1)
denim,
now
and been
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been weaving
onlargely
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other hand,
fabric.
denim, on
denim, on the the other other hand,
hand,
Total Ends is is still
still woven
woven on on shuttle
shuttle EPI
result, weaving machine production stops. The following is still superseded
1)superseded
The Reed
woven Space
following byby
on modern
= modern
calculation
shuttle weaving
looms weaving
areto machines.
used machines.
produce in ReedSelvedge
weaving
a Selvedge
genuine
Count
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and
× No. of yarn pass into reed e
looms
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a genuine
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genuine
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is is
2)and
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still
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=
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woven onon shuttle
fabric.
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calculations are used in dyeing & Sizing section. The
1)
2) denim,
high-quality
Reed
EPI followingon
=Space
Reed the other
Count
fabric.calculation= hand,
Total
No.
The following ofEnds
yarn
are still
pass intowoven
reed eye
calculation
used inwarpweaving shuttle
areyarnused
section.in
The
looms following
to produce calculation
a genuine 2 are
3) used
and No. ofin
high-quality weaving infabric. selvedge
section. =
1) Count weavinglooms to
section. produce aTotal
genuine
EPIEnds and
selvedge high-quality
width in cm × fabric.
EPI
3)
The No.
1)TheReed of
following warp in
Spacecalculation
Reed =yarn
Count ×
Totalselvedge
No. of
Ends yarn
are used =
pass into
in in reed
weaving eye section.÷
2)
1) EPI
Reed
selvedge
following
=Space
width in cm =
calculation
× EPI EPI are used 2.54weaving section.
Total ÷EPI
Ends 2 pass into reed eye
N = Count 1)
2)1)ReedReed Space Reed
Space =Count ×Total
No. Ends
of No.
yarn of yarn pass into reed eye *selvedge
L = The length of the sample 3)
2) EPI
No.
EPI of
== warp
2.54 Reed Count in=yarn × No.selvedge
EPIEPI 2
of yarn pass = into reed eye
No. of yarn
selvedge width pass
Reed in Count
Reed into
cmCount reed
× No.
× EPI × No. eye
of yarn cotton
of2yarn *selvedge
pass 1.50
into
pass reed
into
&
reed
for
width
eyeeye 1.70
= for
l = The length of the system 2)
3)2)
3) EPI
No.
No.
cotton EPI of= warp
of
1.50 warp
= & forin in yarn
yarn
1.70 selvedge
÷
selvedge == motor PPM × moto pully diam
W =The weight of the sample 2.54 2 4) Loom Speed =
selvedge width in cm ×motor EPI PPM ×2moto pully diameter loom pully diameter
w = The unit of the weight of 3)No.
4) No.
selvedge
3)
Loom ofofyarn
No. warp
width
of
Speed warp in
pass in
cm ×
=×inyarn
EPI
into
yarn selvedge
÷selvedge
reed eye = *selvedge
= width = for
selvedge width2.54 in cm EPI ÷ 5) Loom
loom pully diameter efficiency percentage =
Actually pr
the system cottonselvedge1.50 2.54
width & for
in cm 1.70
× EPI ÷
No.
No.
5) Loom of yarn
of yarn 2.54
efficiency passpercentage
pass into reed
into reed
÷÷selvedge
eye
= *selvedge
eyeActually width
*selvedge prod = width for
×width
100 == for
cotton for calculated pr
2.54 motor PPM 6) ×Moisture
moto pully regain%
diameter =
cotton
4)No.Loom
No.
cotton ofof 1.50
yarn
1.50 Speed
yarn &&
pass for=
pass
for 1.70
into
1.70into reed reed eye eye
yarn *selvedge
calculated
*selvedge
weight
prodn
− Dried width
width = for
yarn weight = for
6) Moisture
cotton 1.50 &regain%
for 1.70 = PPM
motor loom ×pully
moto diameter
pully diameter × 100
4) cotton
Loom 1.50
Speed & for 1.70
=weightmotor PPM × moto Driedpully
Actually diameter
yarn weight
prod
4)
5) Loom
yarn weightSpeed− Dried yarn
efficiency = percentage = pully diameter × 100 13
= = motor× 100
motor PPM × moto
loom pully diameter
4)4)Loom
Loom Speed
Dried Speed
yarn weight
PPM
loom7) Moisture
× moto
pully pullycontent%
diameterdiameter
calculated prodn
Actually prod
=
5) Loom efficiency loom
percentage pully
= diameter yarn × 100× 100
6)
5) Moisture
7) Loom
Moisture regain%
content%
efficiency =
=
percentage
yarn
loom pully Actually
weight
diameter
= Actually
prod
− Dried
prod
calculated
Actually prodn
prod ×
weight
100
5)yarn
Loom efficiency percentage = = calculated
yarn weight
prodn× ×100
6)5) Loom
yarn weight
weight −efficiency
−Dried
Dried yarn
yarn percentage
weight
weight 100
6) Moisture
Moisture regain%
regain%
yarnyarn
weight
=
= × 8) ×
100 100
calculated
Cloth coverprodn
calculated factor,
prodn
6)yarn Dried
Moisture weight
weight − regain% ==
6) Moisture regain%
Dried yarn weight EPI
 Total Ends
1) Reed Space =
EPI
Reed Count × No. of yarn pass into reed eye
2) EPI =
2
3) No. of warp in yarn selvedge =
selvedge width inJournal
cm × EPI of Management Science & Engineering Research | Volume 05 | Issue 01 | March 2022
÷
2.54
No. of yarn pass into reed eye *selvedge width = for
1.50 & for 1.70 minimize the washing problem, cutting measurement and
cotton 1.50 & for 1.70
motor PPM × moto pully diameter function of cutting, industrial Engineering purposes and
4) Loom Speed =
loom pully diameter CAD system which They’ve played a key role in reducing
Actually prod
5) Loom efficiency percentage = calculated prodn × 100 the cycle time, increasing accuracy, and placing clothes
6) Moisture regain% = products in stores significantly closer to when custom-
yarn weight − Dried yarn weight
× 100 ers need them. Bangladesh is exporting denim products
Dried yarn weight
approximately 200 million pieces every year all over the
7) Moisture content% =
yarn weight − Dried yarn weight world. Bangladesh is recognized as one of the most signif-
× 100
yarn weight icant centers for denim apparel production in the world. It
8) Cloth cover factor, ranks as the second-largest denim garments exporter after
EPI
warp cover factor = China (According to WTO). The statistical review shows
warp count
weft cover factor =
PPI that the denim sector of Bangladesh plays a very import-
weft count
ant role in the denim market all over the world. Especially
Cloth cover factor = warp cover factor + weft cover after the denim sector of China, Bangladesh’s position.
Ecology | Volume 03 | Issue 04 | December 2021
factor - {(warp cover factor - weft cover factor) / 28} Seeing such a huge achievement in the denim sector of
10
Distributed under creative commons license 4.020 Bangladesh, other countries can also become competitive.
c2, c3 are 7.4 Finishing
Cloth cover factor = warp cover factor + weft cover
Denim garments are one of the most necessary parts of the
factor - {(warp cover factor - weft cover factor) / 28}
Fabric finishing is the final step in the denim textile sector in Bangladesh. In the global market all over
7.4 Finishing
0.59
unt
manufacturing Fabric finishing
process. Thisis is
thewhere
final step products the world, Bangladesh is now more prominent as a suppli-
in the denim
the finished
manufacturing process. This is where the finished
are applied, and it can have a massive effect on how the cloth er of denim products. Therefore, Bangladesh will be more
products are applied, and it can have a massive effect
3
looks, feels, and fades. The following calculation are used as interested to take the denim sector to the first position. By
on how the cloth looks, feels, and fades. The
follows:
following calculation are used as follows: reviewing this paper, the manufacturer of denim garments
1) warp / length shrinkage (%) = (Greigh pick − in Bangladesh and other countries will be more interest
Finished Pick) × 100 ÷ Finished Pick and improve their economy by exporting their denim
gm/mtr
2) Skew (%) products all over the world. Finally, it will help to develop
A → skew(C. M) ÷ 2.54 × 100 ÷ width (inch) the economy and people living standards of Bangladesh.
B → skew(inch) × 100 ÷ width (inch)
me 3) Meter to Yards
or,
A → length(meter) × 1.0936 = yards
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** All
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14
 Journal of Management Science & Engineering Research | Volume 05 | Issue 01 | March 2022

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