Process wise Standard Wash price in USD per Dzn for Denim & Non- Denim

 Wash for denim : 

 Wash for Non-denim : 

Ozone Wash

 Ozone Wash is a sustainable and innovative fabric treatment technique used primarily in the textile and garment industries. This process utilizes ozone gas (O₃), a powerful oxidizing agent, to treat garments and fabrics, replacing or reducing the need for traditional chemical washes. Ozone wash is popular for its ability to create vintage or faded looks on garments, especially denim, with minimal environmental impact.

Key Features of Ozone Wash:

1. Eco-Friendly:

   • Reduces water consumption compared to conventional washing processes.
   • Minimizes the use of harsh chemicals, thereby reducing chemical waste and pollution.
   • Emits no harmful byproducts as ozone converts back to oxygen after use.

2. Energy-Efficient:

   • Operates at lower temperatures, saving energy.

3. Time-Saving:

   • Shortens processing times as ozone acts quickly on fabric.

4. Cost-Effective:

   • Reduces the need for water, chemicals, and energy, lowering operational costs.

5. Fabric Benefits:

   • Softens the fabric and enhances color contrast without damaging the material.
   • Achieves uniform fading effects for denim and other garments.

Applications in the Denim Industry:

• Used to achieve whiskering, fading, or a stone-wash look without using pumice stones or excessive water.
• Enhances the distressed look of jeans while preserving fabric integrity.

How It Works:

1. Garments are placed in a closed chamber where ozone gas is introduced.
2. Ozone oxidizes the organic matter on the fabric's surface, creating a faded or bleached effect.
3. After treatment, ozone is neutralized back to oxygen, ensuring safety.

Advantages Over Traditional Methods:

• Drastically reduces water consumption (up to 70–80%).
• Eliminates harmful residues, making it more sustainable.
• Reduces worker exposure to chemicals.

Challenges:

• Initial investment in ozone-generating equipment can be high.
• Requires precise monitoring and control to ensure safety and desired effects.

Ozone (O₃) is typically produced using ozone generators through the following primary methods:

1. Corona Discharge Method (CDM)

The Corona Discharge Method is the most common and efficient way to produce ozone industrially.

Process:

• Oxygen gas (O₂) is passed through an electric discharge chamber.
• High-voltage electricity creates a corona or electric arc that splits O₂ molecules into single oxygen atoms (O).
• These single atoms recombine with O₂ molecules to form ozone (O₃).

Reaction:
$3O₂ → 2O₃$

Key Features:

• Cost-effective for large-scale ozone generation.
• Used in industries like textile washing, water purification, and air sterilization.
  
  
  

2. Ultraviolet (UV) Light Method

This method uses short-wavelength UV light (185 nm) to produce ozone.

Process:

• UV light splits oxygen molecules (O₂) into individual oxygen atoms (O).
• These atoms combine with O₂ to form ozone (O₃).

Key Features:

• Simpler and more compact than corona discharge.
• Ideal for low ozone production, such as in small water purification systems.
• Not energy-efficient for industrial applications.

3. Electrolytic Ozone Generation

This method produces ozone directly from water using electrolysis.

Process:

• Water (H₂O) is split into hydrogen (H₂) and oxygen (O₂) through electrolysis.
• The oxygen molecules are further split into atomic oxygen (O), which combines to form ozone (O₃).

Key Features:

• Produces pure ozone without additional gases.
• Mainly used for small-scale or highly specific applications like medical equipment sterilization or food preservation.

4. Cold Plasma Method

Cold plasma (non-thermal plasma) generates ozone at lower temperatures.

Process:

• A gas (usually air or pure oxygen) is passed through a plasma field.
• The plasma creates a highly reactive environment, splitting O₂ molecules into oxygen atoms that recombine to form O₃.

Key Features:

• Produces high concentrations of ozone.
• Energy-efficient and suitable for industrial-scale applications.

Choosing the Right Method

• Corona Discharge: Best for industrial-scale production (e.g., ozone wash in textiles).
• UV Method: Suitable for small-scale systems or low ozone requirements.
• Electrolytic Method: Ideal for specific applications requiring high-purity ozone.
• Cold Plasma: Emerging technology for high-efficiency production.

Sustainable washing

Sustainable washing in the textile and garment industry focuses on minimizing environmental impacts while maintaining quality and efficiency. It incorporates practices, technologies, and processes that reduce water, energy, and chemical usage, as well as emissions and waste generation. This is especially important in industries like denim, where traditional washing techniques can be resource-intensive.

Key Practices and Technologies in Sustainable Washing

1. Water Reduction

• Ozone Washing: Uses ozone gas to bleach or clean garments with minimal water.
• Low Liquor Ratio Machines: Machines designed to use less water in the wash cycles.
• Water Recycling: Reuse water from rinsing processes or integrate filtration systems to recycle water for multiple uses.
• E-Flow Technology: Uses air nanobubbles to apply treatments (like softeners) without excess water.

2. Energy Efficiency

• Cold Wash Cycles: Wash at lower temperatures to save energy.
• Renewable Energy Sources: Power washing machines with solar, wind, or other renewable energy.
• Efficient Dryers: Use advanced dryers or natural air-drying methods to reduce energy consumption.

3. Chemical Management

• Eco-Friendly Chemicals: Use biodegradable or certified eco-chemicals for washing and treatment.
• Enzymatic Treatments: Replace harsh chemicals with bioenzymes for processes like desizing, stonewashing, or bleaching.
• Laser Technology: Replace chemical distressing with laser systems for denim finishing.

4. Process Optimization

• Shorter Wash Cycles: Reduce washing and rinsing times to save water and energy.
• Batch Optimization: Maximize garment loads per wash cycle to increase efficiency.
• Automatic Dosing Systems: Precisely control chemical usage to minimize waste.

5. Sustainable Alternatives for Traditional Washing

• Eco-Stone Washing: Replace pumice stones with enzyme-based treatments or synthetic stones that produce less waste.
• Ozone Bleaching: Substitute chemical bleaching with ozone gas to achieve similar effects with lower environmental impact.
• Air Washing: Clean garments using air circulation, reducing water usage.

6. Wastewater Treatment

• Effluent Treatment Plants (ETPs): Treat wastewater to remove harmful chemicals and impurities before disposal.
• Zero Liquid Discharge (ZLD): Systems that recycle 100% of wastewater, leaving no liquid waste.
• Sludge Management: Safely manage and repurpose waste sludge from washing processes.

7. Worker and Social Responsibility

• Safe Chemical Handling: Ensure workers use eco-friendly chemicals and proper protective gear.
• Training Programs: Educate workers on sustainable practices and the importance of reducing environmental impacts.

8. Certifications and Standards

• Adopting standards like:
• GOTS (Global Organic Textile Standard): Focuses on sustainable and organic production processes.
• OEKO-TEX: Ensures textiles are free from harmful chemicals.
• Bluesign®: Promotes resource conservation and safety in the supply chain.

Benefits of Sustainable Washing:

• Environmental: Reduces pollution, water consumption, and energy use.
• Economic: Lowers production costs by reducing resource consumption.
• Social: Promotes safer working environments and improves brand image.
• Regulatory: Helps meet compliance with international environmental laws.

 

EIM (Ecological Effect Estimation or Environmental Impact Measurement)

 In clothing, EIM (Ecological Effect Estimation) is a scoring framework created by Jeanologia, an innovation organization work in feasible material arrangements. The EIM Score is utilized to quantify the ecological effect of article of clothing completing cycles like washing, blanching, and coloring. It centers around key maintainability measurements like water utilization, energy utilization, substance use, and laborer medical issue.

EIM Score Breakdown:

Low Effect (0-33)Demonstrates profoundly practical cycles with negligible ecological effect.

Medium Effect (34-66)Recommends a moderate ecological effect, with opportunity to get better in maintainability.

High Effect (67-100)Addresses a huge ecological effect and signals the requirement for guaranteed changes to decrease asset utilization and take on economical practices.

Key Measurements Estimated:

Water Utilization: Estimated in liters per piece of clothing handled.

Energy Utilization: Determined in view of the energy consumed during the cycle.

Synthetic Effect: Assesses the sort and amount of synthetics utilized.

Specialist Security: Evaluates likely dangers to laborers implied in the cycles.

Reason:

The EIM Score helps clothing offices and article of clothing makers:

Improve cycles to decrease natural effect.

Meet manageability objectives.

Improve straightforwardness and consistence with eco-accommodating norms.

Could you like more itemized direction on further developing EIM Scores or applying feasible strategies in denim washing?

                                        Instructions to build EIM score

Expanding the EIM (Natural Effect Estimation) score implies making your clothing processes more feasible and harmless to the ecosystem. Here are key advances you can take to accomplish this:

1. Lessen Water Utilization, 

Upgrade Wash Cycles: Limit the quantity of flushes and take on procedures like Ozone washing, which utilizes less water.

Use Water Reusing Frameworks: Reuse water from past cycles (e.g., flush water in pre-wash).

Low Alcohol Proportions: Utilize progressed machines with lower water-to-article of clothing proportions.

2. Limit Energy Use

Update Apparatus: Put resources into energy-proficient clothes washers, dryers, and laser machines.

Utilize Environmentally friendly power Sources: Sunlight based chargers or other sustainable power choices can assist with lessening energy reliance.

Improve Drying Cycles: Utilize proficient dryers or air-dry strategies to bring down energy utilization.

More limited Cycles: Diminish process times without compromising quality.

3. Diminish Compound Effect

Change to Eco-Accommodating Synthetic compounds: Utilize biodegradable or less destructive synthetic substances for processes like blanching or mellowing.

Use Proteins: Consolidate bioenzymes for medicines like stonewashing or desizing, as they are more eco-accommodating.

Limit Synthetic Measurements: Streamline how much substance specialists to stay away from abuse.

Take on Laser or Ozone Innovation: Supplant compound escalated processes with feasible options like lasers for upsetting or ozone for fading.

4. Guarantee Laborer Wellbeing and Security

Preparing: Train staff on taking care of synthetic substances and keeping up with gear securely.

Defensive Hardware: Give gloves, veils, and other security gear.

Non-Poisonous Other options: Supplant dangerous synthetics with more secure choices like potassium permanganate options.

5. Carry out Practical Innovation

Jeanologia Laser Innovation: Decreases the requirement for water and unsafe synthetic substances in denim wrapping up.

Ozone Machines: Brings down water, substance, and energy use.

e-Stream Innovation: Applies completing items like conditioners utilizing nanobubbles, fundamentally decreasing water and compound waste.

6. Track and Screen

EIM Programming: Utilize Jeanologia's EIM programming to screen, break down, and work on your cycles continuously.

Measure Every now and again: Routinely evaluate your EIM score to recognize regions for development.

7. Affirmations and Consistence

Adjust your cycles to worldwide maintainability certificates like GOTS, OEKO-TEX, or Bluesign, which advance harmless to the ecosystem rehearses.

Could you like point by point ideas on a particular region, similar to water-saving procedures or compound decrease systems?

Origin of Textile

The origin of textiles dates back thousands of years and is deeply tied to the development of human civilization. Early humans relied on natural fibers to create basic clothing and shelter. Here's an overview of the origins of textiles:

Prehistoric Period

• Earliest Evidence: Textiles date back to at least 30,000 years ago, with evidence of twisted fibers found in caves, such as those in Georgia (Eurasia). These fibers were likely used for ropes or simple garments.
  
  
  
• Natural Materials: Early textiles were made from plant fibers (like flax, hemp, and grass) and animal fibers (like wool and hair).
  
  
  
• Techniques: Weaving, knotting, and felting were primitive methods used to create fabrics.                                                 

Ancient Civilizations

1. Mesopotamia (Sumerians and Babylonians):
   • Flax and wool were commonly used.
   • Textiles were produced for both practical and ceremonial purposes.
     
     
     
2. Egypt (circa 5000 BCE):
   • Egyptians cultivated flax to make linen, which was a key fabric for clothing and mummification.
   • Linen was prized for its lightness and durability, suitable for hot climates.
     
     
     
3. Indus Valley Civilization (circa 2500 BCE):
   • Cotton cultivation and weaving flourished here, especially in modern-day Pakistan and India.
   • Evidence of dyed cotton fabrics has been discovered in archaeological sites like Mohenjo-daro.
     
     
     
4. China (circa 3000 BCE):
   • The Chinese mastered silk production through sericulture (silk farming).
   • Silk became a symbol of luxury and was traded along the Silk Road.
     
     
     
5. Mesoamerica:
   • Indigenous cultures used fibers like agave for weaving.
   • Textiles often incorporated vibrant colors and patterns.
     
     
     

Technological Advances

• Spinning Wheel: Invented around 500–1000 CE in India and spread globally.
  
  
  
• Looms: Early forms of looms date back to Neolithic times and were refined in various cultures.
  
  
  
• Industrial Revolution (18th Century):
  • The textile industry became mechanized, with inventions like the spinning jenny, water frame, and power loom.
  • Factories emerged, leading to mass production of textiles.
    
    
    

Significance

Textiles played a crucial role in trade, culture, and identity. They were often indicators of status, used as currency, and key in the exchange of ideas and goods across civilizations. 

Elements of Dry Process

 Different types of Process are as below:

1)    Whisker ,

2)    Hand Sand ,

3)    Tacking ,

4)    PP Spray ,

5)    Grinding ,

6)    Tying ,

7)    3D Resin whisker

8)    Laser etc..

Whisker

•       Whisker is a manual Process.

•       It is done by using pattern.

To evaluate Whisker in Finish garment following points need to consider –

1)    Whisker Area,

2)    Whisker Intensity,

3)    Feathering / Gradual slopping,

4)    Whisker Pattern.

Chevron

Chevron is one kind of whisker.

It’s position usually seen beneath the crotch Area.

Chevron is such a oblique line towards the seam of garments.

 

Hand Sand

•       Hand Sand is a manual process.

•       Hand Sand usually done on Balloon dummy (Horizontal type or Vertical type) or Pillow by using Sand Paper.

 

To evaluate Hand Sand need to consider below points:

1)    Area,

2)    Intensity,

3)    Feathering.

 

 

3D Resin Whisker

•       3D resin whisker is one Three dimensional shape (Length, width & height) of whisker which is produce by applying resin (polymeric solution) on the fabric.

•       Upon curing the resin is cross-linked (Polymerization Chain reaction) with Fabric to give a 3-dimensional shape which remain unchanged while applying several home laundry.

 

 

For 3D Resin whisker following points need to focus:

1)    Area or Position,

2)    Pattern,

3)    Intensity.

 

Tacking

Tacking is a manual Process which is done by Hand needle or by Tag gun or Stapler machine.

Position and intensity of tacking effect is the major area to be considered for the finish evaluation.

 

Grinding

Grinding is a manual process which is done by roller grinding or pen grinding machine.

Grinding usually done on pocket edge, bottom hem & in between double seam area of the garments.

Grinding position & intensity is the focusing point to evaluate grinding.

 

Destroy

Destroy is a manual process which is done by pen grinding machine.

Destroy should have a certain shape as well as position for evaluation.

 

Tying

Tying is a manual process in which garments are tied with rope in different format as per the pattern of tie effect.

To get the proper tie effect, tie is removed from garments either after de-size or after enzyme process.

 

Potassium permanganate

Potassium permanganate Spray (PP Spray) is usually applied on the Hand Sand area of a garment to make the Hand Sand more brighter.

After PP Spray, it need to be neutralized. Generally, Sodium Meta Bi-Sulphite is used as neutralizer.

 

To evaluate PP Spay, need to consider below points:

1)    PP Area,

2)    PP intensity,

3)    PP Area Cast.

 

Laser 

Light amplification by stimulated emission of radiation. 

To make fading of color, laser is applied in denim or jeans garments instead of Potassium Permanganate (PP) spray. This ray is used to enhance any type of design on denim cloth according to demand.

Some Combination of Dry process

Enzyme Bleach Wash Recipe details & Flow Chart

 Objective: To achieve a faded look with a soft hand feel on denim or other garments using enzymes and bleach.

 

Recipe Components

1. Water:
• 7:1 liquor-to-fabric ratio (e.g., 70 liters of water for 10 kg of fabric).
2. Detergent:
• Dosage: 0.5–1 g/L.
• Purpose: Removes surface dirt and prepares fabric for enzyme action.
3. Soda Ash (Sodium Carbonate):
• Dosage: 1–2 g/L.
• Purpose: Adjusts pH to the optimal range for enzymes (pH 6–7).
4. Enzyme (Cellulase):
• Dosage: 1–3% of fabric weight.
• Purpose: Breaks down surface fibers, creating a worn effect and softness.
5. Bleach (Sodium Hypochlorite):
• Dosage: 1–3 g/L (depending on the desired fade level).
• Purpose: Lightens the fabric to achieve a faded effect.
6. Anti-back Staining Agent (Optional):
• Dosage: 0.5–1 g/L.
• Purpose: Prevents redeposit ion of dyes onto the fabric.
7. Acetic Acid:
• Dosage: As needed (for neutralization).
• Purpose: Neutralizes alkali and stops enzyme/bleach activity.

 

Process

1. Load the Fabric: Add garments into the washing machine or drum.
2. Pre-Wash:
• Water at 40°C.
• Add detergent and run for 10 minutes.
3. Enzyme Treatment:
• Adjust pH to 6–7 using soda ash.
• Add cellulase enzyme.
• Run at 50–55°C for 20–30 minutes.
4. Bleach Application:
• Lower the temperature to 30–40°C.
• Add sodium hypochlorite gradually.
• Run for 10–15 minutes until the desired shade is achieved.
5. Rinse:
• Rinse thoroughly with water to remove residual bleach.
6. Neutralization:
• Add acetic acid to neutralize any remaining alkali or bleach.
• Rinse again to remove all residues.
7. Softening (Optional):
• Add a softener (1–2 g/L) during the final rinse for enhanced softness.