Characterization of Lycra Breakage in Denim Washing.
The aim of this project ?Characterization of Lycra Breakage in Denim Washing? is to identify the key factors that are responsible for Lycra breakage during denim washing processes. The aim is to analyze the effects of different parameters which are amount of bleach, time and temperature by changing
2025-06-28 16:25:47 - Adil Khan
Characterization of Lycra Breakage in Denim Washing.
Project Area of Specialization Mechanical EngineeringProject SummaryThe aim of this project “Characterization of Lycra Breakage in Denim Washing” is to identify the key factors that are responsible for Lycra breakage during denim washing processes. The aim is to analyze the effects of different parameters which are amount of bleach, time and temperature by changing only one parameter at a time while keeping all other parameters constant. Comparison is done between the results obtained by changing different parameters to find which parameter is affecting the Lycra most. The other objectives of this project is to focus on the effect of these parameters on other important properties of fabric i.e. tensile strength, tear strength, construction and dimensional stability. By analyzing these results, the aim is to suggest optimum recipe that neither causes Lycra to break nor causes a significant change in the other properties of the fabric. by different washing process routes on the selected type of denim fabric we will characterize the various reason by which lycra breakage occurs.
Project Objectives- Understanding of the denim washing process, the effects achieved through different washings on denim garments.
- Thorough understanding of the previous researches related to the project to understand the main reasons of Lycra breakage and issues arising in denim washing.
- Understanding the industrial limitation in the denim washing process and how they control the Lycra breakage issue in denim washing.
- Parameter identification of denim washing through preliminary work to understand the key variables affecting Lycra and denim properties.
- Optimization of denim washing process by selecting the harsh wash process route and super stretched fabric on which standardization will be done through R&D (Research and development) process also by analyzing the preliminary work data available and previous research.
- Suggesting all possible remedies to protect Lycra through data analysis, research and results.
- Prepare a report which will help researchers and the R&D team of industries that which factors are responsible for Lycra breakages and how to control them.
Denim garments (Jeans) washing is of significant importance and is a necessity because the garments after stitching are not comfortable to wear, aesthetically unpleasant and harsh. Due to regular changes in trends and demands of the customer, the industries must fulfill the customer requirements by creating different effects on denim through denim washing but this requires a lots of skill and understanding of the process along with this proper care should also be taken into consideration that it does not damages the fabric properties and most importantly Lycra which is used to impart stretchability to denim jeans. Most importantly there are two things which are rejected by the customer and shipment is not approved,
- Size change of garments
- Lycra Breakage
Lycra usually breaks from the side seams and areas where the denim is already in excessive tension due to stitching, also the bar tack area. A bubble is formed on the denim where Lycra breaks so it affects the denim stretchability in that area as well as look of the denim is also unpleasing. When these high tension points of denim during washing are attacked by stones, acid, enzymes, and bleach so high chances are there that damage to the denim properties and Lycra will increase. Also the effect of temperature, time, pH, RPM of the machine, the amount of chemicals, quantity and harshness of stones play a significant role in achieving the required effect on denim and its properties are also changed by these parameters as well. So, through this project, the main objective is to optimize the denim washing process by the selection of the right parameters for different types of washes which will give the required shade and also not adversely affect the denim properties and Lycra. So in the preliminary work, firstly the identification of parameters is done that affect the properties through different process route selection for denim washing then testing of denim for the change in properties is done. Through this preliminary work the parameters identification and selection of fabric on which a harsh and extensive washing process route can be performed for the future work is done, then optimize the process in a way that there would not be any significant effect on the properties of denim and Lycra by developing the recipe for that particular denim fabric. Further, it would also help to suggest the different remedies that can be followed to control the Lycra breakages issues.
Benefits of the ProjectAlmost all the denim manufacturing industries are facing this problem due to the types of washing that damages Lycra. There are several types of denim washing. Every type of washing gives stress to Lycra and damages individually in a process route. Till today, this problem has not been eliminated due to which several garments get rejected in the final inspection done after washing and it’s a loss for the industry.
If there are fewer breakages of Lycra in denim, this would result in the enhancement of the quality of denim garments. It would also result in more production and lots won’t be rejected which would increase customers’ demand for the particular industry.
As the rejection rate is high as lycra breakage increases so more chemicals will be required more water will increase the cost as well as it will harm the environment.
Technical Details of Final Deliverable- final report will be delievered in which optimize recipes of different wash process routes in which there will be no lycra breakage on selected type of fabric.
- characterizing causes of lycra breakage by different denim washing process.
- properties of denim effected by different denim washing processes, for e.g. tensile strength, tear, strength, dimensional stability etc.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 75000 | |||
| Material cost (Denim Garments) | Equipment | 50 | 800 | 40000 |
| Process Accessories (Chemicals, stones, bleach etc.) | Equipment | 1 | 20000 | 20000 |
| Washing, Testing Cost (Tensile, tear etc) | Equipment | 50 | 200 | 10000 |
| Over Head | Miscellaneous | 1 | 5000 | 5000 |