[0001] The present invention relates to textile manufacturing and more particularly to an
improved wet processing technique to produce terry fabrics exhibiting enhanced softness, bulk,
absorbency, hand-feel, reduced lint loss, improved pile standing ability without use of Poly
Vinyl Alcohol (PVA).
Background of the invention
[0002] Fabrics are flexible materials produced from fibers, yarns or threads. Fabrics may be
categorized into woven, knitted and also some non-woven fabric categories. The woven,
knitted and non-woven fabric may be further categorized into terry fabrics, flat fabrics etc.
Terry fabrics, also known as, toweling fabrics are generally thick, and are manufactured with
an aim to absorb greater amount of water and moisture. Terry fabrics, may be made from 100%
cotton fiber yarns, yarns made from fiber blends such as cotton and viscose, blends of cotton
and modal, blends of silk and modal, and blends of cotton and polyester yarns. Conventional
processes of manufacturing soft terry fabrics comprises using cotton yarns and yarns made
from a blend of cotton and Polyvinyl alcohol ("PVA") fibers, where the PVA fibers in the
fabric, that exhibit a unique property of dissolving in hot water, are dissolved during a wet
processing stage of fabric manufacture, thereby producing empty spaces within the structure
of yarn and making the fabric soft and bulky. Typically, conventional processes involve
doubling base yarn with PVA yarn in opposite direction to un-twist base yarn or involve
inserting PVA fibres in the yarn across cross-section of the yarn or in the core of the yarn. It
has been observed that these methods produced fabrics which are not durable and exhibit
inferior appearance after several repeated washes. Moreover, usage of PVA is detrimental to
the environment and PVA recovery from effluent treatment plant is a costly process. Further,
the process of blending cotton and PVA fibers is costly. Furthermore, it has been observed that
the fabric obtained using the conventional wet processing methods exhibit lint loss and
shrinkage.
[0003] In light of the aforementioned drawbacks, there is a need for a process for
manufacturing terry fabrics exhibiting enhanced softness, bulk, absorbency, hand-feel, reduced
3
lint loss, improved pile standing ability without using PVA. Yet further, there is a need for an
improved process which produces fabrics that exhibit high wettability, easy dry ability, and
quick absorbency. Yet further, there is a need for a process which is cost effective, economical
and environment friendly.
Summary of the Invention
[0004] In various embodiments of the present invention, an improved wet processing method
for producing improved terry fabrics is provided. The method comprises the steps of treating a
woven fabric based on an enzymatic treatment process, wherein the woven fabric is de-sized
using optimized dosage of predetermined de-sizing ingredients, washed and bio-washed using
optimized dosage of bio-washing ingredients. The method further comprises pre-treating the
enzyme treated fabric and subjecting the pre-treated fabric to a hot air beat-up process. The hot
air beat-up process comprises mechanically treating the pre-treated fabric in open-width in a
textile tumbling machine with optimized hot air beat-up parameters, wherein air is blown onto
the pre-treated fabric from both directions for a predetermined duration and at a predetermined
frequency causing to and fro movement of the fabric in tumbling chambers of the tumbling
machine resulting in an instantaneous impact produced on every pile loop of the pre-treated
fabric such that built in stress within fibers and the pile loops is released and the fibers rearrange
in a path of least resistance to produce a relaxed, open and aligned fiber structure in the fabric.
The method further comprises dyeing the mechanically treated hot air-beaten up fabric and
finishing the dyed fabric, wherein the dyed fabric is dried and finished with a softener, and
subjected to tumbling using optimized finishing parameters to obtain an improved terry fabric.
[0005] In an embodiment of the present invention, the woven fabric is woven from pile yarn
having TM between 2.0 and 3.4 during spinning at a ring frame or at a modified ring frame.
Further, the enzyme treated fabric is pre-treated including scouring and bleaching.
Furthermore, the pre-treated fabric is partly dried until 10% to 20% moisture is retained.
[0006] In an embodiment of the present invention, the de-sizing step comprises loading the
woven fabric in a machine for de-sizing, raising the temperature of the machine up to 85-95
degree centigrade, adding the optimized dosage of de-sizing ingredients in the machine, and
dwelling the woven fabric for a predetermined duration of 10-20 minutes.
[0007] In an embodiment of the present invention, the optimized dosage of de-sizing
4
ingredients comprises an enzyme optimized to 0.5 gram per litre (gpl), green acid optimized to
1 gram per litre (gpl), and wetting agent optimised to 0.5 grams per litre (gpl).
[0008] In another embodiment of the present invention, the step of bio-washing comprises
water filling, raising temperature up to 55 – 65 degree centigrade, adding the optimised dosage
of bio-washing ingredients, dwelling the woven fabric for a predetermined duration of for 25-
35 minutes, draining water, hot wash, cold wash and unloading of fabric. The bio-washing
ingredients include a bio-washing agent of 0.4 % of dry fabric weight, green acid optimized to
1 gram per litre (gpl) and a wetting agent optimized to 1.5 gpl.
[0009] In an embodiment of the present invention, the optimized hot air beat-up parameters
include speed of the tumbling machine ranging between 12-18 mpm, temperature of tumbling
chambers ranging between 150 to 180 degree centigrade, duration of beating between 07
minutes to 15 minutes and frequency of beating of about 03 seconds. The hot air beaten-up
fabric is dyed using any of the standard dyeing processes selected from pad steam dyeing or
cold pad dyeing.
[0010] In an embodiment of the present invention, the optimized finishing parameters include,
speed of the tumbling machine ranging between 12-18 mpm (meter per minute), temperature
of tumbling chambers ranging between 150 to 180 degree centigrade, duration of beating
between 07 minutes and 15 minutes and frequency of beating of about 3 seconds beat up and
3 seconds dwell, and further repeating the same cycle of beat-up and dwell.
BRIEF DESCRIPTION OF DRAWINGS
[0011] These and other features, aspects, and advantages of the present invention will
become better understood when the following detailed description is read with reference to
the accompanying drawings, wherein:
[0012] Fig. 1 is a flow chart illustrating an improved wet processing technique for producing
terry fabrics exhibiting enhanced softness, bulk, hand feel reduced lint loss and improved pile
standing ability without using PVA, in accordance with an embodiment of the present
invention.
[0013] Fig. 1A illustrates air flow subjected on fabric in open-width during hot air beat-up in
a textile finishing machinery, in accordance with an embodiment of the present invention; and
5
[0014] Fig. 1B illustrates fabric structure after the improved wet processing technique, in
accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention provides an improved wet processing technique for producing
terry fabrics. In particular, the improved process of the present invention includes an optimized
wet processing stage comprising an enzymatic treatment step and a hot air beat-up step to
produce ultra-soft terry fabrics having enhanced, absorbency, hand-feel and bulk, reduced lint
loss and improved pile standing capability without using Polyvinyl Alcohol (PVA). In
operation, the improved process of the present invention comprises: obtaining a woven fabric
by weaving a ground warp yarn, a low TM pile warp yarn and a weft yarn using optimized
weaving parameters. Further, the improved process of the present invention comprises wet
processing the woven fabric. The wet processing stage comprises the step of enzymatic
treatment, where the woven fabric is de-sized, washed and bio-washed using optimized dosage
of predetermined ingredients to inhibit lint loss tendency in the fabric. Further, the wet processing
stage comprises a pre-treatment step where the soft processed fabric undergoes scouring and
bleaching. Furthermore, the pre-treated fabric is subjected to a hot air beat-up step, where the pretreated fabric is mechanically treated by blowing air, producing an instantaneous impact on
every pile loop of the pre-treated fabric, and causing the loop to straighten longitudinally and
release built in stress to obtain a relaxed, open and aligned fiber structure in the fabric. Further,
the air blown fabric is dyed and finally, the dyed fabric is finished with softener and subjected
to tumbling using optimized finishing parameters to obtain an improved terry fabric. The
improved terry fabric exhibits enhanced softness, easy dry ability, quick absorbency and
increased thickness and improved pile standing capability due to longitudinal straightening of
the pile loops, and alignment in fabric structure. Additionally, the improved terry fabric inhibits
lint loss due to enzymatic treatment process.
[0016] Exemplary embodiments herein are provided only for illustrative purposes and various
modifications will be readily apparent to persons skilled in the art. The general principles
defined herein may be applied to other embodiments and applications without departing from
the spirit and scope of the invention. The terminology and phraseology used herein is for the
purpose of describing exemplary embodiments and should not be considered limiting. Thus,
the present invention is to be accorded the widest scope encompassing numerous alternatives,
modifications and equivalents consistent with the principles and features disclosed herein. For
6
purposes of clarity, details relating to technical material that is known in the technical fields
related to the invention have been briefly described or omitted so as not to unnecessarily
obscure the present invention.
[0017] Definitions of a few terms as used in the specification are provided below for ease of
understanding.
[0018] English count (Ne)”: Number of hanks of 840 yards per pound.
[0019] Hank: Mass per unit length of sliver (measure of linear mass density of sliver). A hank
of wool is 560 yards, cotton and silk is 840 yards, and linen is 300 yards.
[0020] Absorbency - The propensity of a material to take in and retain liquid, generally water.
[0021] Blend - A textile containing two or more different types fibers, variants of the same
fiber or different colors and grades of the same fiber.
[0022] Blending - The mixing of predetermined quantities of the same fiber taken from many
lots or of different types of fiber to produce a uniform result.
[0023] Carding - A process in manufacturing spun yarn in which the fibers are separated,
distributed, equalized and formed into a web. The web can be very thin or thick. The process
of carding removes some impurities, and a certain amount of short or broken fibers.
[0024] Doubling: The process of combing two or more carded sliver into a single form is called
doubling.
[0025] Spinning: The final step in the production of yarn. The twisting of fibers in the form of
the sliver or roving.
[0026] Denier: Refers to the thickness of a fiber. It is the measurement of the diameter of the
fiber and refers to weight in grams for 9000 meters.
[0027] Pile: A surface effect on a fabric formed by tufts or loops of yarn that stand up from the
body of the fabric such as terry towel fabric.
[0028] Warp: In woven fabric, the yarns that run lengthwise and are interwoven with the fill
(weft) yarns.
7
[0029] Weft: In woven fabric, the filling yarns that runs perpendicular to the warp yarns.
[0030] Yarn: A continuous strand of textile fibers created when a cluster of individual fibers
are twisted around one another.
[0031] Base material: refers to cotton, cotton blends, silk, modal fibers, acrylic, blends of
cotton and bamboo, blends of cotton and sea weeds, blends of cotton and silver, blends of
cotton and charcoal, blends of polyester and cotton, blends of polyester and viscose, blends of
cotton and modal and combinations thereof.
[0032] Polyvinyl alcohol ("PVA")- a man-made water soluble material fiber material having
unique property of dissolving in hot water,
[0033] Porosity: Porosity is the ratio of the volume of openings (voids) to the total volume of
material. Porous surface of the yarn having more air gaps in the yarn structure provide quick
absorption and early shedding of water that is being absorbed.
[0034] Wettability: Wettability or wetting is the actual process when a liquid spreads on a
solid substrate or material. It can be estimated by determining the contact angle or
calculating area of spreading or time taken to spread.
[0035] IPI stands for Imperfection Index of yarns - Imperfections is the description for thin,
thick places and neps in 1000m of yarn.
[0036] The present invention would now be discussed in context of embodiments as illustrated
in the accompanying drawings.
[0037] In various embodiments of the present invention, an improved wet processing
technique for manufacturing a terry fabric exhibiting enhanced softness, absorbency, bulk,
hand-feel, reduced lint loss and improved pile standing capability is provided. In an
embodiment of the present invention, the terry fabric is obtained by weaving and the process
of obtaining the woven fabric includes interlacing a plurality of warp yarns with a plurality of
weft yarns using one or more weaving patterns. In particular, a plurality of ground warp yarns,
a plurality of pile warp yarns and a plurality of weft yarns are interlaced using optimized
weaving parameters. In an embodiment of the present invention, the optimized weaving
parameters include, but are not limited to, size percentage, picks per inch and picks per minute.
In an exemplary embodiment of the present invention, the optimized size percentage is 2%,
8
picks per inch is 40 and picks per minute is 550 revolutions per minute.
[0038] In an embodiment of the present invention, the ground warp, the pile warp and the weft
yarn may be selected from 100% pure cotton, cotton blends, processed or greige cotton, silk
fibers, modal fibers, lyocell (Tencel), greige or dyed acrylic fibers, greige or dyed polyester,
polybutylene terephthalate (PBT), recycled polyester, polytrimethylene terephthalate (PTT),
any other cellulose based stable fiber, blends of cotton and bamboo, blends of cotton and sea
weed fibers, blends of cotton and lyocell fibers, and blends of cotton and charcoal fibers. In an
exemplary embodiment of the present invention, at least one of: the ground warp, the pile warp
and the weft yarn is a 100% pure cotton natural fiber spun yarn having increased volume,
homogeneous fiber distribution across cross section with low packing density. The 100% pure
cotton natural fiber spun yarn exhibits increased diameter, more air pockets, low Imperfection
Index (IPI) and less hairiness. In a preferred embodiment of the present invention, the natural
fiber spun yarn is used as a pile warp yarn. The ground warp yarn and the weft yarn may be
selected from materials including, but are not limited to, polyester, modal, lyocell and cotton
and its blends o f polyester & viscose; blends of polyester & cotton; blends of cotton and
modal; blends of cotton and silk and modal; blends of cotton and bamboo; blends of cotton
and sea weed fibers; blends of cotton and silver fibers; blends of cotton and charcoal fibers,
and any combinations thereof.
[0039] In a preferred embodiment of the present invention, the pile warp is a true twist yarn
having a low twist multiplier (TM) ranging from between 2.0 TM to 3.4 TM depending on
count, staple length of corresponding fiber and spinning technique. In an exemplary
embodiment of the present invention, the twist multiplier of the ground warp yarn may be
selected from a range 3.8 to 6.0 TM. In an exemplary embodiment of the present invention, the
weft yarn may be a ring spun or open-ended yarn having a twist multiplier ranging from 3.2 to
4.8 TM. In an embodiment of the present invention, the ground warp yarn and the weft yarn
may have a count ranging from 3s to 60s. In an exemplary embodiment of the present invention,
percentage of the natural fiber spun yarn as pile warp in the fabric may range from 30-80 %.
In an exemplary embodiment of the present invention, the low TM yarn has reduced hairiness
across the cross-section of the yarn.
[0040] In an embodiment of the present invention, an improved terry fabric exhibiting
enhanced softness, absorbency, bulk, hand-feel, reduced lint loss improved pile standing
capability is obtained by using improved wet processing technique on the woven terry fabric
9
produced from the low TM yarn. The wet processing technique comprises the steps of desizing, enzymatic treatment, pre-treatment, hot air beat-up, dyeing, and finishing including
tumbling as explained later in the specification with reference to FIG. 1. In an exemplary
embodiment of the present invention, the hot air beat-up is an open-width hot air beat-up. In
another embodiment of the present invention, wet processing comprises the steps of enzymatic
treatment, hot air beat-up, dyeing, and finishing including tumbling. Table 1 below lists
exemplary structural parameters associated with the terry fabric obtained by the process of the
present invention.
[0041] Table 1
Product name Eco soft Bath Towel
Size in cm 76.2 X 137.16
GSM 506
Reed/Ends/cm 56 / 11.02
Pick/cm 16
Pile height in mm 5.9
Pile Count 1/12 CW (combed warp)
Ground Count 2/24 KW (carded warp)
Weft Count 1/16 KW
Border Count 2/20 CW
[0042] Fig. 1 is a flow chart illustrating an improved wet processing method for producing
terry fabrics exhibiting enhanced softness, absorbency, bulk, hand-feel, reduced lint loss and
improved pile standing capability, in accordance with an embodiment of the present invention.
[0043] Referring to Fig. 1, at step 102, the woven fabric is subjected to an enzymatic treatment.
In an embodiment of the present invention, the woven fabric is obtained from a low TM yarn
and is subjected to the enzymatic treatment. The enzymatic treatment comprises de-sizing the
woven fabric using optimized dosage of de-sizing ingredients. In an embodiment of the present
invention, the de-sizing step comprises loading the woven fabric in a machine for de-sizing. In
10
an exemplary embodiment of the present invention, the machine for de-sizing may be a
softflow dyeing machine, machines with Pre-treatment Range (PTR) technology, Continuous
Bleaching Range (CBR) machines or machines having pad batch process. Further, the
temperature of the machine for de-sizing is raised up to a predefined range as mentioned in
Table 2 below. Further, the de-sizing comprises adding optimized dosage of de-sizing
ingredients in the machine and holding or dwelling the woven fabric for a predetermined
duration as mentioned in Table 2 below. In an exemplary embodiment of the present invention,
the de-sizing ingredients include green acid, de-sizing agent and a wetting agent. In an
exemplary embodiment of the present invention, the de-sizing agent may be an amylase
enzyme.
[0044] The optimized de-sizing conditions are exemplified below in Table 2.
[0045] Table 2
De-sizing Conditions
Enzyme 0.3-1 GPL and preferably 0.5 GPL for
softflow machine OR 1 ml/Kg for PTR
machines
Green Acid 1 GPL
Temperature 85 - 95°C
Dwell time 10 - 20 Min (preferably 15 minutes)
[0046] Further, the enzymatic treatment comprises washing the de-sized fabric. In an
embodiment of the present invention, for soft-flow desizing, washing is carried out in a softflow machine. Yet further, the step of enzymatic treatment comprises bio-washing of the desized fabric obtained after washing using optimized dosage of predetermined ingredients for biowashing to remove maximum number of protruding fibers from the de-sized fabric and inhibiting
lint loss tendency in the fabric. In an embodiment of the present invention, the bio-washing step
comprises water filling, temperature raising, adding optimized dosage of bio-washing
ingredients, draining, hot wash, cold wash and unloading of fabric. The optimized bio-washing
conditions are exemplified below in Table 3.
11
[0047] Table 3
Bio-washing conditions
Bio-washing agent 0.4 % of dry fabric weight or 2.5 ml/Kg in
PTR machines
Green Acid 1 GPL
Wetting Agent 1.5 GPL
Temperature 55 - 65°C
Dwell time 25 - 35 Min (At above said temperature)
[0048] In an exemplary embodiment of the present invention, the total operation time of the
enzymatic treatment step including de-sizing, and bio-washing, as explained above is 140-170
minutes.
[0049] At step 104, the enzyme treated fabric is subjected to a pre-treatment step. In an
embodiment of the present invention, the step of pretreatment includes scouring and bleaching.
At step 106, the pre-treated fabric is subjected to a hot air beat-up step. In an embodiment of the
present invention, the pre-treated fabric material is partly dried until 10% to 20% moisture is
retained. Further, the pre-treated fabric is mechanically treated in a textile tumbling machine
with optimized air beat-up parameters. In operation, the pre-treated fabric is loaded on a J scray
component of the textile tumbling machine. Further, the pretreated fabric moves into one or
more tumbling chambers of the textile tumbling machine, where a temperature of 150 to 180
degree centigrade is maintained and air is blown onto the pre-treated fabric from both directions
as shown in Fig. 1A. The air pressure exerted by the blown air onto the pre-treated fabric causes
to and fro movement of the fabric in the tumbling chambers, and producing an instantaneous
impact on every pile loop of the pre-treated fabric. The blowing air action causes a series of
elongation and compression on each pile loop uniformly and causes the pile loop to straighten
longitudinally. Subsequently, built in stress within the fibers and pile loops is released, and the
fibers rearrange in the path of least resistance to produce a relaxed, open and aligned fiber
structure in the fabric.
[0050] In an exemplary embodiment of the present invention, the textile tumbling machine is
an AIRO® 24 machine. The AIRO®24 machine is operated with optimized air beat-up
12
parameters as listed below in Table 4.
[0051] Table 4
Airo ®24 speed 12 - 18 mpm (metre per minute) (GSM
(gram per square metre) ranges from 400 -
750) - low GSM towel requires low
mechanical beat-up whereas high GSM
requires more mechanical beat-up)
Temperature of tumbling chambers (150 degree centigrade to 180 degree
centigrade)
Duration of beating 7 minutes -15 minutes
Frequency of beating 03 seconds beat-up and 03 seconds dwell;
and the same cycle is repeated
[0052] At step 108, the hot air beaten-up fabric is dyed. In an embodiment of the present
invention, the hot air beaten-up fabric is unloaded from the tumbling chambers of the textile
finishing machinery. In an exemplary embodiment of the present invention, the hot air beatenup fabric is dyed using any of the standard dyeing processes such as pad steam dyeing or cold
pad dyeing. In an exemplary embodiment of the present invention, dyeing is carried out with
suitable dyeing agent which is of suitable shade and depth %.
[0053] At step 110, the dyed fabric is subjected to a finishing step. In an embodiment of the
present invention, the dyed fabric may be dried via one of: hydro extractor, rope opener, loop
dryer and stenter. Further, the fabric is finished with softener and subjected to tumbling in a
textile finishing machinery using optimized finishing parameters to obtain an improved terry
fabric. In an exemplary embodiment of the present invention, the dosage of the softener may
be 4 to 33 gpl suitable as per GSM of the Towel.
[0054] In operation, the dyed fabric is loaded into the tumbling chambers of the textile
tumbling machine via J scray component of the tumbling machine. The temperature of the
tumbling chamber is raised and maintained between 150 and 180 degree centigrade. Further,
air is blown onto the dyed fabric from both directions. The air pressure exerted by the blown
air onto the pre-treated fabric causes to and fro movement of the dyed fabric in the tumbling
chambers which produces an instantaneous impact on every pile loop of the dyed fabric. The
13
blowing air action causes a series of elongation and compression on the pile loops and causes
the pile loop to further straighten longitudinally. Subsequently, built in stress within the fibers
and pile loops is released, and the fibers rearrange in the path of least resistance to produce a
fabric structure with increased porosity. Further, apart from porosity thickness (bulkiness) of
the fabric is improved. The fabric structure after improved wet processing technique of the
present invention is shown in Fig. 1B. As shown in the figure the fabric structure after the wet
processing technique is more porous than the fabric structure before wet processing.
[0055] In an exemplary embodiment of the present invention, the textile tumbling machine is
an AIRO®24 machine. The AIRO®24 machine is operated with optimized finishing
parameters as listed below in Table 5.
[0056] Table 5
Airo -24 speed 12 - 18 mpm (GSM ranges from 400 -
750)
Temperature of tumbling chambers 150 degree centigrade to 180 degree
centigrade
Duration of beating 7 minutes to 15 minutes
Frequency of beating 03 seconds

[0057] Advantageously, in accordance with various embodiments of the present invention, the
improved process of the present invention, more particularly, the improved wet processing
technique of the present invention, unexpectedly causes longitudinal straightening of the pile
loops, and alignment in the fabric structure, resulting in improvement in the terry fabric. The
terry fabric manufactured without PVA using true twist yarn of low packing density and the
improved wet processing technique of the present invention exhibits enhanced softness, easy
dry-ability, quick absorbency, reduced lint loss, improved pile standing ability and increased
thickness as compared to conventional 100% cotton towel and PVA towels. Additionally, the
improved terry fabric inhibits lint loss due to enzymatic treatment process. The controlled
alignment of pile loops and fibers in the fabric achieved results in enhancing softness and bulk in
the fabric without using PVA. In various embodiments of the present invention, the controlled
alignment of fibers in the fabric is achieved through the enzymatic treatment and hot air beat-up
of the fabric before dyeing, along with precise computations and optimization of parameters such
14
as optimum dosage of enzymatic treatment ingredients, speed of the machine for hot air beat up,
and temperature of tumbling chambers, as has been demonstrated in accordance with various
embodiments of the present invention, which has been obtained through extensive
experimentation and application of inventive skill.
[0058] Table 6A and 6B below shows a comparative analysis between the woven fabric obtained
from the improved wet processing process of the present invention and fabric obtained from
conventional process using PVA. As shown in Table 5A, the terry fabric obtained from the
improved process of present invention, exhibits reduced lint loss and enhanced absorbency (after
wash) in comparison to terry fabric obtained from conventional process using PVA. Further, as
shown in Table 5 B, the fabric obtained from the process of the present invention has improved,
hand-feel and washing performance.
[0059] Table 6A
S. No. Parameters Woven Fabric (towel)
produced using low TM
yarn of TM 2.75
obtained through the
improved wet
processing process in an
embodiment of the
present invention
Conventional towel with
PVA produced using
yarn of 3.6 TM

1. GSM 506 506
2. Dimension Specification: 137 x 76 cm 137 x 76 cm
3. Weight/Pcs (Grams) 537.00 524.00
4. Lint loss % after 5 HL
(Home Laundering)
0.28 0.53
5. Absorbency% before wash 77 74
15
6. Absorbency% after HL 94 90
Hand- feel scale
Table 6B
Woven Fabric (towel) produced using
low TM yarn of TM 2.75 obtained
through the improved wet processing
process in an embodiment of the
present invention
Conventional towel with
PVA produced using yarn of
3.6 TM
Before Home
Laundering
1 2
After 5X Home 3 4
1
2
3
4
5
6
7
Soft
Coarse
16
Laundering
After 10X Home
Laundering
5 6
[0060] While the exemplary embodiments of the present invention are described and illustrated
herein, it will be appreciated that they are merely illustrative. It will be understood by those
skilled in the art that various modifications in form and detail may be made therein without
departing from or offending the spirit and scope of the invention.

We Claim:

1. An improved wet processing method for producing improved terry fabrics, the
method comprising the steps of:
treating a woven fabric based on an enzymatic treatment process, wherein the woven
fabric is de-sized using optimized dosage of predetermined de-sizing ingredients, washed
and bio-washed using optimized dosage of bio-washing ingredients;
pre-treating the enzyme treated fabric and subjecting the pre-treated fabric to a hot
air beat-up process, wherein the hot air beat-up process comprises mechanically treating the
pre-treated fabric in open-width in a textile tumbling machine with optimized hot air beatup parameters, wherein air is blown onto the pre-treated fabric from both directions for a
predetermined duration and at a predetermined frequency causing to and fro movement of
the fabric in tumbling chambers of the tumbling machine resulting in an instantaneous
impact produced on every pile loop of the pre-treated fabric such that built in stress within
fibers and the pile loops is released and the fibers rearrange in a path of least resistance to
produce a relaxed, open and aligned fiber structure in the fabric;
dyeing the mechanically treated hot air-beaten up fabric; and
finishing the dyed fabric, wherein the dyed fabric is dried and finished with a
softener, and subjected to tumbling using optimized finishing parameters to obtain an
improved terry fabric.
2. The method as claimed in claim 1, wherein the enzyme treated fabric is biowashed, scoured and bleached.
3. The method as claimed in claim 1, wherein the woven fabric is woven from pile
yarn having TM between 2.0 and 3.4 during spinning at a ring frame or at a modified ring
frame.
4. The method as claimed in claim 1, wherein the pre-treated fabric is partly dried
until 10% to 20% moisture is retained.
5. The method as claimed in claim 1, wherein the de-sizing step comprises loading
the woven fabric in a machine for de-sizing, raising the temperature of the machine up to
18
85-95 degree centigrade, adding the optimized dosage of de-sizing ingredients in the
machine, and dwelling the woven fabric for a predetermined duration of 10-20 minutes.
6. The method as claimed in claim 1, wherein the optimised dosage of de-sizing
ingredients comprises an enzyme optimized to 0.5 gram per litre (gpl), green acid optimised
to 1 gram per litre (gpl), and wetting agent optimised to 0.5 grams per litre (gpl).
7. The method as claimed in claim 1, wherein the step of bio-washing comprises
water filling, raising temperature up to 55 to 65 degree centigrade, adding the optimised
dosage of bio-washing ingredients, dwelling the woven fabric for a predetermined duration
of for 25 to 35 minutes, draining water, hot wash, cold wash and unloading of fabric.
8. The method as claimed in claim 1, wherein the bio-washing ingredients include
a bio-washing agent of 0.4 % of dry fabric weight, green acid optimized to 1 gram per litre
(gpl) and a wetting agent optimized to 1.5 gpl.
9. The method as claimed in claim 1, wherein the optimized hot air beat-up
parameters include speed of the tumbling machine ranging between 12-18 mpm,
temperature of tumbling chambers ranging between 150 to 180 degree centigrade, duration
of beating between 07 minutes and 15 minutes and frequency of beating of about 03
seconds and dwell of 3 seconds.
10.The method as claimed in claim 1, wherein the hot air beaten-up fabric is dyed
using any of the standard dyeing processes selected from soft flow, pad steam dyeing or
cold pad dyeing.
11.The method as claimed in claim 1, wherein the optimised finishing parameters
include, speed of the tumbling machine ranging between 12-18 meter per minute (mpm),
temperature of tumbling chambers ranging between 150 to 180 degree centigrade, duration
of beating between 7 minutes and 15 minutes and frequency of beating of about 3 seconds
beat up and 3 seconds dwell, and further repeating the same cycle of beat-up and dwell.