Abstract: A woven fabric formed of dyed blended cotton/polyester warp yarns and polyester stretch fill yarns is finished by passing the fabric through a brusher and singer and then through a finishing pad box to apply the finish. Immediately after application of the finish to the yarns, the fabric is passed over pre-drying cans and set by attaching the fabric to an unheated tenter chain for width control. The fabric is then passed over steam drying cans to reduce the moisture level to 8-10%. Subsequently, the fabric is passed through a first compressive shrinking machine, a scrubbing operation and then through a final compressive shrinking machine.

Abstract: Denim fabric and articles of clothing having a “washed” or heather look/effect are produced in a manner that retains color intensity and substantially avoids the waste of chemicals and/or water inherent in conventional washing processes. A first coarse feeder yarn of cotton and/or other natural fiber by ring or open end spinning, and then is continuously dyed (such as by indigo rope dyeing, slasher dyeing, or sheet dyeing). The dyed yarn is dried and then cut up into lengths of about four inches long or less (and opened if necessary) into individual fibers. The fibers are blended with other fibers (e.g. about 10-90% greige fibers) to produce a blended composite. The blended composite is then carded, spun into yarn, and woven into denim fabric having a washed look, or a heather effect, which then can be made into any suitable article. A second coarse yarn made similar to the first coarse yarn may be added to the blending station.

Abstract: Open end spun cotton yarns are ring dyed with a thickened dyebath to limit dye penetration to the outer circumference of the yarn leaving a substantial undyed core. Stonewashed indigo dyed denim fabrics and garments are prepared.

Abstract: Cotton denim fabrics are treated to enhance abrasion and shade reduction thereby reducing stonewashing time and expense by embrittling the fibers with an acid, heat-activated finish.