Enzyme washing | Flow chart of Enzyme wash | How to apply Enzyme washing technique in a Washing Plant

Enzyme Wash: Enzyme washing is a process of laundering that uses enzymes to soften and finish fabric; it creates a worn-in look and feels for jeans and other garments. The enzyme's action during the enzyme wash, it hydrolyzes the cellulose, it first attacks and hydrolyzes the fiber that has been expected. It attacks the portion of the yarn inside the fabric and partially hydrolyzes the portion of the yarn and produces a faded effect.

Enzyme washing is Eco-friendly washing due to the enzyme's natural origins. It's also a popular process of washing garments. The garment is washed using enzymes to decrease the negative effect of stone washing.

Two types of enzyme used mainly. The acid enzyme (liquid) is one, and the neutral enzyme is another. There are two types of neutral enzyme;

1. Powder form.
2. Liquid form i.e. SL enzyme.

Enzyme Wash

Chemical used in Enzyme washing: Enzyme Washing is a chemical or wet washing technique. Therefore, some chemical used in this washing technique for getting desire fading outlook and comfortability. 

1. Desizing Agent: Desizing agent is being used to eliminate starches, CMC, wax, fats, mineral resources, oil & unfixed dye, twills, poplin & canvas fabrics, and garment.
2. Detergent: Detergent is broadly applicable in the continuous and discontinuous pre-treatment of all fiber types and their blends. It usually applies to eliminate impurities, contamination of mineral oil and sizes from the garments. 
3. Enzyme: Enzymes hydrolyze the cellulose during enzyme wash, In the beginning, it attacks and hydrolyzes the fibers. Then the yarn portion in the fabric is attacked and the yarn portion is hydrolyzed. This produces color from the yarn and causes fading effects.
4. Acetic Acid (CH3COOH): Acetic Acid is used in the wash bath to neutralize the alkaline condition of the garments and to control the pH value.
5. Anti-stain: Anti-stain is used to avoid staining of denim yarn (white yarn), white fabric pockets, levels and infected fabric components; it also behaves as anticreasing agent.
6. Cationic softener: Softener is often used to make textile-treated garments a surface feel that is both fluffy and smooth and also offers excellent lubricating characteristics.

Flowchart of Enzyme wash:

Batching

↓

Loading

↓

Desizing

↓

Enzyme Wash

↓

Hot wash

↓

Neutralization

↓

Softening

↓

Hydroextracting

↓

Drying

↓

Delivery

Process of Enzyme wash:
1. Batching: Batching is the method to get prepared the garments which will be washed and processed for a specific lot of a specific order.
2. Loading: Loading is the work where how many pieces garments will be washed is ready and load it to the machine.
3. Desizing: Desizing is an important stage of all textile processing in which' size material ' is removed from the fabric or garment before the pre-treatment process is completed, which is necessary before garment wash or other textile processes. Here, we add desizing agent and detergent for cleaning and removing size material.

• Lot weight (100 pes) = 70 kg denim long pant.
• Add water: L: R = 1: 9, 630 liter.
• Machine Running.
• Temperature: raise 60°c.
• Add Desizing agent: 0.6 gm / liter, 378 gm.
• Add Detergent: 0.8 gm / liter, 504 gm.
• Time: Run machine 10-20 minute.
• Drop the liquor.
• Wash 1 time by cold water.

4. Enzyme wash: This is the main step of the enzyme wash. Here, acid enzyme adds for the required washing technique and shade. In this process, we also add Acetic acid for pH control and anti back staining for preventing the staining on weft yarn of the denim garment.

• Add water L : R = 1:8, 560 Liter.
• Temperature: Raise 45°c.
• Add Acetic Acid: 0.6 gm/liter, 336 gm.
• Add Anti back staining: 0.6 gm/liter, 336 gm.
• Add Acid Enzyme: 2.00 gm/liter, 1120 gm.
• Time: 40-60 minute (As required for desired shade).
• Raise temperature up to 90°c and run 1 minute for killing enzyme.
• Drain the bath.
• Rinse Twice, each in 3 minutes.

5. Softening: In the softening process, cat-ionic softener use for soft hand feel and improve lubricating properties.

• Add water L : R = 1 : 7, 490 Liter.
• Add Acetic Acid: 0.6 gm/liter, 294 gm.
• Cat-ionic Softener: 1 gm/liter, 490 gm.
• Temperature: Normal or  Cold.
• Time: 15 to 20 minute.
• Drain the bath.
• Then unload the garments on trolley.

6. Hydro-extracting: After doing all the process, hydro-extracting is done for removing extra water from the garment and deliver to the drying process. 

7. Drying: Here all garments are dried by using the gas dryer or steam dryer.

8. Delivery: Finally the garment is delivered to the next process.

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References:

1. "Denim: Manufacture, Finishing, and Applications" Edited by Roshan Paul.
2. https://www.metrodyeing.com/dyeing/enzyme-washing.
3. "Effective Mechanical and Chemical Washing Process in Garment Industries" by Monoroma Hossain, American Journal of Applied Physics 2017, 2:1-25.