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.

Description

Attorney Docket: 6482.ET042_PCT CLEAN INDUSTRIAL WASH RECIPES FOR WET AND DRY PROCESSES FOR DENIM, AND GARMENTS PRODUCED BY THE PROCESSES CROSS-REFERENCE TO RELATED APPLICATIONS AND CLAIM TO PRIORITY

[0001] This application is a non-provisional application of U.S. Provisional Application No. 63 / 659,579, filed June 13, 2024, the complete disclosure of which is incorporated herein by reference and to which priority is claimed. BACKGROUND OF THE INVENTION 1. Field of the Invention

[0002] The present invention is directed to novel means to reduce and eliminate major problems associated with wet and dry processing of denim garments, such as jeans, namely the excessive number of processing steps to wash the jeans and the associated increase in water, energy, chemicals, carbon footprint and machine time and the use of harmful chemicals such as potassium permanganate in order to achieve the desired looks consumers demand. The embodiments include the use of a largely white core fabric, along with innovative laundry recipes disclosed in this application which allow for a reduction in the number of steps in the wet process, a significant reduction in water, chemicals, energy, carbon footprint and machine time, and the elimination of the use of potassium permanganate and dual laser processes. The embodiments generate unprecedented improvements in sustainability, with associated significantsavings in water, chemicals, energy, carbon footprint, and / or most importantly time due to the easier washdown of the fabrics. 2. Description of the Related Art

[0003] Denim garments, such as jeans, are made from denim fabric produced at the denim mill. The fabric is then sent to denim jeans manufacturers who cut and sew the denim fabric into rigid denim jeans. Then the denim jean manufacturers further convert the denim jeans to salable denim jeans for retail by the wet process laundry techniques and the dry processes of hand sanding, laser abrading, and potassium permanganate (PP) application. Since PP is a very toxic chemical, manufacturers have tried unsuccessfully for years to eliminate this step. However, the PP spray provides a very bright abrasion pattern that is very desirable in the marketplace to create a worn look on denim jeans. Some manufacturers actually have to laser the jean twice to get the bright abrasion achieved with PP and replace the same despite the marked cost increase with dual laser treatments. They will laser etch on the rigid garment, start the wash process, dry the garment, laser etch again, then finish the wash process. Laser boosters and other chemicals are attempted to replicate PP, but there is nothing in the industry that can successfully eliminate PP spray and all the steps that go with it. Some manufacturers apply the laser at an intermediate stage of washing, so they dry the garment before applying the laser. They wash the garment, then dry the garment, and then apply the laser, after which they again wash and dry the garment. The garment is thus dried twice, which consumes large amounts of energy.

[0004] Denim washing provides an aesthetic finish to denim fabric to enhance the appearance and to provide strength. The "wash down" and other "post-make" processes applied to denim garments are many and varied. Often the objective is to distress the garment so that itlooks old and worn. This distressing gives the garments a "fashion" appeal and also softens an otherwise harsh fabric. The chemicals typically used in the washing process consist of several of the following: • Anti-back staining Agent / Dispersing chemicals • Detergent or soaping chemical. • Desizing chemicals. • Soda ash. • Caustic Soda. • Hydrogen peroxide. • Bleaching chemicals. • Laundry enzymes. • Sodium metabisulfite (Meta) • Sodium thiosulfate or hypo Chlorite. • Calcium Hypochlorite. • Dye stuffs (Tints). • Potassium Permanganate (PP). • Softeners. • Acids • Dye Fixing chemicals. • Lubricating chemicals • Wetting chemicals

[0005] There are a number of major problems associated with the use of such chemicals and the wet and dry processes used in the production of denim jeans. The current industrial laundryrecipes are too lengthy and use more water, energy, chemicals, machine time, and labor time. The Los Angeles Times recently reported that “Water shortages are becoming a way of life in cities across the globe — Los Angeles; Cape Town, South Africa; Jakarta, Indonesia; and many more — as climate change worsens and authorities often pipe in water from ever-more-distant sources.” “Water sources are depleted around the world,” said Victoria Beard, a professor of city and regional planning at Cornell University. “Every year, more cities will face ‘Day Zero,’ with no water in their piped systems.” The Los Angeles Times further reports that “Mexico City — founded by the Aztecs on an island amid lakes, with a rainy season that brought torrents and flooding — might have been an exception. For decades, the focus has been on getting rid of water, not capturing it. But a grim convergence of factors — including runaway growth, official indifference, faulty infrastructure, rising temperatures, and reduced rainfall — have left this mega-city at a tipping point after years of mostly unheeded warnings. Distant reservoirs and underground wells are drying up as leaders belatedly confront an existential dilemma.”

[0006] Further, current industrial laundry recipes use harmful chemicals like PP to whiten the abrasion. Current industrial recipes sometimes use pumice stones, which is a non-sustainable process, where many repercussions to be faced like ETP sand powder collection, stone removals from individual garments 1 by 1 and its time-consuming, and also due to natural ferrous contamination, which is a challenge in metal detectors, etc. The current industrial recipes are very costly and time-consuming.

[0007] The inventors have determined through a series of innovative concepts that there is indeed a unique solution to this industry-wide problem, with such invention delivering unheard- of and substantial improvements in sustainability and cost savings for denim manufacturing.Significant reductions in water, electricity, harmful chemicals, energy, and carbon footprint are the unprecedented benefits of the inventors’ invention in denim jean manufacturing. SUMMARY OF THE INVENTION

[0008] The inventors have invented a technology to reduce the number of steps and eliminate processes in the denim jean wet process, with associated substantial reductions in water, chemicals, energy, carbon footprint, and production time. Embodiments detailed herein provide several examples of innovative recipes to reduce the number of wet process steps from about 16 steps for the conventional jean wet process to about 7 steps for the invention described here for a medium wash. Further, the inventors have shown that PP spray can be absolutely eliminated, and other tedious steps also eliminated to achieve the necessary brightness consumer’s demand. The invention comprises two principal components to achieve significant sustainability improvements and cost reduction. The first component is to use denim fabric that has a relatively large white core in the yarn, such core at least 65% of the cross-sectional area of the yarn with the core exhibiting a whiteness that is more white than blue / black on the Commission Internationale De L"Elcairage (CIE) chromaticity scale. The second component to achieve the extraordinary results of reducing the number of wet process steps, possibly in half or more, is to employ the inventive recipes disclosed in this invention. The benefits of this invention are simply extraordinary and include: 1. The inventive recipes of this invention can be applied to all industrial laundries and can be leaned down to generate significant savings in water, energy, chemicals, carbon footprint, machine time, and importantly labor time.2. Associated remarkable and unheard-of cost savings per denim garment as proven from numerous plant trials. 3. Hazardous chemicals like PP can be completely eliminated from the denim washing industry by introducing laser applications or manual hand-scrapping processes on the rigid garment through following the disclosures herein.

[0009] The pumice stone usage can be fully eliminated in inventive dyed fabrics by using stone-free enzymes as the fabric is giving faster panel abrasions. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Additional objects and advantages of the invention will become apparent from a study of the following specification when viewed in light of the accompanying drawings, wherein:

[0011] FIG.1 is an example of denim fabric with large white core;

[0012] FIG.2 is an example of off-white core in conventional denim fabric;

[0013] FIG.3 is a dark wash standard for 100% sulfur black dyed denim;

[0014] FIG.4 is a dark wash standard for indigo dyed denim;

[0015] FIG.5 is medium wash standard for 100% sulfur black dyed denim;

[0016] FIG.6 is a medium wash standard for indigo dyed denim;

[0017] FIG.7 is a light wash standard for 100% sulfur black dyed denim;

[0018] FIG.8 is a light wash standard for indigo-dyed denim;

[0019] FIG.9 is a laser wash medium standard for indigo denim;

[0020] FIG.10 is a hand-sanded standard for 100% sulfur-dyed denim;

[0021] FIG.11 is an acid wash standard for indigo-dyed denim;

[0022] FIG.12 shows the invention recipe for 100% sulfur black dark wash;

[0023] FIG.13 shows the conventional recipe for 100% sulfur black dark wash;

[0024] FIG.14 shows the invention recipe for indigo dark wash;

[0025] FIG.15 shows the conventional recipe for indigo dark wash;

[0026] FIG.16 shows the invention recipe for 100% sulfur black medium wash;

[0027] FIG.17 shows the conventional recipe for 100% sulfur black medium wash;

[0028] Figure 18 shows the invention recipe for indigo medium wash;

[0029] Figure 19 shows the conventional recipe for indigo medium wash;

[0030] Figure 20 shows the invention recipe for 100% sulfur black light wash;

[0031] Figure 21 shows the conventional recipe for 100% sulfur black light wash;

[0032] Figure 22 shows the invention recipe for indigo light wash;

[0033] Figure 23 shows the conventional recipe for indigo light wash;

[0034] Figure 24 shows the invention recipe for indigo medium shade with hand sanding;

[0035] Figure 25 shows the conventional recipe for indigo medium wash PP spray;

[0036] Figure 26 shows the invention recipe for 100% sulfur black medium wash with laser;

[0037] Figure 27 shows the conventional recipe for 100% sulfur black medium shade wash with laser;

[0038] Figure 28 shows the invention recipe for indigo with acid wash high abrasion look; and

[0039] Figure 29 shows a conventional recipe for indigo with stone wash and acid wash with PP look. BRIEF DESCRIPTION OF THE TABLES

[0040] The tables below illustrate the parameters for the conventional wash vs the invention washes for 100% sulfur black dye and indigo dye for each of the standard washes – light, medium, dark, and acid wash. The parameters include yarn size and color, water and chemical(s) used, steam, machine time, # hydro , dryer and dry process cycles, and use of Potassium Permanganate and stones in the washing bath. Hydro extraction is removal of water from the washed wet garments by mechanical methods It is a machine process where the wet garments are loaded into a machine that rotates very fast so that its centrifugal forces are created and to squeeze water from the garments. For each case, the percent savings, batch savings, and total savings realized from the inventive wash recipe vs the conventional wash recipe are shown.

[0041] TABLE I. Benefits of invention recipes vs. conventional recipes for 100% sulfur black dye and dark wash standard;

[0042] TABLE II. Benefits of invention recipes vs. conventional recipes for indigo dye and dark wash standard;

[0043] TABLE III. Benefits of invention recipes vs. conventional recipes for 100% sulfur black dye and medium wash standard;

[0044] TABLE IV. Benefits of invention recipes vs. conventional recipes for indigo dye and medium wash standard;

[0045] TABLE V. Benefits of invention recipes vs. conventional recipes for 100% sulfur black dye and light wash standard;

[0046] TABLE VI. Benefits of invention recipes vs. conventional recipes for indigo dye and dark wash standard;

[0047] TABLE VII. Benefits of invention recipes vs. conventional recipes for indigo medium wash standard with hand sanding;

[0048] TABLE VIII. Benefits of invention recipes vs. conventional recipes for 100% sulfur black hand sanded; and

[0049] TABLE IX. Benefits of invention recipes vs. conventional recipes for indigo dye acid wash standard. DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S)

[0050] The first component of the invention is to use denim fabric that has a relatively large white core in the yarn, such white core having at least 65% of the cross-sectional area of the yarn with the core exhibiting a whiteness that is more white than blue / black on the Commission Internationale De L"Elcairage (CIE) chromaticity scale. An exemplary description of such a yarn can be found in U.S. Patent No.10,508,388 entitled “Yarn Material with a White Center”, the complete disclosure of which is incorporated herein by reference. Figure 1 shows an example of a yarn with the characteristics of the white core, which include a bright whiteness associated with the core that is very large and at least 65% of the cross-sectional area of the yarn. One way to achieve these characteristics is with denim mill processes as disclosed in U.S. Patent No. 10,508,388. However, other denim mill practices or chemical treatments may be appropriate to achieve similar white core characteristics, and the important first component of the invention is not the process to create the white core characteristic in denim but the use of the white core product with the defined characteristics in denim jean manufacturing.

[0051] One should note the stark contrast of white-core yarn required for the invention and yarn cores from conventional denim products. This is best illustrated by a comparison of Figures 1 and 2, where Figure 2 is a picture of the core of conventional denim yarn and clearly shows anoff-white character and a relatively inconsistent core size. Yarn cores with these types of characteristics are not optimized for the invention and will not deliver the extraordinary sustainability and cost savings benefits shown for the invention. Figure 1 shows a relatively large core more white than blue / black and is representative of the type of core optimized for this invention.

[0052] The second component of the invention to achieve the extraordinary results disclosed is to use the innovative wet and dry process recipes detailed below. These recipes are examples of how the invention results in lean and reduced wash recipes. Regardless of the type of finish, the disclosed invention will always lead to a dramatic reduction in process steps and major sustainability savings. The invention recipes are shown for the following wash standards and denim dyes:

[0053] Dark wash standard with 100% sulfur black dyed fabric;

[0054] Dark wash standard with indigo-dyed fabric;

[0055] Medium wash standard with 100% sulfur black dyed fabric;

[0056] Medium standard with indigo-dyed fabric;

[0057] Light wash standard with 100% sulfur black dyed fabric;

[0058] Light wash standard with indigo-dyed fabric;

[0059] Medium wash standard for hand sanded jeans with indigo-dyed fabric;

[0060] Medium wash standard for laser processed jeans with 100% sulfur black dyed fabric; and

[0061] Medium wash standard for acid wash jeans with Indigo dyed fabric.

[0062] Pictures of the different denim-dyed fabrics washed to the different wash standards illustrated in Figures 3 - 11. Detailed specifications for each case (three different denim dyed fabrics washed to different wash standards) are given in Figures 12-29 in the attachments. Figures 12, 14, 16, 18, 20, 22, 24,26 and 28 are specifications for the invention recipes on fabric with large white cores, and Figures 13, 15, 17, 19, 21, 23, 25, 27 and 29 are the corresponding recipes for the standard conventional denim products with off white cores with diffused dye inside the cores of the yarn. The invention recipes are then compared to the conventional recipes to achieve the same standard in Tables I-IX where the remarkable sustainability advantages, environmental savings, and cost savings are shown. The difference between dark, medium, and light wash standard is the base shade ( in other words base color of the denim garment). The denim fabric at the unwashed stage is dark. When it is washed with different types of chemicals at different conditions like temperatures, Ph levels, water levels, dosages of chemicals, machine types, etc, it starts losing the dyes and starts becoming abraded (hi-low effect which is the common phenomena on denims) on the stitched edges. The base shade starts getting lighter as the wash aggression increases. The fabric can be controlled at different shade levels from dark to light during washing. The difference is not recognized as industry standard because different fabric comes with different amounts of dye. A fabric with a higher amount of dye shows darker shades compared to less amount of dye. Every type of fabric can be washed from the existing shade level to lighter levels. The differences of standards in base shades are set by the brand people, mainly by designers as per their choices after analyzing market trends, sales strategies, seasonal aspects etc. These standards will be unique for the individual brands for specific season, fabric, wash type, etc and not common standards for all denims in whole industry. Here the abraded garment means a garment with dry processes ( whiskers, scrapping / blasting, PP sprayed one in terms of conventional wash. The inventors can achieve the same look by following steps: (1) Before washing the garment, (2) Place the garment underthe laser, (3) apply the laser per the design set, (4) Turn off the laser, and (5) remove the garment,

[0063] INVENTION RECIPE FOR 100% SULFUR BLACK DARK WASH SHOWN IN FIG.12.

[0064] The first invention recipe for 100% sulfur black dye for the dark wash standard is found in the attached Figure 12. Figure 12 details both the wet and dry processes and includes information on washing machine type, item type, washing machine time, water used, total chemicals used, dry process time, hydro time, dryer time, and detailed specifications including temperature, time and steam for enzyme wash, rinse, softener and hydro extraction. This type of detail is what the laundry needs to practice the dry and wet process part of the invention.

[0065] As used herein, the following terms have the following meanings:

[0066] Sustainable values (EIM)- Environmental Impact Measurement, which is a software- based calculation tool created by Jeanolgogia of Spain to evaluate the environmental impact of a wash recipe;

[0067] Laser / Manual DP (min) means the time required to apply an effect on a garment in minutes or seconds, whether by laser abrading or hand sanding;

[0068] Wash time is the time required to treat a garmen t in a washing machine;

[0069] Dry Process Time (full) means the time required to create an effect on the garment, whether by laser or manual hand sanding;

[0070] Hydro Time is the time required for hydro extraction;

[0071] Total Chemicals Used means the total amount t of chemicals used during the wash step;

[0072] L / R means the material to liquid ratio;

[0073] MLR means the total water required for a garment;

[0074] Gpl means grams / liter; and

[0075] OWG means on the weight of the garment. (For example, 2% enzyme means 2 grams of enzyme / 100 grams of garment.

[0076] By examining the column titled Time (Min), five steps for the invention recipe for the 100% sulfur black dyed fabric are required to achieve the dark wash standard. This is quite favorably compared to 10 steps for the same case with the conventional wet processing to achieve the same dark wash standard in most laundries in the world shown in the attached Figure 13 for the 100% sulfur black dyed fabric and a dark wash. In both cases, the goal was to achieve the same aesthetic look for the dark wash standard. To get the same aesthetic look for the conventional dark wash for conventional fabrics and the invention recipe dark wash for the white core fabric, the invention recipe garments underwent just 5 steps in a wet process and further saved 1 complete hydro extraction and 1 drying cycle, while eliminating the potassium permanganate spraying process, manual hand sanding whisker and scrapping processes, PP neutralizing and rinse wash steps, as revealed in the comparison of the invention recipe shown in Figure 12 with the conventional recipe shown in Fig.13 Potassium permanganate is typically used at the end of the wash process just before the tint and softening steps. The garment must be dried before PP application. Typically the garments are hydro extracted, dried, and then PP sprayed onto the garments.

[0077] The example wash comparison has been done with 100% Sulfur black conventionally dyed fabric washed with conventional wash recipes against the invention wash recipes on 100% sulfur dyed fabric with large white cores to achieve the same aesthetic and level of wash standard. The conventional wash recipe has dry processes, such as laser, manual hand sandingwhiskers, manual scrapping and PP spraying on top of scrapped areas, plus wet processes including enzyme wash, PP neutralizing, and then softener.

[0078] In the conventional recipe of 100% sulfur black dark wash, manual hand sanding whisker, manual scrapping on front and back, and PP spraying are done on top of scrapping areas and also PP is sprayed there. The garment has to undergo an extra hydro and drying cycle compared to the invention recipe. And in the enzyme wash, faster abrasion is achieved in the invention recipe compared to the same on the conventional recipe.

[0079] In the invention recipe, the dry processes are achieved by laser abrading at the before- wash stage, where there is no need for two-time hydro and two-time drying. And also, an extra neutralizing process is needed in the conventional recipe.

[0080] The invention fabric has a largely white core in the yarn cross-section, and it has the ability to abrade the dyeing layer on the yarn cross-section easily. Hence, the whitish core appears on the surface in the case of the invention recipe. The same whiteness is very hard to achieve in the conventional fabric of 100% sulfur, even though PP spraying is done to get the required whiteness on the scrapped areas.

[0081] This significant improvement in the wet and dry processes for the invention recipe vs the conventional recipe for 100% sulfur black dyed fabric and the dark wash standard generates substantial sustainability advantages and large cost savings per denim jean. Indeed, and remarkably, the dramatic improvement can be clearly seen in Table 1, details of which follow:As used in the footnotes, “Machine Time” is the treatment time of the garment in the washing machine, hydro extractor and dryer, “The Other Operation Time” means the time required to treat the garment for dry processes, such as laser abrading, manual hand sanding, PP spteay, etc. In the Example, total garment batch size is 200 garments, it takes 1 minute / garment, so total time is 200 minutes. 1.25 minutes / garment is required for manual hand sanding, so the total time is 250 minutes.

[0082] Sustainability Savings:

[0083] Comparisons of both recipes reveals the major savings achieved with the invention recipe over the conventional recipe as follows:

[0084] The water savings of 1,250 Liters represents a 43.86% reduction in water usage;

[0085] Total chemical savings of 1.6 kgs represents a 30.77% reduction in chemicals;

[0086] Steam savings of 200 Kg represents a 48.14% savings in steam usage;

[0087] Wet process machines’ time savings of 79 minutes represents a 45.66% savings; and

[0088] Time savings on dry (other) processes is an extremely beneficial 90 minutes.

[0089] Water Savings:

[0090] In the conventional recipe, additional wet processes have to be undertaken due to the nature of the fabrics, to get the white bright look of the dry processed areas with PP spraying. Hence there is an additional rinse wash and neutralizing process compared to the invention recipes. This along with PP spraying chemical preparing water together gives the water saving as such.

[0091] Chemical Savings:

[0092] In the conventional recipe, neutralizing chemicals (sodium metabisulfite) must be used after PP spraying process to neutralize the PP chemicals in the sprayed areas, and then only it becomes a whitish color. And, the PP amount counted into additional chemical amounts to go up in conventional compared to invention recipes.

[0093] Steam Savings:

[0094] Major steam savings are achieved due to the additional drying cycle involved in conventional recipes due to PP spraying. Before PP spraying, the garment will first undergo a simple enzyme wash and then hydro extraction and drying the garment before preparing for the PP spraying. So, the garments will run around 60 minutes in the drying cycle, which uses maximum steam compared to the invention recipes.

[0095] Wet process Machine Time Savings:

[0096] In the wet process area mainly three machines are used. The washing machine, hydro extract machine, and drying machines. So, in the conventional recipe an additional rinse step, one neutral step, one hydro extract process, and one drying process additionally are required. This is because PP spraying processes are involved in the conventional wet processing recipes.

[0097] This machine time savings means a lot for a laundry, as the drying and extract capacities are going to go up by 50% and allow more drying and hydro extractions. The analysis in Table I shows an impressive machine time savings of 79 minutes for the invention recipe compared to the conventional recipe.

[0098] Time Savings in the Dry Processes

[0099] The dry processes are known as prior processes to the wet process and involve many laborers in the washing industry. The conventional washing requires that laundries are using many workers in dry processes, such as hand sanding whiskers, hand sanding scrapping and PP spraying, grinding, and tacking.

[0100] However, the latest technologies are being used to get the labor oriented dry processes to be replaced by laser. The laser is a process where it burns out or abrades the surface dye stuff and if need be the yarn itself per design requests for the garments. Two of the inventors of this invention actually invented, patented and licensed laser abrasion to major denim brands across the globe.

[0101] The wash recipe decides the final washed shade of the garment. The laser intensity is adjusted considering the type of fabric, type of wash, and required brightness. If the fabric hassynthetic material in the weft, then the laser intensity should be reduced because high laser intensity may damage the synthetic component of the weft. The laser intensity is also set based on the wash. If the wash recipe is very aggressive and results in a relatively light shade, then the shade difference in between non-lasered areas and the lasered areas reduces; and to enhance the difference, the laser intensity is increased. As the laser intensity increases, the laser beam penetrates more into the fabric, resulting in more layer removal of the fabric surface. This may result in more brightness on lasered area on a washed garment. This is because the dye concentration is higher on the top layers and reduces in the inner layers of indigo and sulfur dyed yarn.

[0102] So, in the invention recipes, garments always do the dry processes before the wash stage with laser, and hence manual 3 processes - manual whisker, manual scrapping and PP spraying, are replaced by one single process using a laser. The most beautiful aesthetic look can be obtained by adjusting and fine tuning the laser designs. In the cases where garment manufacturers do not have lasers or enough capacity of lasers, hand sanding alone on the rigid (unwashed) garment can also achieve the necessary brightness using this invention.

[0103] The necessary brightness is the brightness of the abrasion area of the denim garment that is aesthetically pleasing using this invention. Dry processes aesthetics are a set standard similar to those based on shade level. To achieve the specified levels, laser settings need to be tested, typically through trial and error, to match the same look what brands require. Once the aesthetics are achieved, the laser machine settings, mainly two parameters like DPI (dots per inch) and TPX ( Time per pixel) are set for a particular wash and continue.

[0104] Here in this case, substantial process time is saved in the invention recipe as the labor oriented 3 processes takes a long time to complete. This recipe analysis shows 90 minutes of operation savings and in combination with the other time savings represents a considerable advantage in terms of productivity and additional throughput.

[0105] Total Cost Savings:

[0106] One would expect that all these savings for the invention recipes compared to the conventional recipes would generate substantial economic savings. Indeed, that is correct as Table I amazingly reveals a total savings per batch of $58.33 and a savings per garment of $0.29. [Prices fluctuate based upon many factors, so do we need to put a date on when the pricing was utilized? Possibly instead show as a percentage saving to eliminate actual prices?]

[0107] INVENTION RECIPE INDIGO DARK WASH SHOWN IN FIG.14

[0108] The second invention recipe for indigo-dyed fabric for the dark wash standard is found in the attached Figure 14. By examining the column titled Time (Min), five steps for the invention recipe for the indigo-dyed fabric are required to achieve the dark wash standard. This is favorable compared to 10 steps for the same case with the conventional wet processing to achieve the same dark wash standard in most laundries in the world, and as shown in the attached Figure 14 for the indigo dyed fabric and a dark wash. In both cases, the goal was to achieve the same aesthetic look for the dark wash standard. To get the same aesthetic look as the conventional dark wash and the invention recipe dark wash, the invention recipe garments underwent just 5 steps in the wet processes and further saved 1 complete hydro extraction and 1 drying cycle, while eliminating the PP spraying process, manual hand sanding whisker andscrapping processes, PP neutralizing and a few rinse wash steps as revealed in the comparison of the invention recipe shown in Figure 14 with the conventional recipe shown in Figure 15.

[0109] The example wash comparison has been done with indigo-dyed fabric against the invention recipes to achieve the same standard. The conventional wash recipe followed a conventional washing recipe where it has dry processes, such as manual hand sanding whiskers, manual scrapping and PP spraying on top of the scrapped areas, plus wet processes such as enzyme wash, PP neutralizing and then softener.

[0110] In the conventional recipe of Indigo fabric in dark wash, manual hand sanding whisker, manual scrapping on front and back, and PP spraying are done on top of scrapping areas and the PP is sprayed there. The garment has to undergo extra hydro and drying cycles compared to invention recipe.

[0111] In the Invention recipe, the dry processes are achieved by laser burning at the before-wash stage, and there is no need for two-time hydro and two-time drying.

[0112] The largely more white than blue / black core fabric has a white core in the yarn cross-section and has the ability to burn the dyeing layer on the yarn cross-section easily, and hence the whitish core appears on the surface in the case of the invention recipe. The same whiteness is very hard to achieve in conventional fabrics and hence they must undergo PP spraying to get the whiteness. Normally when PP spraying is applied to the denim jeans, the garment is first washed and completely dried, and PP thereafter applied so that PP spray is absorbed and feathers on dry process areas.

[0113] The dramatic improvement in the wet and dry processes for the invention recipe vs the conventional recipe for indigo-dyed fabric and the dark wash standard generatessubstantial sustainability advantages with significant cost savings per denim jean. Indeed, this is the case, and the dramatic improvement can be clearly seen in Table II, details of which follow:

[0114] Sustainability Savings:

[0115] Comparisons of both recipes reveal the major savings achieved with the invention recipe over the conventional recipe.

[0116] The water savings of 1,350 Liters represents a 45.76% reduction in water usage;

[0117] Total chemical savings of 2.7 kgs represents a 41.22% reduction in chemicals;

[0118] Steam savings of 215.6 Kg represents a 51.88% savings in steam usage;

[0119] Wet process machines’ time savings of 79 minutes represents a 45.66% savings; and

[0120] Time savings on dry (other) processes is an extremely beneficial 90 minutes.

[0121] Water Savings:

[0122] In the conventional recipe, additional wet processes must be utilized due to the nature of the fabrics, to get the white bright look of the dry processed areas with PP spraying. Hence there are additional rinse wash and neutralizing processes required compared to the invention recipe. These along with PP spraying chemical preparing water, give the water saving as such.

[0123] Chemical Savings:

[0124] In the conventional recipe, neutralizing chemicals (sodium metabisulfite) must be used after the PP spraying process to neutralize the PP chemicals in the sprayed areas, and only then it becomes the whitish color. Also, the PP amount is counted into additional chemical amounts in the conventional recipe compared to the invention recipes.

[0125] Steam Savings:

[0126] Major steam savings are achieved due to the additional drying cycle involved in the conventional recipe on account of PP spraying. Before PP spraying, the garment will undergo first a simple enzyme wash and then hydro extraction and drying the garment before preparing for PP spraying. So, the garments will require approximately 60 minutes in the drying cycle, which uses maximum steam compared to the invention recipes.

[0127] Wet Process Machine Time Savings:

[0128] In the wet process area, mainly three machines are used. The washing machine, hydro extract machine, and drying machines. So, in the conventional recipe, additional rinsesteps and one neutralizing step, one hydro extract process, and one drying process additionally are required. This is because PP spraying processes are involved in the conventional wet processing recipes.

[0129] This machine time savings means a lot for a laundry as the drying and extract capacities are going to go up by 50%, which will allow more garments to be dried and hydro extractions. The analysis in Table II showed an impressive machine time savings of 79 minutes for the invention recipe compared to the conventional recipe.

[0130] Time Savings in the Dry Processes

[0131] The dry processes are known as prior processes to the wet processes and involve many laborers in the washing industry. The conventional washing means that laundries are using many workers for dry processes, such as hand sanding whiskers, hand sanding scrapping and PP spraying, grinding, and tacking.

[0132] However, the latest technologies are being used to get these labor oriented dry processes replaced by laser abrasion. The laser is a process where it burns out the surface dyestuff and, if needed, the yarn itself per design specifications for the garments.

[0133] So, in the invention recipes, garments always do the dry processes before the wash stage with laser, and hence 3 manual processes - manual whisker, manual scrapping and PP spraying, are replaced by one single process of laser. The most beautiful aesthetic look can be obtained by adjusting and fine-tuning the laser designs.

[0134] Here in this case, process timing can be saved in the invention recipes as the 3 labor-oriented processes take a long time to complete. This recipe analysis shows 90 minutes ofsavings and, in combination with the other time savings, represents a considerable advantage in terms of productivity and additional throughput.

[0135] Total Cost Savings:

[0136] One would expect that all these savings for the invention recipes compared to the conventional recipes would generate substantial economic savings. Indeed, that is correct as Table II amazingly reveals total savings per batch of $59.42 and an unheard-of savings per garment of $0.30.

[0137] INVENTION RECIPE 100% SULFUR BLACK MEDIUM WASH SHOWN IN FIG.16

[0138] The third invention recipe is for 100% sulfur black dyed fabric for the medium wash standard and can be found in the attached Figure 16. By examining the column titled Time (Min), the seven steps for the invention recipe for the 100% sulfur black dyed fabric are required to achieve the medium wash standard. This is quite favorably compared to 14 steps for the same case with the conventional wet processing to achieve the same medium wash standard in most laundries in the world, and is shown in the attached Figure 17 for 100% sulfur black dyed fabric and a medium wash. In both cases, the goal was to achieve the same aesthetic look for the medium wash standard. To get the same aesthetic look for the conventional medium wash and the invention medium wash, the invention recipe garments underwent just 7 steps in the wet processes and further saved 1 complete hydro extraction and 1 drying cycle plus potassium permanganate spraying process, manual hand sanding whisker and scrapping processes, PPneutralizing and a few rinse wash steps as revealed in the comparison of the recipes shown in Figs.16 and 17.

[0139] The example wash comparison was done with 100% sulfur black dyed fabric against the invention recipe to achieve the same standard. The conventional wash recipe followed the conventional washing recipe and has dry processes, such as manual hand sanding whiskers, manual scrapping and PP spraying on top of scrapped areas, plus wet processes, such an enzyme wash, PP neutralizing and then softener.

[0140] In the conventional recipe of 100% sulfur black medium wash has similar wash comparisons of dark wash in the same fabric, and there are additional hydro extraction, drying and neutralizing steps. And, the dry processes differences are the same as for dark wash. To make the base shade a bit lighter than the dark wash, there is a bleaching process with hydrogen peroxide, along with either soda ash or caustic soda at 60° C temperature.

[0141] The largely more white than blue / black core fabric is due to white core in the yarn cross-section, and it permit the ability to burn the dyeing layer on the yarn cross-section easily. Hence the whitish core appears on the surface in the case of the invention recipe, whereas the same whiteness is very hard to achieve in the conventional fabric of 100% sulfur even though PP spraying being done increase the whiteness on the scrapped areas.

[0142] The dramatic improvement in the wet and dry processes for the invention recipe vs the conventional recipe for sulfur black dyed fabric and the medium wash standard generates substantial sustainability advantages and significant cost savings per denim jean. Indeed, this is the case and the dramatic improvement is clearly shown in Table III on the next page, details of which follow:

[0143] Sustainability Savings:

[0144] Comparisons of both recipes reveals the major savings achieved with the invention recipe over the conventional recipe.

[0145] The water savings of 2,550 Liters represents a 47.66% reduction in water usage;

[0146] Total chemical savings of 3.55 kgs represents a 32.87% reduction in chemicals;

[0147] Steam savings of 210.3 Kg represents a 45.95% savings in steam usage;

[0148] Wet process machines’ time savings of 91 minutes represents a 45.5% savings; and

[0149] Time savings on dry (other) processes is an extremely beneficial 90 minutes.

[0150] Water Savings:

[0151] In the conventional recipe additional wet processes are required due to the nature of the fabrics, to get the white bright look of the dry processed areas with PP spraying. Hence there are an additional rinse wash and neutralizing processes compared to the invention recipes. These, along with PP spraying chemical preparing water, give the water saving as such.

[0152] Chemical Savings:

[0153] In the conventional recipe, neutralizing chemicals (sodium metabisulfite) must be used after PP spraying process to neutralize the PP chemicals in the sprayed areas, and only then it achieves a whitish color. Also, the PP amount is counted into additional chemical amounts compared to the invention recipes.

[0154] Steam Savings:

[0155] Major steam savings are achieved due to the additional drying cycle involved in the conventional recipe on account of PP spraying. Before PP spraying, the garment will undergo first a simple enzyme wash and then hydro extraction and drying the garment before preparing for the PP spraying. So, the garment requires approximately 60 minutes in a drying cycle, which uses maximum steam compared to the invention recipes.

[0156] Wet Process Machine Time Savings:

[0157] In the wet process area mainly three machines are used. These are the washing machine, hydro extract machine and drying machines. So, in the conventional recipe additional rinse steps and one neutralizing step and one hydro extract process and one drying process additionally are required. This is because PP spraying processes are involved in the conventional wet processing recipes.

[0158] This machine time saving means a lot for a laundry as the drying and extract capacities are increased by up to 50%, which allows more garment drying and hydro extractions. The analysis in Table III shows an impressive machine time savings of 91 minutes for the invention recipe compared to the conventional recipe.

[0159] Time Savings in the Dry Processes

[0160] The dry processes are known as prior processes to the wet processes and involve many laborers in the washing industry. The conventional washing means that laundries are using many workers in dry processes, like hand sanding whiskers, hand sanding scrapping and PP spraying, grinding, and tacking.

[0161] However, the latest technologies are being used to get this labor oriented dry processes to be replaced by laser. The laser is a process where it burns out the surface dye stuff and, if needed, the yarn itself per designs wanted in the garment.

[0162] So, in the invention recipe garments always undergo the dry processes before the wash stage with laser, and hence three manual processes (manual whisker, manual scrapping and PP spraying) are replaced by one single laser process. The most beautiful aesthetic looks can be obtained by adjusting and fine-tuning the laser designs.

[0163] Here in this case, much process timing is saved by the invention recipes because the three labor-oriented processes take a long time to complete. This recipe analysis shows a 90 minute savings for the other operations and, in combination with the other time savings, represents a considerable advantage in terms of productivity and additional throughput.

[0164] Total Cost Savings:

[0165] One would expect that all these savings for the invention recipes compared to the conventional recipes to generate substantial economic savings. Indeed, that is correct as Table III amazingly reveals a total savings per batch of $66.19 and a remarkable savings per garment of $0.33.

[0166] INVENTION RECIPE INDIGO MEDIUM WASH SHOWN IN FIG.18

[0167] The fourth invention recipe for indigo dyed fabric for the medium wash standard can be found in the attached Figure 18. By examining the column titled Time (Min), the seven steps are required for the invention recipe for the indigo dyed fabric to achieve the medium wash standard. This is quite favorably compared to 16 steps for the same case with the conventional wet processing to achieve the same medium wash standard in most laundries in the world, and is shown in the attached Figure 19 for indigo dyed fabric and a medium wash. In both cases, the goal was to achieve the same aesthetic look for the medium wash standard. To get the same aesthetic look for the conventional medium wash and the invention medium wash, the invention recipe garments underwent just 7 steps in the wet processes and eliminated 1 complete hydroextraction and 1 drying cycle plus potassium permanganate spraying process, manual hand sanding whisker and scrapping processes, PP neutralizing and a few rinse wash steps as revealed in the comparison of the invention recipe shown in Figure 18 with the conventional recipe shown in Figure 19.

[0168] The example wash comparison was done with 100% indigo dyed fabric compared to the invention recipes to achieve the same standard. The conventional wash recipe followed the conventional washing recipe, which has dry processes, such as manual hand sanding whiskers, manual scrapping and PP spraying on top of scrapped areas, plus wet processes such as enzyme wash, PP neutralizing and then softener.

[0169] In the conventional recipe of indigo fabric in medium wash also has major additional wash processes as in the dark wash comparison, such as extra hydro extraction, drying cycle and a neutralizing cycle. To achieve the medium base shades in the conventional recipe, it undergoes a chlorine bleaching process with calcium hypochlorite / sodium hypochlorite. The same shade is achieved in the invention recipe by use of just hydrogen peroxide and soda ash. The reason for the faster bleach down in the invention recipe is due to the fabric difference in white core vs conventional fabrics.

[0170] The largely more white than blue / black core fabric white core in the yarn cross- section provides the ability to burn the dyeing layer on the yarn cross-section easily. Hence the whitish core appears on the surface in the case of invention recipe whereas the same whiteness is very hard to achieve in conventional fabric, and hence must undergo PP spraying to get the whiteness. Normally when PP spraying is applied on to denim jeans, the garment is first washed and completely dried, and PP applied so that PP spray is absorbed and feathers on dry processes areas.

[0171] The dramatic improvement in the wet and dry processes for the invention recipe vs the conventional recipe for indigo dyed fabric and the medium wash standard generates substantial sustainability advantages with significant cost savings per denim jean. Indeed, this is the case, and the dramatic improvement is clearly shown in Table IV on the next page, details of which follow:

[0172] Sustainability Savings:

[0173] Comparisons of both recipes reveals the major savings achieved with the invention recipe over the conventional recipe.

[0174] The water savings of 4,150 Liters represents a 58.87% reduction in water usage.

[0175] Total chemical savings of 7.55 kgs represents a 48.09% reduction in chemicals.

[0176] Steam savings of 229.9 Kg represents a 49.91% savings in steam usage.

[0177] Wet process machines’ time savings of 76 minutes represents a 41.76% savings.

[0178] Time savings on dry (other) processes is an extremely beneficial 90 minutes.

[0179] Water Savings:

[0180] In the conventional recipe, additional wet processes are utilized due to the nature of the fabrics, to get the white bright look of the dry processed areas with PP spraying. Hence there are an additional rinse wash and neutralizing processes compared to the invention recipes These, along with PP spraying chemical preparing water, together give the water saving as such.

[0181] Chemical Savings:

[0182] In the conventional recipe, neutralizing chemicals (sodium metabisulfite) must be used after the PP spraying process to neutralize the PP chemicals in the sprayed areas, and only then it achieves a whitish color. And, the PP amount is counted in additional chemical amounts in the conventional compared to the invention recipe.

[0183] Steam Savings:

[0184] Major steam savings are due to the additional drying cycle involved in the conventional recipe due to PP spraying. Before PP spraying, the garment will first undergo fa simple enzyme wash and then hydro extraction and drying the garment before preparing for the PP spraying. So, the garment will require approximately 60 minutes in the drying cycle, which uses maximum steam compared to the invention recipes.

[0185] Wet Process Machine Time Savings:

[0186] In the wet process areas, mainly three machines are used. These are the washing machine, hydro extract machine and drying machines. So, in the conventional recipe, there is an additional rinse step, one neutral step, and one hydro extract process, and one drying process additionally comes in. This is because the PP spraying processes are involved in the conventional wet processing recipes.

[0187] This machine time savings means a lot for a laundry as the drying and extract capacities go up by 50%, which allows more garment drying and hydro extractions. The analysis in Table IV showed an impressive machine time savings of 76 minutes for the invention recipe compared to the conventional recipe.

[0188] Time Savings in the Dry Processes

[0189] The dry processes are known as prior processes to the wet processes and involves many laborers in the washing industry. The conventional washing means that laundries are using many workers in dry processes, like hand sanding whiskers, hand sanding scrapping and PP spraying, grinding, and tacking.

[0190] However, latest technologies are being used to have these labor-oriented dry processes replaced by laser. The laser is a process that burns out the surface dyestuff and, if needed, the yarn itself per design requirements for the garment.

[0191] So, in the invention recipes, garments always do the dry processes before the wash stage with a laser. Hence three manual processes - manual whisker, manual scrapping and PP spraying are replaced by one single laser process. The most beautiful aesthetic looks are obtained by adjusting and fine-tuning the laser designs.

[0192] Here in this case, much process time is saved in the invention recipe, as the three labor oriented processes take a long time to complete. This recipe analysis shows 90 minute savings for other operations and, in combination with the other time savings, represents a considerable advantage in terms of productivity and additional throughput.

[0193] Total Cost Savings:

[0194] One would expect that all these savings for the invention recipe compared to the conventional recipes would generate substantial economic savings. Indeed, that is correct as Table IV amazingly reveals a total savings per batch of $62.16 and a remarkable savings per garment of $0.31.

[0195] INVENTION RECIPE 100% SULFUR BLACK LIGHT WASH SHOWN IN FIG. 20

[0196] The fifth invention recipe is for 100% sulfur black dyed fabric for the light wash standard and can be found in the attached Figure 20. By examining the column titled Time (Min), the seven steps for the invention recipe for the 100% sulfur black dyed fabric are required to achieve the light wash standard. This is quite favorably compared to 14 steps for the same case with the conventional wet processing to achieve the same light wash standard in most laundries in the world and is shown in the attached Figure 21 for 100% sulfur black dyed fabric and a light wash. In both cases, the goal was to achieve the same aesthetic look for the light wash standard. To get the same aesthetic look as the conventional light wash and the invention light wash, the invention recipe garments underwent just 7 steps in wet processes and eliminated saved 1 complete hydro extraction, 1 drying cycle and also a potassium permanganate sprayingprocess, manual hand sanding whisker and scrapping processes, PP neutralizing and a few rinse wash steps as revealed in the comparison of the invention recipe shown in Figure 20 with the conventional recipe shown in Figure 21.

[0197] The example wash comparison has been done with 100% sulfur black dyed fabric compared to the invention recipe to achieve the same standard. The conventional wash recipe followed the conventional washing recipe, which has dry processes, such as manual hand sanding whiskers, manual scrapping and PP spraying on top of scrapped areas, plus wet processes such as enzyme wash, PP neutralizing and then softener.

[0198] The conventional recipe of 100% sulfur black Light wash is also like the same wash comparisons of dark wash in the same fabric, and there are additional hydro extraction, drying, and neutralizing steps. And also, the dry processes differences are the same as a dark wash. To make the base shade lighter than the dark wash and a bit lighter than the medium wash, there is a bleaching process with hydrogen peroxide, along with either soda ash or caustic soda at 60° C temperature, which is a longer time than the medium wash. And in the invention recipe, laser abrasion is faster than the conventional fabric due to the white core fabric achieving faster abrasion in enzyme washes.

[0199] The largely more white than blue core fabric is due to the white core in the yarn cross-section and has the ability to burn the dyeing layer on the yarn cross section easily. Hence the whitish core appears on the surface in the case of the invention recipe. The same whiteness is very hard to achieve in the conventional fabric of 100% sulfur, even though PP spraying is done to get increase whiteness in the scrapped areas.

[0200] This dramatic improvement in the wet and dry process for the invention recipe vs the conventional recipe for sulfur black dyed fabric and the light wash standard generates substantialsustainability advantages, with significant cost savings per denim jean. Indeed, this is the case, and the dramatic improvement is clearly shown in Table V, details of which follow:

[0201] Sustainability Savings:

[0202] Comparisons of both recipes reveals the major savings achieved with the invention recipe over the conventional recipe.

[0203] The water savings of 2,550 Liters represents a 47.66% reduction in water usage;

[0204] Total chemical savings of 3.55 kgs represents a 32.87% reduction in chemicals;

[0205] Steam savings of 216.3 Kg represents a 45.95% savings in steam usage;

[0206] Wet process machines’ time savings of 86 minutes represents a 44.1% savings;

[0207] Time savings on dry (other) processes is an extremely beneficial 90 minutes.

[0208] Water Savings:

[0209] In the conventional recipe, additional wet processes are required due to the nature of the fabric in order to achieve the white bright look in the dry processed areas with PP spraying. Hence there is an additional rinse wash and neutralizing processes compared to the invention recipe. This, along with PP spraying chemical preparing water, gives the water saving as such.

[0210] Chemical Savings:

[0211] In the conventional recipe, neutralizing chemicals (sodium metabisulfite) must be used after PP spraying process to neutralize the PP chemicals in the sprayed areas, and only then it achieve a whitish color. Also, the PP amount is counted in the additional chemical amounts in the conventional compared to the invention recipes.

[0212] Steam Savings:

[0213] Major steam saving is achieved due to the additional drying cycle involved in the conventional recipe on account of PP spraying. Before PP spraying, the garment will undergo first a simple enzyme wash and then hydro extraction and drying the garment before preparing for the PP spraying. So, the garment will require approximately 60 minutes in the drying cycle, which uses maximum steam compared to the invention recipes.

[0214] Wet Process Machine Time Savings:

[0215] In the wet process area mainly three machines are used. These are the washing machine, hydro extract machine and drying machines. So, in the conventional recipe, an additional rinse step and one neutral step and one hydro extract process and one drying process additionally are required. This is because the PP spraying processes are involved in the conventional wet processing recipes.

[0216] This machine time saving means a lot for a laundry as the drying and extract capacities are increased by up to 50%, which allows more garments drying and hydro extractions. The analysis in Table V shows an impressive machine time savings of 86 minutes for the invention recipe compared to the conventional recipe.

[0217] Time Savings in the Dry Processes

[0218] The dry processes are known as prior processes to the wet processes and involve many laborers in the washing industry. The conventional washing means laundries are using many workers in dry processes, such as hand sanding whiskers, hand sanding scrapping, and PP spraying, grinding, and tacking.

[0219] However, latest technologies are being used to get the labor oriented dry processes to be replaced by laser. The laser is a process where it burns out the surface dye stuff and, if needed, the yarn itself per designs requirements for the garments.

[0220] So, in the invention recipe, garments always do the dry processes with a laser before the wash stage and hence three manual processes - manual whisker, manual scrapping and PP spraying are eliminated by one single process of laser. The most beautiful aesthetic looks can be obtained by adjusting and fine tuning the laser designs.

[0221] Here in this case, process time is saved in the invention recipe as the three labor oriented processes takes a long time to complete. This recipe analysis shows 90 minute savings for other operations and, in combination with the other time savings, represents a considerable advantage in terms of productivity and additional throughput.

[0222] Total Cost Savings:

[0223] One would expect that all these savings for the invention recipes compared to the conventional recipes would generate substantial economic savings. Indeed, that is correct as Table V amazingly reveals a total savings per batch of $64.59 and a remarkable savings per garment of $0.32.

[0224] INVENTION RECIPE INDIGO LIGHT WASH SHOWN IN FIG.22

[0225] The sixth invention recipe is for indigo-dyed fabric for the light wash standard and is found in the attached Figure 22. By examining the column titled Time (Min), the nine steps for the invention recipe for the indigo dyed fabric are required to achieve the light wash standard. This is quite favorably compared to 16 steps for the same case with the conventional wet processing to achieve the same light wash standard in most laundries in the world and is shown in the attached Figure 23 for indigo dyed fabric and a light wash. In both cases, the goal was to achieve the same aesthetic look for the light wash standard. To get the same aesthetic look for the conventional light wash and the invention light wash, the invention recipe garment underwent just 9 steps in wet process and further saved 1 complete hydro extraction and 1 drying cycle, in addition to eliminating PP spraying process, manual hand sanding whisker andscrapping processes, PP neutralizing and rinse wash steps as revealed in the comparison of the invention recipe shown in Figure 22 with the conventional recipe shown in Figure 23.

[0226] The example wash comparison has been done with indigo dyed fabric against the invention recipes to achieve the same standard. The conventional wash recipe followed the conventional washing recipe which has dry processes, such as manual hand sanding whiskers, manual scrapping and PP spraying on top of scrapped areas, plus wet processes such as enzyme wash, PP neutralizing and then softener.

[0227] The conventional recipe of indigo fabric in light wash also has major additional wash processes as in the dark wash comparisons, such as extra hydro extraction, drying cycle and a neutralizing cycle. To achieve the light base shades and higher abrasion level in the conventional recipe, a chlorine bleaching process is used with calcium hypochlorite / sodium hypochlorite whereas the same shade is achieved in invention recipe by just hydrogen peroxide and soda ash. The reason for a faster bleach down in the invention recipe is due to the fabric difference in the inventive fabric compared to conventional fabrics. And, the abrasion in the conventional recipe of indigo light wash is achieved using both enzyme as well as pumice stone, whereas the invention recipe uses just stone free enzymes with same timing is required. The use of largely white core fabric gives higher abrasion comparatively.

[0228] The largely more white than blue core fabric has a white core in the yarn cross section, and it has the ability to burn the dyed layer on the yarn cross section easily. Hence the whitish core appears on the surface in the case of the invention recipe whereas the same whiteness is very difficult to achieve with conventional fabric and hence it has to undergo PP spraying to increase the whiteness. Normally when PP spray is applied onto the denim jeans, onefirst washes the garment and completely dries it and then applies PP spray to absorb and feather on dry processes areas.

[0229] This dramatic improvement in the wet and dry process for the invention recipe vs the conventional recipe for indigo dyed fabric and the light wash standard generates substantial sustainability advantages, with significant cost savings per denim jean. Indeed, this is the case, and the dramatic improvement can be clearly shown in Table VI, details of which follow:

[0230] Sustainability Savings:

[0231] Comparisons of both recipes reveals the major savings achieved with the invention recipe over the conventional recipe.

[0232] The water savings of 2,650 Liters represents a 37.59% reduction in water usage.

[0233] Total chemical savings of 6.15 kgs represents a 30.0% reduction in chemicals.

[0234] Steam savings of 263.1 Kg represents a 56.82% savings in steam usage.

[0235] Wet process machines’ time savings of 93 minutes represents a 40.61% savings.

[0236] Time savings on dry (other) processes is an extremely beneficial 90 minutes.

[0237] Water Savings:

[0238] In the conventional recipe, additional wet processes are utilized due to the nature of the fabrics to achieve the white bright look in the dry processed areas with PP spraying. Hence there is additional rinse wash and neutralizing processes added compared to the invention recipe. These, along with PP spraying chemical preparing water together give the water saving as such.

[0239] Chemical Savings:

[0240] In the conventional recipe, neutralizing chemicals (sodium metabisulfite) must be used after the PP spraying process to neutralize the PP chemicals in the sprayed areas, and only then it achieves a whitish color. Also, the PP amount is counted into the additional chemical amounts in the conventional compared to the invention recipe.

[0241] Steam Savings:

[0242] Major steam savings are achieved due to the additional drying cycle involved in the conventional recipe due to PP spraying. Before PP spraying, the garment will undergo first a simple enzyme wash and then hydro extraction and drying the garment before preparing for thePP spraying. So, the garment will require approximately 60 minutes in the drying cycle which uses maximum steam compared to the invention recipes.

[0243] Wet Process Machine Time Savings:

[0244] In the wet process area mainly three machines are used. They are the washing machine, hydro extract machine and drying machines. So, in the conventional recipe, an additional rinse step and one neutral step and one hydro extract process and one drying process are required. This is because of the PP spraying processes involved in the conventional wet processing recipes.

[0245] This machine time savings means a lot for a laundry as the drying and extract capacities will increase by up to 50% which allows to make more garments drying and hydro extractions. The analysis in Table VI shows an impressive machine time savings of 93 minutes for the invention recipe compared to the conventional recipe.

[0246] Time Savings in the Dry Processes

[0247] The dry processes are known as prior processes to the wet processes and involve many laborers in the washing industry. The conventional washing means that laundries are using many workers in the dry processes, such as hand sanding whiskers, hand sanding scrapping and PP spraying, grinding, and tacking.

[0248] However, latest technologies are now being used to allow the labor oriented dry processes to be replaced by a laser. The laser is a process which burns out the surface dye stuff and, if need be, the yarn itself per design requirements for the garments.

[0249] So, in the invention recipes, garments always do the dry processes before the wash stage with laser and hence three manual processes - manual whisker, manual scrapping and PP spraying are replaced by one single process of laser. The most beautiful aesthetic looks are obtained by adjusting and fine tuning the laser designs.

[0250] Here in this case, process timing is saved in the invention recipes as the three labor oriented processes takes a long time to complete. This recipe analysis shows 90 minutes of savings for the other processes and, in combination with the other time savings, represents a considerable advantage in terms of productivity and additional throughput.

[0251] Total Cost Savings:

[0252] One would expect that all these savings for the invention recipes compared to the conventional recipes would generate substantial economic savings. Indeed, that is correct as Table VI amazingly reveals a total savings per batch of $67.73 and again an unheard-of savings per garment of $0.34.

[0253] INVENTION RECIPE FOR INDIGO MEDIUM SHADE WITH HAND SANDING SHOWN IN FIG.24

[0254] The seventh invention recipe is for indigo-dyed fabric for the medium wash standard and is found in the attached Figure 24. By examining the column titled Time (Min), seven steps for the invention recipe for the 100% sulfur-dyed fabric are required to achieve the medium wash standard. This is quite favorably compared to 12 steps for the same case with the conventional wet processing to achieve the same medium wash standard in most laundries in the world, and is shown in the attached Figure 25 for 100% indigo dyed fabric and a medium wash. In bothcases, the goal was to achieve the same aesthetic look for the medium wash standard. To get the same aesthetic look for the conventional medium wash and the invention medium wash, the invention recipe garments underwent just 7 steps in wet process and further saved 1 complete hydro extraction and 1 drying cycle plus potassium permanganate spraying process, manual hand sanding whisker and scrapping processes, PP neutralizing and a few rinse wash steps as revealed in the comparison of the conventional recipe shown in Figure 25 with the invention recipe shown in Figure 24.

[0255] The example wash comparison has been done with indigo-dyed fabric compared to the invention recipes to achieve the same standard. The conventional wash recipe followed the conventional washing recipe which has dry processes, such as manual hand sanding whiskers, manual scrapping and PP spraying on top of scrapped areas, plus wet processes such as enzyme wash, PP neutralizing and then softener.

[0256] In the conventional recipe of indigo-dyed fabric in a medium shade with laser wash has major additional wash processes as in the dark wash comparisons, such as extra hydro extraction, drying cycle and a neutralizing cycle.

[0257] Here the major difference is that the laser dry process is done before the wash stage in the invention recipe to match the aesthetic look of the conventional recipe where it is done after the first wash and dried stage.

[0258] The white core fabric has a large portion of white core in the yarn cross-section and has the ability to burn the dyed layer on the yarn cross-section easily, and hence the whitish core appears on the surface in the case of invention recipe. The same whiteness is very hard to achieve in conventional fabric, and hence it has to undergo PP spraying to increase the whiteness. Normally when PP spray is applied to the denim jeans, the garment is first washedand completely dried, and PP applied so that PP spray is absorbed and feathers on dry processes areas.

[0259] This dramatic improvement in the wet and dry process for the invention recipe vs the conventional recipe for indigo-dyed fabric and the medium wash standard generates substantial sustainability advantages with significant cost savings per denim jean. Indeed, this is the case, and the dramatic improvement can be clearly shown in Table VII, details of which follow:

[0260] Sustainability Savings:

[0261] Comparisons of both recipes reveals the major savings achieved with the invention recipe over the conventional recipe.

[0262] The water savings of 1,250 Liters represents a 30.86% reduction in water usage.

[0263] Total chemical savings of 1.45 kgs represents a 16.67% reduction in chemicals.

[0264] Steam savings of 189 Kg represents a 43.31% savings in steam usage.

[0265] Wet process machines’ time savings of 89 minutes represents a 44.95% savings.

[0266] Time savings on dry (other) processes is an extremely beneficial 40 minutes.

[0267] Water Savings:

[0268] In the conventional recipe, additional wet processes must be utilized due to the nature of the fabrics, in order to achieve the white bright look in the dry processed areas with PP spray. Hence there are additional rinse wash and neutralizing processes compared to the invention recipe. These, along with PP spraying chemical preparing water, together gives the water saving as such.

[0269] Chemical Savings:

[0270] In the conventional recipe, neutralizing chemicals (sodium meta bisulfite) must be used after the PP spraying process to neutralize the PP chemicals in the sprayed areas, and only then it achieves a whitish color. Also, the PP amount is counted into the additional chemical amounts in the conventional compared to the invention recipes.

[0271] Steam Savings:

[0272] Major steam savings come in due to the additional drying cycle involved in the conventional recipe due to PP spraying. Before PP spraying, the garment will undergo first a simple enzyme wash and then hydro extraction and drying the garments before preparing for thePP spraying. So, the garment will require approximately 60 minutes in the drying cycle which uses maximum steam compared to the invention recipes.

[0273] Wet Process Machine Time Savings:

[0274] In the wet process area, mainly three machines are used. They are the washing machine, hydro extract machine and drying machines. So, in the conventional recipe, an additional rinse step and one neutral step and one hydro extract process and one drying process are required. This is because PP spraying processes are involved in the conventional wet processing recipes.

[0275] This machine time savings means a lot for a laundry as the drying and extract capacities are increasing by up to 50%, which allows more garment drying and hydro extractions. The analysis in Table VI shows an impressive machine time savings of 89 minutes for the invention recipe compared to the conventional recipe.

[0276] Time Savings in the Dry Processes

[0277] The dry processes are known as prior processes to wet processes and involve many laborers in the washing industry. The conventional washing means laundries use many workers in dry processes, such as hand sanding whiskers, hand sanding scrapping and PP spraying, grinding, and tacking.

[0278] However, latest technologies are now being used to allow the labor-oriented dry processes to be replaced by a laser. The laser is a process which burns out the surface dye stuff and, if need be, the yarn itself per designs requirements for the garments.

[0279] So, in the invention recipes garments always do the dry processes before the wash stage with a laser and hence three manual processes - manual whisker, manual scrapping and PP spraying are replaced by one single process of laser. The most beautiful aesthetic looks are obtained by adjusting and fine-tuning the laser designs.

[0280] Here in this case, much process timing is saved in the invention recipe as the three labor-oriented processes take a long time to complete. This recipe analysis shows 90 minute savings for the other processes and, in combination with the other time savings, represents a considerable advantage in terms of productivity and additional throughput.

[0281] Total Cost Savings:

[0282] One would expect that all these savings for the invention recipes compared to the conventional recipes would generate substantial economic savings. Indeed, that is correct as Table VII amazingly reveals a total savings per batch of $47.26 and a savings per garment of $0.24.

[0283] INVENTION RECIPE FOR 100% SULFUR BLACK MEDIUM SHADE WASH WITH LASER SHOWN IN Fig.26

[0284] The eighth invention recipe is for 100% sulfur-dyed fabric for the medium wash standard, and can be found in Figure 26. By examining the column titled Time (Min), the nine steps for the invention recipe for the 100% indigo-dyed fabric are required to achieve the medium wash standard. This is quite favorably compared to 13 steps for the same case with the conventional wet processing to achieve the same medium wash standard in most laundries in theworld, and is shown in the attached Figure 27 for 100% sulfur dyed fabric and a medium wash. In both cases, the goal was to achieve the same aesthetic look for the medium wash standard. To get the same aesthetic look for the conventional medium wash and the invention medium wash, the invention recipe garments underwent just 9 steps in wet processing and further saved 1 complete hydro extraction and 1 drying cycle, in addition to eliminating PP spraying, manual hand sanding whisker and scrapping processes, PP neutralizing and a few rinse wash steps as revealed in the comparison of the conventional recipe shown in Figure 27 with the invention recipe shown in Figure 26.

[0285] The example wash comparison has been done with 100% sulfur fabric against the invention recipes to achieve the same standard. The conventional wash recipe followed the conventional washing recipe, which has dry processes, such as manual hand sanding whiskers, manual scrapping and PP spraying on top of scrapped areas, plus wet processes such as enzyme wash, PP neutralizing and then softener.

[0286] In the conventional recipe of 100% sulfur black medium shade with hand sanding wash is also similar to the same wash comparisons for dark wash in the same fabric, and there are additional hydro extraction, drying and neutralizing steps. And, the dry process differences are the same as dark wash.

[0287] Here, the beauty of the invention recipe dry processes is achieved by only manual hand sanding whisker and sanding, no PP and no laser application. However, in the conventional recipe manual hand sanding whiskers, sanding plus PP spraying in dry processes are required.

[0288] The largely more white than blue core fabric gives a white core in the yarn cross section and has the ability to burn the dyed layer of the yarn cross section easily, and hence the whitish core appears on the surface in case of invention recipe. The same whiteness is verydifficult to achieve in conventional fabric of 100% sulfur, even though PP spraying is done to increase the whiteness on the scrapped areas.

[0289] This dramatic improvement in the wet and dry processes for the invention recipe vs the conventional recipe for 100% sulfur dyed fabric and the light wash standard generates substantial sustainability advantages with significant cost savings per denim jean. Indeed, this is the case, and the dramatic improvement can be clearly shown in Table VIII, details of which follow:

[0290] Sustainability Savings:

[0291] Comparisons of both recipes reveals the major savings achieved with the invention recipe over the conventional recipe.

[0292] The water savings of 1,300 Liters represents a 22.81% reduction in water usage.

[0293] Total chemical savings of 1.45 kgs represents a 11.42% reduction in chemicals.

[0294] Steam savings of 243.5 Kg represents a 53.04 % savings in steam usage.

[0295] Wet process machines’ time savings of 82 minutes represents a 43.16 % savings.

[0296] Water Savings:

[0297] In the conventional recipe, additional wet processes must be utilized due to the nature of the fabrics in order to achieve the white bright look in the dry processed areas with PP spray. Hence, there are additional rinse wash and neutralizing processes added compared to the invention recipes. This, along with PP spraying chemical preparing water, gives the water saving as such.

[0298] Chemical Savings:

[0299] In the conventional recipe, neutralizing chemicals (sodium metabisulfite) must be used after the PP spraying to neutralize the PP chemicals in the sprayed areas, and only then it achieves a whitish color. Also, the PP amount is counted into the additional chemical amounts to in the conventional recipe compared to the invention recipe.

[0300] Steam Savings:

[0301] Major steam savings comes in due to the additional drying cycle involved in the conventional recipe due to PP spraying. Before PP spraying, the garment will undergo first a simple enzyme wash and then hydro extraction and drying the garments before preparing for thePP spraying. So, the garment will require approximately 60 minutes in the drying cycle which uses maximum steam compared to the invention recipes.

[0302] Wet Process Machine Time Savings:

[0303] In the wet process area, mainly three machines are used. They are the washing machine, hydro extract machine and drying machines. So, in the conventional recipe an additional rinse step and one neutral step and one hydro extract process and one drying process comes in. This is because PP spraying processes are involved in the conventional wet processing recipes.

[0304] This machine time savings means a lot for a laundry, as the drying and extract capacities are going to go up by 50%, which allows more garment drying and hydro extractions. The analysis in Table VIII showed an impressive machine time savings of 82 minutes for the invention recipe compared to the conventional recipe.

[0305] Time Savings in the Dry Processes

[0306] The dry processes are known as prior processes to the wet processes and involve many laborers in the washing industry. The conventional washing means laundries use many workers in dry processes, such as hand sanding whiskers, hand sanding scrapping and PP spraying, grinding, and tacking.

[0307] However, latest technologies are now being used to allow the labor oriented dry processes to be replaced by lasers. The laser is a process which burns out the surface dye stuff and, if needed, the yarn itself per design requirements for the garments.

[0308] So, in the invention recipe, garments always do the dry processes with laser before the wash stage and hence the three manual processes (manual whisker, manual scrapping and PP spraying) are replaced by one single process of laser. The most beautiful aesthetic looks are obtained by adjusting and fine-tuning the laser designs.

[0309] Here in this case, process time is saved in the invention recipes as labor-oriented three processes take a long time to complete.

[0310] Total Cost Savings:

[0311] One would expect that all these savings for the invention recipes compared to the conventional recipes would generate substantial economic savings. Indeed, that is correct as Table VIII amazingly reveals a total savings per batch of $34.77 and a savings per garment of $0.17.

[0312] INVENTION RECIPE FOR INDIGO WITH ACID WASH HIGH ABRASION LOOK SHOWN IN FIG.28

[0313] The ninth invention recipe is for indigo dyed fabric for the acid wash standard, and can be found in Figure 28. By examining the column titled Time (Min), twelve steps for the invention recipe for the indigo fabric are required to achieve the acid wash standard. This is quite favorably compared to 17 steps for the same case with the conventional wet processing to achieve the same acid wash standard in most laundries in the world, and is shown in the attached Figure 29 for indigo dyed fabric and an acid wash. In both cases, the goal was to achieve the same aesthetic look for the acid wash standard. To get the same aesthetic look for the conventional acid wash, the invention acid wash recipe garments underwent just 12 steps in wetprocessing and further eliminated 1 complete hydro extraction and 1 drying cycle, in addition to PP spraying, manual hand sanding whisker and scrapping processes, PP neutralizing and a few rinse wash steps as revealed in the comparison of the invention recipe shown in Figure 28 with the conventional recipe shown in Figure 29.

[0314] The example wash comparison has been done with indigo fabric against the invention recipe to achieve the same standard. The conventional wash recipe followed the conventional washing recipe, which has dry processes, such as manual hand sanding whiskers, manual scrapping and PP spraying on top of scrapped areas, plus wet processes such as enzyme wash, PP neutralizing and then softener.

[0315] The conventional recipe of Indigo fabric in acid wash with high abrasion also has major additional wash processes, such as in the dark wash comparisons, such as extra hydro extraction, drying cycle and a neutralizing cycle. To achieve the higher abrasion level in the conventional recipe, pumice stones with enzyme wash processes are required along with increased time. The invention recipe achieved it with only enzyme wash.

[0316] The acid wash higher abrasion look is achieved in conventional recipes with traditional thermocoal / synthetic towels along with PP wash in dry conditions of the garments for some time. However, the same look of the acid wash is achieved in the invention recipe by using chemicals, such as the branded chemical Lob Clean V. Lob Clean V is a potassium permanganate replacement chemical.

[0317] The mostly white core fabric has a white core in the yarn cross section, and it can burn the dyed layer of the yarn cross section easily, and hence the whitish core appears on the surface in the case of invention recipe. The same whiteness is very difficult to achieve in conventional fabrics, and hence it has to undergo PP spray to increase the whiteness. Normallywhen PP spray is applied onto the denim jeans, the garment is first washed, completely dried, and PP applied so that PP spray is absorbed and feathers on dry processes areas.

[0318] This dramatic improvement in the wet and dry process for the invention recipe vs the conventional recipe for indigo dyed fabric and the light wash standard would be expected to generate substantial sustainability advantages with significant cost savings per denim jean. Indeed, this is the case, and the dramatic improvement can be clearly shown in Table IX, details of which follow:

[0319] Sustainability Savings:

[0320] Comparisons of both recipes reveals the major savings achieved with the invention recipe over the conventional recipe.

[0321] The water savings of 1,570 Liters represents a 23.9% reduction in water usage.

[0322] Total chemical savings of 2.54 kgs represents a 16.24% reduction in chemicals.

[0323] Steam savings of 243.5 Kg represents a 53.04 % savings in steam usage.

[0324] Wet process machines’ time savings of 85 minutes represents a 39.53 % savings.

[0325] Water Savings:

[0326] In the conventional recipe, additional wet processes have to be utilized due to the nature of the fabrics in order to achieve the white bright look in the dry processed areas with PP spraying. Hence there are additional rinse wash and neutralizing processes added compared to the invention recipe. This, along with PP spraying chemical preparing water, gives the water saving as such.

[0327] Chemical Savings:

[0328] In the conventional recipe, neutralizing chemicals (sodium metabisulfite) must be used after the PP spraying to neutralize the PP chemicals in the sprayed areas, and only then it achieves a whitish color. Also, the PP amount is counted in the additional chemical amounts in the conventional compared to the invention recipe.

[0329] Steam Savings:

[0330] Major steam savings come in due to the additional drying cycle involved in the conventional recipe due to PP spraying. Before PP spraying, the garment will undergo first asimple enzyme wash, and then hydro extraction and drying the garments before preparing for the PP spraying. So, the garment will require approximately 60 minutes in the drying cycle which uses maximum steam compared to the invention recipes.

[0331] Wet Process Machine Time Savings:

[0332] In the wet process area mainly three machines are used. They are the washing machine, hydro extract machine and drying machines. So, in the conventional recipe, an additional rinse step and one neutral step and one hydro extract process and one drying process are required. This is because PP spraying processes are involved in the conventional wet processing recipes.

[0333] This machine time savings means a lot for a laundry as the drying and extract capacities are going to go up by 50%, which allows more garment drying and hydro extractions. The analysis in Table IX shows an impressive machine time savings of 85 minutes for the invention recipe compared to the conventional recipe.

[0334] Time Savings in the Dry Processes

[0335] The dry processes are known as prior processes to wet processing and involve many laborers in the washing industry. The conventional washing means that laundries are using many workers in dry processes like hand sanding whiskers, hand sanding scrapping and PP spraying, grinding, and tacking.

[0336] However, latest technologies are now being used to allow the labor-oriented dry processes to be replaced by a laser. The laser is a process which burns out the surface dye stuff and, if needed, the yarn itself as per designs requirements for the garments.

[0337] So, in the invention recipes, garments always do the dry processes with laser before the wash stage and hence three manual processes - manual whisker, manual scrapping and PP spraying are replaced by one single process of laser. The most beautiful aesthetic looks are obtained by adjusting and fine tuning the laser designs.

[0338] Here in this case, lots of process timing is saved in the invention recipe as the three labor oriented processes takes a long time to complete.

[0339] Total Cost Savings:

[0340] One would expect that all these savings for the invention recipes compared to the conventional recipes would generate substantial economic savings. Indeed, that is correct as Table IX amazingly reveals a total savings per batch of $66.69 and an amazing savings per garment of $0.33.

[0341] In conclusion, the inventors have invented an extraordinary means to markedly improve sustainability for denim production and achieve never-before-seen results with environmental savings and cost savings. Examination of Tables I – IX reveals astonishing water savings, ranging from 1,250 liters per batch to 4,150 liters per batch, depending upon the denim dye and wash standards. These results are simply without peer in the industry and represent a clear breakthrough in sustainability for denim production at a time when water shortages around the world are climbing to critical proportions. The disclosed invention further shows significant chemical savings from reducing harmful chemicals, such as potassium permanganate, which alsorepresents a major accomplishment for sustainability improvement. The machine time reductions of up to 93 minutes per batch realized with the invention recipes produce significant energy reductions and have a clear marked improvement in the carbon footprint. Finally, the machine time savings will allow more denim jeans to be washed per unit of time, which will markedly increase productivity.

[0342] One skilled in the art will know that although numerous recipes were disclosed for the invention recipes for a matrix of different wash standards and different denim-dyed fabrics, other iterations would still be part of the embodiments of the invention. For instance, using similar recipes as disclosed in the attached Figures 12, 14, 16, 18, 20, 22, 24, 26 and 28, the invention recipes could be easily extended to a variety of other washes and other denim dyes which are important embodiments because similar extraordinary sustainability and cost savings benefits will result for similar recipes. The number of steps shown in these examples could be slightly modified up or down to get good results which are yet another set of embodiments.

Claims

CLAIMS:

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 according to any of Claims 1 and 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 according to any of Claims 1-3, 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 according to any of Claims 1-4, 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 according to any of Claims 1-5, 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 according to any of Claims 1-6, 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 according to any of Claims 1-7, 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 according to any of Claims 1-8, 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 according to any of Claims 1-9, 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 according to 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 according to any of Claims 11-12, 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 according to any of Claims 11-13, 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 according to any of Claims 11-14, 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 according to any of Claims 11-15, 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 according to any of Claims 11-16, 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 according to any of Claims 11-17, 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 according to any of Claims 11-18, 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.

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