Enzyme Stone Wash Process of Garments

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Last Updated on 22/08/2021

Stone Enzyme Wash:
Stone wash means washing garments with special stones so that garments achieve a very strong washed effect. To get a faded look on the garment surface, white stones are used with enzymes during washing. During washing, the fabric comes in contact with stones and the color fades by the rubbing action.

In stone enzyme wash, the type of enzyme chosen has an important bearing on the process. Stonewashing effects as achieved by pumice stones can be duplicated by the action of cellulases which artificially ‘age’ the fabric by chemically degrading the cotton and thereby releasing indigo dye particles, giving an abraded, washed-out look.

Stone Enzyme Wash
Fig: Stone Enzyme Wash

Now in Bangladesh maximum denim garment washing is done by stone enzyme wash. It is most popular wash for Buyer.

Sometimes, bleach is added to the wash so that the color fades in a more pronounced manner. This is done to turn navy blue jeans into a more faded light blue color. Such a wash requires a lot of skill, experience, workmanship and expertise so that desired results are achieved.

In stone wash, the following points should be carefully checked:

a) Size of the stones: Stone sizes have a varied effect on the garment being washed. Larger stones give tough abrasion while smaller ones lend less abrasion. Stones should be selected based on the required abrasion affect as well as the type of fabric of the garments. Larger stones may damage comparatively lightweight fabric.

b) Garment-stone ratio: (Weight of the stones relative to the weight of garment) A wash with more stones may lead to a more apparent blue/ white contrast on the fabric.

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c) Washing time: Washing time is also important in stone wash.

d) Quantity of the bleach: Use of more bleach can shorten wash time, leading to more productivity. Bleach, however, cannot be used indiscriminately. Disproportionate amount of bleach may lead to loss of the desired blue/white contrast on the fabric. To get better results, one should cut a balance between the quantity of bleach, stone size and the amount of stone. Sometimes, one needs to use a normal quantity of stone and longer washing time to achieve the color standard requirements.

Objects of Stone Enzyme Wash:

  1. To create irregular fading affect on old looking affect on garments.
  2. To remove dust, dart, oil spot, impurities from the garments.
  3. For soft feeling to wear the garments i.e. to improve softness.
  4. To achieve the buyer washing standard.
  5. To remove the size materials from the garments.
  6. To improve anti-pilling properties.

Process of Stone Enzyme Wash:
A process of stone enzyme wash of 60 kg batch of Denim Long Pant as mentioned below:

First Step: Pretreatment/Desizing

  1. Batch size………………….. 60 kg Denim Long Pant.
  2. Add water @ L: R = 1 : 9 ………………………. 540 liters.
  3. Start the machine.
  4. Temperature……………….. 60°c
  5. Add Desizing agent @ 0.6 gm / liter…………….. 324 gm.
  6. Add Detergent / Antistain @ 1 gm / liter ……… 540 gm.
  7. Time………………………….. 15 to 25 mts.
  8. Drop the liquor.

Second Step: Hot Wash

  1. Add water @ L: R = 1: 9………….. 540 liters.
  2. Temperature……………………………… 60°c.
  3. Time…………………………………………. 5 mts.

Third Step: Enzyme Stone Washing

  1. Add water @ L : R = 1 : 8 ………….. 480 liters.
  2. Add pumic stone @ ½ vol of garments.
  3. Add Enzyme @ 1.50 gm/liter ………………… 720 Gms.
  4. Add Acetic Acid @ 0.6 gm/liter ……………… 288 Gms.
  5. Add Antistain @ 0.8 gm/liter ………………… 384 Gms.
  6. Temperature………………………………….. 40°c to 50°c
  7. Time (Depend upon the shade) ………. 60 to 70 mts.
  8. Then temperature raise to 90°c for 1 minute.
  9. Drop the liquor.
  10. Rinse Twice, each 3 minutes.
  11. Then pumic stone out from washing machine

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Fourth Step: Bleaching

  1. Add water @ L: R = 1: 8………….. 480 liters.
  2. Machine running.
  3. Add bleaching powder (k.c.i) @ 10 gm/liter ….4800 gms.
  4. Add soda ash @ 5 gm/liter………………………….. 2400 gms.
  5. Temperature………………………………………………….. 60°c.
  6. Time (Depend upon the shade) ………………… 12 to 15 mts.
  7. Drop the liquor.
  8. Rinse twice, each 3 minutes.

Fifth Step: Neutral Wash

  1. Add water @ L: R = 1: 9 ………………………. 540 liters.
  2. Add sodium hyposulphite @ 3 gm/liter ……. 1620 Gms.
  3. Temperature…………………………………………….. 40°c.
  4. Time ……………………………………………………. 10 to 12 mts.
  5. Drop the liquor.
  6. Rinse one.

Sixth Step: Soft Wash

  1. Add water @ L : R = 1 : 8 ………….. …………..480 liter.
  2. Add Acetic Acid @ 0.6 gm/liter ………………… 288 Gms.
  3. Cationic softner @ 1 gm/liter …………………… 480 Gms.
  4. Time………………………….. 5 mts.
  5. Drop the liquor.
  6. Unload the garments to trolley.

Seventh Step: Hydro-extractor Machine

  • Hydroextraction the garment to remove excess water from the washed garments.

Eighth Step: Drying Machine

  1. Load 40 kg garments
  2. Set temperature ……………. 75°c to 85°c.
  3. Time ……………………. 35 to 40 mts.
  4. Time ………………… 10 minutes in cold dry.

Ninth Step: Delivery

  • After quality checking garment will be delivery.

References:

  1. Denim: Manufacture, Finishing and Applications Edited by Roshan Paul
  2. Handbook of Value Addition Processes for Fabrics By B. Purushothama
  3. Sustainability in Denim Edited by Subramanian Senthilkannan Muthu
  4. Chemical Technology in the Pre-Treatment Processes of Textiles by S. R. Karmakar
  5. Chemistry of the Textile Industry By C. Carr

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