Sizing is then done in the conventional manner. The Conventional Shuttle loom results in lesser production due to slow speed and excessive wear and tear of machinery. The yarn then is wrapped on a bobbin as it spins on a spindle by use of a traveler.  The cost of production is lower. The standard width denim fabrics is then sent for making up. Normally if warp sheet is with patterns of different coloured yarns it is processed on sectional warping machine. These bales are selected using USDA High Volume Instrument (HVI) data, and PCCA’s unique computer blending software produces optimal yarn strength. These operations are essential because normally weavers beam can carry only certain length of warp sheet on it and when so woven, whole length is converted to the fabric by weaving machine. As far as manufacturing process of denim is concerned, it is similar to that of Grey fabric up to the process of weaving with the only difference that in case of Denim Fabric, it is dyed at the stage of sizing where as in case of Grey Fabric, the decision regarding dyeing stage depends upon the … Airjet Looms These types of looms adopt the latest development in Weaving Technology where weft insertion is done with the help of compressed air. d. Making-Up Weaving of fabrics on such multi sizes is not economical, hence a standard width fabrics is then sent to making up. The weft thread is inserted between two layers of warp sheets by means of a suitable carrier, such as Shuttle, Projectile, Rapier, Air current, Water current, etc. Yarn is then spun through Open-End Spinning or Ring Spinning. The details of each process are given below: Spinning The initial stage of denim production is Opening and Blending. Normally the process of dyeing dictates the technology of Denim manufacturing. The dyed yarn enters the starching device and sizing is done. The final woven fabric, wound on a cloth roll, is taken out from weaving machines at particular intervals and checked on inspection machines so that any possible weaving fault can be detected. Service Marks / Trademarks of Cotton Incorporated. Roving is also carried on, if the spinning has to be done through Ring Spinning. The drawing process produces a single, uniform sliver from six card slivers. Hence multiplication of sheets by drawing yarns together from many warp beams and again making one sheet is also performed on sizing machine. Normally dyed and Grey ring or open- end yarns are used in warp and weft respectively. On sizing, normally, 8-12 % size material on warp thread is applied. The warp is dyed, oxidized, dried and sized at a one go. Generally there are two most popular methods of dyeing Denim Fabric. The special properties of denim fabrics are mostly attributed to the yarns. Further, number of threads in warpers beam sheet is very less against number of threads required in whole width of fabric. We are racing in Denim global market. Open End Spinning The Open End Spinning Machines have robots on each side which automatically pieces up (repairs broken ends). The number of warp ends per inch is sometimes referred to as the “sley.” Of course, the size of the yarn used, the fabric weave design, and the fabric tightness will influence the weight, as will the amount of size left on the finished fabric. Based on the size of the rope dyeing plant, 12-40 ropes, at a time, are dyed, oxidized, dried and placed in large containers. Denim was traditionally colored blue with indigo dye to make blue “jeans”. Please click on these Terms and Conditions and Privacy Policy links for more details. 12-40 ropes run adjacent to each other through the continuous dyeing unit. There are various dyeing and sizing processes, which can be classified into four categories. This shuttle loom technology has now become obsolete. The term "Denim" has originated from the city of Nimes in France where "serge de Nimes" was manufactured. Although this process is less cumbersome, the risk of individual thread breakage is greater than dyeing in rope form. The route cotton comes from fields all over the world. As far as manufacturing process of Denim is concerned, it is similar to that of Grey fabric up to the process of weaving with the only difference that in case of Denim Fabric, it is dyed at the stage of sizing where as in case of Grey Fabric, the decision regarding dyeing stage depends. On a different track, they have another robot that automatically doffs (removes full packages) and starts up a new package. The look and quality of the Denim Fabric shall improve after dyeing, the process of which differs from plant to plant. Even today Denim Fabric without Indigo Dyeing is not called authentic Denim. For Ring Spinning, however, the sliver must pass through an additional process called Roving. Individual fibers are laid down in the groove of a fast spinning rotor and twisted into yarn. Warp yarns used in indigo denim fabrics must go through numerous unique processing steps before they are ready to be placed on the weaving machine. is categorized quality-wise. This operation is called Beam Gaiting. The two different technologies available for weaving machines are – Conventional Shuttle Weaving System which is done by Ordinary Looms or Automatic Looms; and the Shuttle less Weaving System which is done by Airjet, Waterjet, Rapier, or a Projectile weaving machine. The size and quality of each yarn end are monitored by the Barco Profile System to ensure uniformity. After sizing, the sized warp beam goes for weaving. Denim Manufacturing Process Collection of Cotton. Apart from being glossy and flexible, glass fiber is also heat resistant. It is the technique in which the yarns are made that bring in certain value additions to the fabrics like strength, rugged look and reduced need for washing. If such faults are seen anywhere in fabric during inspection, certain corrective steps are taken at weaving, warping, sizing, etc so that they can be minimised in subsequent product. Brushing and singeing eliminate impurities and help to even the surface of Denim fabric. The term “Denim” has originated from the city of Nimes in France where “serge de Nimes” was manufactured. ACG also has the capacity to produce Amsler Open-End yarn, also known as Faux Ring Spun yarn.  Shuttle less Weaving System by Airjet /Waterjet/Rapier/Projectile Shuttle loom is a conventional Technology with much less production on account of slow speed and excessive wear and tear of machinery. b. Warping on Sectional/ Direct Warping The warp yarn is required to be fed into a sheet form to the weaving machines. As such, now denim is generally woven through Shuttle less Weaving System namely, Airjet looms, rapier looms or projectile looms. The weaving process interlaces the warp, which are the length-wise indigo dyed yarn and the filling, which are the natural-colored cross-wise yarn. Yarn is formed from cotton fibers that are twisted together after being drafted by passing between three steel rolls and three rubber rolls. (i) Threads from several back beams are combined to form a warp sheet and dyed and sized on the same machine. After inspection, the sets are wrapped with polythene covers and sent for despatch as per buyer’s specifications. As fashion designers create new ideas, fabric manufacturers must follow the demands of marketing teams and market leaders. Traditionally Blue Denim is warp faced cotton fabric with 3 x 1 twill construction with warp being dyed in a solid colour and weft left un-dyed. The fault less fabrics are sent to the packaging department while the defective ones are sent for further corrections. This improvement in strength and frictional resistance characteristic of warp yarn is essential because during weaving, yarn has to undergo severe strain & stress as well as frictional operations. Denim Fabric and Grey Fabric are thoroughly checked for various types of defects such as:  Weaving Defects  Uneven Dyeing  Bleaching and Dyeing Defect  Oil Stain  Patches Here the final product is categorised quality-wise. Carding is done to remove any foreign matter and the short fibers so that cotton takes the form of a web which is then converted into a rope-like form, the sliver. Then drawing process produces a single, uniform sliver from a number of carded slivers. The spinning frames automatically doff bobbins full of yarn and send them to package winding.