DRY & WET PROCESS FOLLOW CHART- Denim Wash

DRY & WET PROCESS FOLLOW CHART- STANDARD OPERATION PROCEDURE (SOP)-

for denim washing 

Sl. No.	Process Name	SOP	If okay	If Not okay- but repairable		If Rejected		Remarks
1	Dry Process	Garments counting and receiving form garments/ sewing factory.
2		Garments placed on rack / shelf after opening each bundle tying.
3		Shade and quality checking before dry process starting.
4		Discussion and finding the critical problems before bulk production starting.	Risk analysis for production of the garments
5		Thread sucking of the garments.
6		Size grading of the garments.
7		Marking for manual whisker / Laser whisker
8		QC of Marking	If okay- then proceed to Next process	If not okay – reprocessed and prepared for Next process
9		Whisker Operation completion
10		QC of Whisker points (Standard Vs. Production)	If okay- then proceed to Next process	If not okay but repairable- then proceed to Next process after repairing		If not okay and Rejected- then send to reject box.
11		Marking for hand sanding area of the garments
12		QC of Marking	If okay- then proceed to Next process	If not okay – Reprocessed and prepared for Next process
13		Manual Hand Sanding / Laser burn hand sanding
14		QC checking of Hand sanding points	If okay- then proceed to Next process	If not okay but repairable- then proceed to Next process after repairing.		If not okay and Rejected- then send to reject box.
15		Marking for Back part hand sanding of garments
16		QC of Marking	If okay- then proceed to Next process	If not okay – Reprocessed and prepared for Next process
17		Back touch competition
18		QC Back part – points	If okay- then proceed to Next process	If not okay but repairable- then proceed to Next process after repairing.		If not okay and Rejected- then send to reject box.
19		Tagging / Tying / Bag- Netting / Scraping	If required as per standard.
20	Wet Process- Enzyme Wash	Unwashed garments shade segregation in the wash floor before Batch making.
21		Batch Making for 1st wash:Batch making by shade wise garments weighing (Balance used).
22		Waist belt tying (if necessary).
23		Complete batch garments loading into clean wash machine.
24		De-Sizing Step	First Wash steps
25		Enzyme Step
26		Cleaning Step
27		Bleaching Step (if necessary)
28		Neutralization Step if garments are bleached using Calcium hypo chlorate.
29		Hydro water extraction from wet garments
30		Dryer:wetgarments drying
31	Dry Process	Dry garments after first wash taken to PP Spray room for PP spray- and Shades are segregated before P.P spray.
32		Destroy design – if remains in the standard. (Manually/ using Laser)
33		Marking of the destroy points
34		QC of Marking points	If okay- then proceed to Next process	If not okay – Reprocessed and prepared for Next process
35		Destroy design made using – Manual method/ Laser Burning
36		QC of Destroy design-	If okay- then proceed to Next process	If not okay but repairable- then proceed to Next process after repairing.		If not okay and Rejected- then send to reject box.
37		Grinding – if remains in the standard. (Using Rolling grinder machine)
38		QC of Grinding process-	If okay- then proceed to Next process	If not okay but repairable- then proceed to Next process after repairing.		If not okay and Rejected- then send to reject box.
39		·         Marking for PP spray of garments
40		QC of Marking	If okay- then proceed to Next process	If not okay – Reprocessed and prepared for Next process
41		Potassium Per Manganite (PP) spray using set recipe
42		QC of PP spray of the garments	If okay- then proceed to Next process	If – P.P is less then re-sprayed to achieve the looking using chalk mark QC direction.		If – P.P is more & rejected- then send to Reject box.
43	Wet Process- Neutral Wash	Again brining the garments to the wash floor after PP spray competition for Neutral Wash.	Second Wash steps
44		Batch Making for 2nd wash: Garments loading into clean wash machine after shade segregation.
45		Towel Abrasion Bleaching if remains in the standard.
46		Second Time bleaching for achieving shade if necessary.
47		P.P and Bleaching Neutralization Step
48		Cleaning Step
49		Drying / Tinting if required.
50		Fixing of dye stuff & washing shade.
51		Softening of garments + PH Controlling in the washing bath in this step.
52		Hydro water extraction from wet garments
53		Dryer: wet garments drying
54	QC	Finishing QC checking after second wash completion	If shade okay- then Pack & Send to Sewing factory for further finishing/ trimming.
			If the shade is not okay	Send for reprocessing	And after reprocessing		If shade okay then send to Finishing QC check (SL-46)
							If shade not okay then send to Reject Box.
55	After Wash complete (Dry process for styling)	Air blowing in the destroy placement area to remove excess stitches which needs to be removed / to make frays. (if required)
56		QC of Destroy placement design/ looking	If okay- then proceed to Next process	If not okay but repairable- then proceed to Next process after repairing.		If not okay and Rejected- then send to reject box.
57		Glue Patch Placement inside of the destroy placement area (if required)
58		Heat Setting to fix the glue patches in the destroy placement area.
59		QC of Destroy glue patch	If okay- then proceed to Next process	If not okay but repairable- then proceed to Next process after repairing.		If not okay and Rejected- then send to reject box.
60		For 3D/ Crimping design- Resin with elastomeric softener is sprayed inside of the garments at the design placement area.
61		Iron 3D (Curved) / Box 3D (Round) is build based on standard.
62		QC of 3D design/ looking	If okay- then proceed to Next process	If not okay but repairable- then proceed to Next process after repairing.
63		Curing in the Oven for fixing the design permanently.
64		Moisture checking of the garments after cooling	If moisture regain is less than RH%- 45% then garments are pack for delivery. Or else for higher than 45% of RH% - garments are re-oven/ re-dryer to control Moisture of the garments.
65	Delivery	Packing the garments to send for final Trimming.

Written By,

K M Zahidur Rahman

Executive- R&D Section
Hameem Group.

Email:- kmzahid.samrat@gmail.com