1. 3rd season of country’s first ever competition for textile, garment &
fashion design students.
Development of Denim effect
on
knitted fabric
Prepared by:
Md. Salim Azad Didar
TTH ID: SEU-10
Department of Textile Engineering
SOUTHEAST UNIVERSITY
Mobile: 01671412254
Email: salim_didar16@hotmail.com
7. About Denim
• The story of jeans begins in the mid19th century simultaneously in two
European cities: Nîmes in France, where
the fabric itself was created, the socalled “Serge de Nîmes” which led to the
name “denim”.
• The classical denim is a heavy fabric
made from 100% cotton and woven
from coarse indigo dyed warp and grey
undyed weft yarn.
• The traditional denim is hard- wearing,
high density fabrics with a high mass
per unit area and a 3/1 or 2/1- twill
weave and 1/1 chambray construction.
10. World Market Analysis
• The world market for denim jeans is projected to exceed
$65 billion by the year 2015.
• This is primarily driven by a rapid rise in the number of
customers purchasing denim jeans that offer better fit,
superior style, durable quality, and an affordable price tag.
• Denim is the most preferred clothing of today’s youth and
accounts about 3% of total world fabric production.
• Conventional woven denim is not as soft in texture as other
knit fabrics and so applications of denim in fashion design
is limited.
• The immense numbers of almost two billion pairs of jeans
are produced each year, claiming about 10 percent of the
worldwide cotton harvest
11. Denim in Bangladesh
• Bangladesh has come up as the third most important
exporter of denim apparel to US after Mexico and China and
second highest to EU after China.
• Bangladesh is also one of the cheapest production centers
for apparel around the world.
• In Bangladesh the market for denims is dominated only by
jeans wear. Therefore we need to focus on fashionable
elements on denim fabric.
• This lead to the idea of creating denim effect on knitted
fabric.
15. Knitted denim creating new business opportunities
Recent survey on children’s denim products showed that
• comfort,
• softness and easy care,
Parents and Children
• lightweight and
• fabric quality of the attributes.
Knitted denim fabric with its
• delicate structure,
• clear lines,
• soft, breathable comfort,
• playing quality thin features is the ultimate solution putting
both fashion and comfort in balance.
16. With the varieties of knitted denim continues to expand,
knit denim can be used as
•Absorbent,
•Antibacterial
•Health Care Purposes, as well as in
• T Shirts,
•Children's Clothing,
•Sleepwear,
•Underwear,
•Sportswear,
•Casual Wear,
•Fashion, Etc.
19. Flow Chart of knit denim
Yarn
Yarn
Indigo dyeing of
yarn
Yarn Dyeing
Beams are created
knitting
Converted to Indigo
cheese
Finishing
Reactive dye process
Knitting
Finishing
Indigo dye process
20. Comparison between woven and knitted denims
Woven
Knitted
Rigid
Highly extensible
Easy to tear
Difficult to tear
Gets Crease And Wrinkled easily
Highly Crease resistant
Stiffer
Limb
Air Permeability is Less
Air Permeability is More
21. Merits of knitted denim
The knitted denim offers the following advantages in comparison
with its woven counterpart:
The comfort ability of knit denim garments is better than woven
denim garments.
It mold and move easily with body movement.
Its stretch ability is good.
It resists wrinkles.
Knit fabrics are soft and drape well.
Air Permeability is more in knit fabrics
Most important perhaps is that knits relate well to contemporary
life-styles.
33. Yarn Dyeing Machine Specification
Machine type
: Sample Yarn Dyeing Machine
Brand
: Fongs
Origin
: China
Yarn quantity given for dyeing
: 6.4 kg
Yarn quantity received after dyeing
: 6.18 kg
34. Flow Chart of yarn Dyeing
Grey yarn received
Soft winding
Batching
Yarn Dyeing in Package
form
Hydro extractor
Dryer
Rewinding
Packing
Delivery
35. Yarn Dyeing Recipe
•
•
•
•
•
Total Weight of Yarn:
Liquor ratio:
No. of cone:
Yarn Type:
Dye color:
6.4 Kg
1:10
8
24/1 Ne
Navy blue
Dyeing(Dyes and Chemicals):
• Dekol-SN:
1.5 g/L
• Triplex-2146:
0.3 g/L
• Parma. NF:
0.25 g/L
• Rema. 4% Red RGB : 2.024 g/L
• Rema. 4% Navy RGB : 3.76 g/L
• Glauber salt:
80 g/L
• Soda:
5 g/L
• Caustic:
2 g/L
• Temperature:
90 ◦C
• Time:
40 min
• PH:
6.00
40. Knitting Machine specification
• Machine type
•
•
•
•
•
•
•
Brand
Model
Cylinder Diameter
Needle gauge
Number of feeder
Number of needle
Rotation
: Single jersey Circular
knitting machine
: Well Run
: SHS-90
: 32”
: 24 G
: 96
: 2412
: Anticlockwise
58. Fabric production cost:
24/1 Ne 100% cotton combed yarn price
Cost of 100 Kg of yarn = 4.5x100
=$4.5 per Kg
= $450
Yarn Dyeing cost
Process loss
Actual yarn dyed
Yarn dyeing cost for 96 kg
= $2.5 per Kg
= 4%
= 96 Kg
=$240
Knitting cost
Process loss
Actual Fabric to be produced
Knitting cost for 93kg yarn
= $0.31 per Kg
= 7%
= 93kg
=$28.83
Total Cost= $450 + 240+28.83
=$718.83
Total cost to produce 1 kg of Knit Denim
= $7.73 per kg
59. Further developments
1. Knitting with indigo dyed yarn of proper flexibility in cone
form
2. Fading effect on reactive dyed yarn by advanced garments
washing technology
3. Creating options for cost minimization by knitting with
rotor yarn, polyester etc.
4. Creating new designs using other knitting machineries.
And more….
60. Conclusion
• To earn more= To invest more
• Adding value to our product is the ultimate solution to
boost and sustain in the future
• The two fabrics that got developed during this research are
softer and comfortable as well as less complicated to be
produced.
• Knit denim is the fabric of the future, a future that we must
understand and adapt so as to survive in this competitive
market.
61. Message
• Value Addition
• Technical textile
• Nanotechnology
• Non woven
• Plasma Technology
• Composite material
“I Believe”
62. Acknowledgement
• Md. Mahamudul Islam, Lecturer
• Prof. Fakhrul Hasan Murad, Chairman, Department of Textile
Engineering, Southeast University
• Prof. A.N.M Ahmedullah,
• Prof. Dr. Shah Mohammad Fatah –Ur- Rahman
Shohan Knit
Composite
Knit Concern Yarn Dyeing Ltd.
Akij Textile mills Ltd.