Clean industrial wash recipes for wet and dry processes for denim, and garments produced by the processes

Abstract

A method of creating an abraded garment without use of potassium permanganate. The method comprises the steps of providing a denim fabric made from yarns having a white core at least 65% of the cross-sectional area of the yarn with the core exhibiting a whiteness that is more white than blue on the Commission Internationale De L'Elcairage (CIE) chromaticity scale, forming the fabric into a denim garment, abrading the unwashed garment to achieve a worn look effect on the garment, washing the garment in a sequence of different types of wash steps to achieve a desired shade and/or look, extracting the water, and drying the garment.

1 . A method of creating an abraded garment without use of potassium permanganate, comprising the steps of:
 providing a denim fabric made from yarns having a white core at least 65% of the cross-sectional area of the yarn with the white core exhibiting a whiteness that is more white than blue on the Commission Internationale De L'Elcairage (CIE) chromaticity scale;   forming the fabric into a denim garment;   abrading the unwashed garment to achieve a worn look effect on the garment;   washing the garment in a sequence of different types of wash steps to achieve a desired shade and/or look;   extracting the water; and   drying the garment.   
     
     
         2 . The method of creating an abraded garment without the use of potassium permanganate of  claim 1 , including the step of:
 extracting the water by hydro extraction.   
     
     
         3 . The method of creating an abraded garment without the use of potassium permanganate of  claim 2 , including the step of:
 drying the garment in a steam powered or heated air drying machine.   
     
     
         4 . The method of creating an abraded garment without the use of potassium permanganate of  claim 1 , including the step of:
 determining the color and shade of the garment and washing the garment in a series of steps adapted to achieve the desired color and shade.   
     
     
         5 . The method of creating an abraded garment without the use of potassium permanganate of  claim 1 , including the step of:
 determining whether the garment is to be one of dark sulfur black, dark indigo, medium sulfur black, medium indigo, light sulfur black, light indigo and a combination of any of them, selecting the wash steps to achieve the desired color and shade.   
     
     
         6 . The method of creating an abraded garment without the use of potassium permanganate of  claim 1 , including the step of:
 abrading the garment with one of laser processing and hand sanding.   
     
     
         7 . The method of creating an abraded garment without the use of potassium permanganate of  claim 4 , including the step of: Utilizing a washing machine, hydro extract machine, and a drying machine only and using a laser to abrade the garment when dark sulfur black is the selected color and shade. 
     
     
         8 . The method of creating an abraded garment without the use of potassium permanganate of  claim 4 , including the step of:
 utilizing a washing machine, hydro extract machine, and a drying machine only and using a laser to abrade the garment when dark indigo is the selected color and shade.   
     
     
         9 . The method of creating an abraded garment without the use of potassium permanganate of  claim 7 , including the step of:
 washing the garment in an enzyme wash, then rinsing the garment, and then softening the garment with a softener prior to extracting water.   
     
     
         10 . The method of creating an abraded garment without the use of potassium permanganate of  claim 1 , including the step of:
 softening the garment with a softener prior to extracting water.   
     
     
         11 . A method of creating an abraded garment without use of potassium permanganate, comprising the steps of:
 providing a denim fabric made from yarns having a white core with the white core exhibiting a whiteness that is more white than blue throughout a majority of the yarn;   forming the fabric into a denim garment;   abrading the unwashed garment to achieve a predetermined look effect on the garment;   washing the garment in a sequence of different types of wash steps to achieve a desired shade and/or look;   extracting the water; and   drying the garment.   
     
     
         12 . The method of creating an abraded garment without the use of potassium permanganate of  claim 11 , including the step of:
 determining the whiteness through the Commission Internationale De L'Elcairage (CIE) chromaticity scale.   
     
     
         13 . The method of creating an abraded garment without the use of potassium permanganate of  claim 11 , including the step of:
 abrading the garment through use of a laser.   
     
     
         14 . The method of creating an abraded garment without the use of potassium permanganate of  claim 11 , including the step of:
 determining whether the garment is to be one of dark sulfur black, dark indigo, medium sulfur black, medium indigo, light sulfur black, light indigo, and a combination of any of them;   selecting the wash steps to achieve the desired color and shade.   
     
     
         15 . The method of creating an abraded garment without the use of potassium permanganate of  claim 14 , including the step of: utilizing a washing machine, hydro extract machine, and a drying machine only and using a laser to abrade the garment when dark sulfur black is the selected color and shade. 
     
     
         16 . The method of creating an abraded garment without the use of potassium permanganate of  claim 14 , including the step of:
 utilizing a washing machine, hydro extract machine, and a drying machine only and using a laser to abrade the garment when dark indigo is the selected color and shade.   
     
     
         17 . The method of creating an abraded garment without the use of potassium permanganate of  claim 11 , including the step of:
 washing the garment in an enzyme wash, then rinsing the garment, and then softening the garment with a softener prior to extracting water.   
     
     
         18 . The method of creating an abraded garment without the use of potassium permanganate of  claim 11 , including the step of:
 forming the fabric from yarns formed from both cotton yarns and synthetic yarns.   
     
     
         19 . The method of creating an abraded garment without the use of potassium permanganate of  claim 11 , including the step of: forming the fabric into one of jeans and a jacket. 
     
     
         20 . An abraded garment produced by the method of  claim 1 .