Page 1 (Dept: TFD)

1. "After wet process dry processes show the desired wash effect."
Explain the statement.
• Explanation: In denim and apparel manufacturing, the "wet process"
(washing with enzymes, bleach, stones, etc.) provides the overall base
color and abrasion. However, wet processing alone often leaves the
garment looking flat or uniform. "Dry processes" (like hand sanding,
whiskers, grinding, or destroying) are mechanical treatments usually
done before the wet wash (though sometimes after).
• Why it shows the effect: The wet process acts as a developer. For
example, if you scratch the surface of denim (dry process/hand sand), it
might look subtle initially. But once the garment goes through the wet
wash (e.g., enzyme wash), the indigo dye is removed more easily from
those scratched/abraded areas compared to the untouched areas. The
contrast between the abraded areas (white/light blue) and the base
areas (dark blue) creates the final "desired wash effect" (vintage look,
3D effect). Without the wet process, the dry process marks would look
like raw scratches; without the dry process, the wet wash would be a
plain flat color.
2. Write down the application of laser on textiles and identify which
application is responsible for fading and why?
• Applications of Laser:
o Cutting: Cutting fabric patterns with high precision and sealed
edges (to prevent fraying).
o Engraving/Fading: Creating patterns, logos, or vintage effects on
the surface.
o Welding: Joining thermoplastic fabrics without thread (seam
sealing).
• Responsible for Fading: Laser Engraving (Marking).
 • Why: The laser beam is focused on the fabric surface. The intense heat
of the beam sublimates (vaporizes) the indigo dye on the surface of the
denim yarn without damaging the core of the yarn significantly. By
controlling the intensity, the laser removes the blue color to reveal the
white core, creating a faded look.
3. Write down the working procedure of grinding and destroy on denim.
• Grinding (Edge distress):
o Tool: Electric grinding machine or pen grinding tools.
o Procedure: The operator runs the grinding tool along the edges of
the garment (hem, pockets, waistband). The abrasive action
breaks the warp/weft yarns at the edge, creating a worn-out,
frayed, or "vintage" look.
• Destroy (Distressing):
o Tool: Pen grinding machine or stone/emery cloth.
o Procedure: Specific areas of the fabric (usually the thigh or knee)
are abraded heavily until the warp (blue) yarns are cut or removed,
leaving only the white weft yarns visible, or creating actual holes.
This simulates heavy wear and tear.
4. Draw and identify dry processes on denim products with definition of
dry process of washing.
• Definition: Dry processes are mechanical or chemical treatments
applied to the garment surface in a dry state (usually before wet
washing) to create localized abrasion, patterns, or fashion effects that
mimic natural wear.
• Identification (Mental Check for Drawing):
o Whiskers: Faded lines on the crotch/thigh area (mustaches).
o Hand Sanding/Scraping: Faded patches on thighs/buttocks.
 o Grinding: Frayed edges on pockets/hems.
o Tagging/Tacking: 3D crinkle effect (usually at pockets/waistband).
o Destroy: Holes or heavy abrasion areas.
o Chevron: V-shaped fade lines at the inner thigh/hem.

Page 2 (Dept: Dyes & Chemical Engineering)

1. Draw the structure of firefighter suit with raw materials and functions.
• Structure: A standard firefighter suit (Turnout Gear) has a 3-layer
system:
1. Outer Shell:
▪ Material: Nomex, Kevlar, or PBI (Polybenzimidazole).
▪ Function: Resists direct flame, abrasion, and cuts. It
protects the inner layers.
2. Moisture Barrier (Middle Layer):
▪ Material: Gore-Tex or similar ePTFE membrane laminated to
a substrate.
▪ Function: Prevents water/chemicals from entering (from
hose or rain) but allows sweat vapor to escape (breathable)
to prevent heat stress.
3. Thermal Barrier (Inner Layer):
▪ Material: Non-woven Aramid batt or quilted Nomex/Viscose
face cloth.
▪ Function: Traps air to insulate the wearer from extreme
heat.
2. Narrates the importance of cotton in terms of protective clothing.
 • Comfort: Cotton is hydrophilic (absorbs sweat) and breathable,
reducing heat stress for the wearer.
• Non-Melting: Unlike polyester or nylon, cotton does not melt or drip
when exposed to heat. Melting fabrics can stick to the skin and cause
severe burns; cotton chars instead.
• Static Control: Cotton naturally generates less static electricity
compared to synthetics, which is crucial in explosive environments (like
mines).
• Base for Treatments: Cotton absorbs flame-retardant chemicals (like
Proban or Pyrovatex) very effectively, making it a good carrier for FR
finishes.
3. Write a short note on cotton ventile with raw materials for heat and
flame-retardant apparel.
• Cotton Ventile: It is a very densely woven fabric made from 100% extra-
long-staple cotton fibers.
• Mechanism: When wet, the fibers swell and seal the gaps in the weave,
making it naturally water-resistant without coating.
• For Heat/Flame: While originally designed for pilot immersion suits
(water protection), its high density reduces the amount of oxygen
available within the fabric structure to support combustion. However,
for strict FR apparel, Ventile cotton must be treated with FR chemicals
(like Pyrovatex or Proban) to meet safety standards. The "raw material"
is specifically extra-long staple (ELS) cotton to allow for the extremely
tight spinning and weaving required.
4. State the features of radiant heat protective clothing.
• Reflectivity: The outer surface is typically aluminized (coated with a
thin layer of aluminum) to reflect up to 95% of radiant heat.
 • Insulation: It often has inner layers of wool or fiberglass to stop
conductive heat transfer.
• Non-Flammable Base: The base fabric under the aluminum is usually
para-aramid, fiberglass, or flame-retardant rayon.
• Loose Fit: Designed to be worn over other gear, trapping an air layer for
further insulation.

Page 3 (Dept: Industrial and Production Engineering)

1. Point out the importance of dry processes of washing in terms of
washing objectives.
• Differentiation: It allows manufacturers to create multiple "styles"
(looks) from the same raw denim fabric, increasing product variety.
• Value Addition: Jeans with whiskers, destruction, or hand sanding sell
for a higher price than plain rigid jeans.
• Vintage aesthetics: Dry processes are the only way to mimic the "worn-
out" look (aging) that naturally occurs after years of wearing, which is a
key fashion demand.
• Comfort: Mechanical abrasion (like sanding) physically softens the
fabric surface by breaking stiff surface fibers.
2. Draw and identify dry processes on denim sample.
(Same as Page 1, Q4). Key features to identify: Whiskers (faded lines at hip),
Hand Sanding (thigh fades), Grinding (pocket edges), Destroy (holes), 3D
Tacking (crinkles).
3. Illustrate and briefly describe the mechanism of laser on denim fading.
• Mechanism:
1. Input: A grayscale image (bitmap) of the design is fed into the
laser computer.
 2. Beam Generation: A laser source (usually CO2) generates a high-
energy light beam.
3. Focus: Mirrors direct the beam to the fabric surface.
4. Sublimation/Burning: The intense heat of the focused beam
vaporizes the indigo dye molecules on the surface of the cotton
yarn instantly. It turns the solid dye into gas (fume) which is
extracted.
5. Result: The white core of the yarn is revealed, creating the
light/faded pattern corresponding to the image intensity.
4. State the successive steps of whiskering on long denim pant.
1. Placement: The denim pant is pulled onto a "balloon" or rubber
mannequin legs.
2. Inflation: The legs are inflated with air to stretch the fabric tight and
smooth.
3. Pattern/Template: A template (pattern with ridges) may be placed
under the fabric, OR the operator uses visual guides.
4. Sanding: The operator uses sandpaper (or a sanding glove) to rub the
fabric over the ridges of the template.
5. Result: The "high" points of the wrinkles get abraded (fade), while the
"low" points remain dark, creating the whisker effect.

Page 4 (Dept: Wet Process Engineering)

1. Draw the structure of Goretex® with raw materials and functions.
• Raw Material: The core material is ePTFE (expanded
Polytetrafluoroethylene).
• Structure: It acts as a semi-permeable membrane.
 o Micro-pores: The membrane has billions of microscopic pores per
square inch. These pores are 20,000 times smaller than a water
droplet (so rain cannot get in) but 700 times larger than a water
vapor molecule (so sweat steam can get out).
• Composite: Typically bonded between an outer face fabric (Nylon/Poly)
and an inner liner (Tricot/Knit).
2. Narrates the importance of cotton in terms of protective clothing.
(Same as Page 2, Q2). Focus on: Non-melting behavior (safety from burns),
antistatic properties (safety in explosive zones), and comfort (reducing heat
stress).
3. Write a short note on Zirpro wool with raw materials for heat and flame-
retardant apparel.
• Process: Zirpro is a chemical treatment for wool fibers to enhance their
natural flame retardancy.
• Raw Materials: It uses complexes of Zirconium (e.g., Potassium
Hexafluoro Zirconate) or Titanium salts dissolved in acid (usually Citric
or Formic acid).
• Function: The negatively charged Zirconium complex exhausts onto the
positively charged wool fiber. When exposed to fire, these chemicals
help the wool form a stable, insulating char that blocks oxygen and
heat, preventing the fire from spreading. It is durable to washing.
4. State the features of coal miners' clothing.
• Flame Retardancy: Must not catch fire or melt if exposed to flash fires.
• Anti-Static: Crucial to prevent sparks that could ignite coal dust or
methane gas.
• High Visibility: Must have retro-reflective tapes because mines are dark
environments.
 • Dust Protection: Tight weaves to prevent coal dust from penetrating to
the skin.
• Durability: Reinforced knees and elbows to withstand rough abrasion
against rocks.

Page 5 (Dept: Textile Machinery Design & Maintenance)

1. State the typical flow process of washing with machines required for
washing.
• Flow Process:
1. Loading: Garments loaded into the washing machine.
2. Desizing: Removal of starch using amylase enzyme (Machine:
Front Loading Washer).
3. Enzyme/Stone Wash: Abrasion step using cellulase enzyme and
pumice stones (Machine: Belly Washer or Front Loading Washer).
4. Bleaching (Optional): Lightening the color (Machine: Washer).
5. Neutralization: Removing residual chemicals.
6. Softening: Adding softeners for hand-feel.
7. Hydro-extraction: Removing excess water (Machine: Hydro-
extractor / Centrifuge).
8. Drying: (Machine: Tumble Dryer).
2. Tabulate the chemicals used in bleach wash with functions.

Chemical Name Function

Sodium Hypochlorite The oxidizing agent that destroys the indigo

(Bleach) color molecules to lighten the shade.
 Chemical Name Function

Sodium Neutralizing agent used to stop the bleaching

Metabisulphite action and remove chlorine residues.

Soda Ash (Sodium Maintains the alkaline pH (approx. pH 10-11)

Carbonate) required for the bleach to work stably.

Used later to neutralize the alkalinity and bring

Acetic Acid
the fabric pH back to neutral (pH 5.5-6.5).

3. Write down the recipe enzyme treatment step of enzyme wash.

• Liquor Ratio: 1:8 to 1:10
• Temperature: 40°C – 55°C (depending on enzyme type).
• pH: 4.5 – 5.5 (for Acid Cellulase) or 6.0 – 7.0 (for Neutral Cellulase).
• Enzyme Dosage: 0.5% – 2.0% (owg - on weight of garment).
• Anti-back staining agent: 1 g/L (prevents loosened dye from
redepositing on the white parts).
• Time: 30 – 60 minutes (depending on desired abrasion).
4. Draw the front view of washing machine with mentioning it's parts.
• Key Parts to Label:
o Drum (Inner Cylinder): Perforated steel drum where clothes go.
o Door: Glass door with safety lock.
o Control Panel: Buttons/Screen for time and temp.
o Dosing Box: Drawer for adding chemicals.
o Paddle/Lifter: Inside the drum to lift and drop clothes.
o Motor/Drive: (Usually at the back, but can be indicated).
o Drain Valve: At the bottom.