Burnout
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Burnout Wash is also called Vault Wash, Vintage Volt Wash, Shook Wash, Shock Wash.
The chemical being used to remove the cotton side is hydro sulfuric acid. Hydro sulfuric acid is reacted on cotton at high temperatures under wet conditions.
After reaction, some cotton parts are removed. Thus, a see-through or sheer look is the characteristic of burnout wash.
Due to the characteristic of the wash, the weight of the garment becomes lower than the weight before wash.
Process
01
1. Stitching
02
2. SCOURING
03
3. BURNOUT
04
3. BURNOUT
04
4. EXTRACTION
01
5. COOL DRY
02
6. HOT DRY
03
7. NEUTRALIZATION
04
8. SOAPING & SOFTENER
04
9. EXTRACTION
01
10. DRY
11. FINISHED GARMENT
Detail Process
1. Cotton fiber is almost pure cellulose. When cellulose (C6H1005) is in contact with acid chemicals, C6H1005 will be converted to C6H12O6.
2. Acid Chemicals: pH level is as low as 3~4 with acid chemicals.
NaHSO4 -> Na+ + H+ + SO4-
(C6H1005) + n(H20) -> (n-a)(C6H12O6) + a(C6H1005)
3. If remained C6H1005, cotton fiber is at pH 6~7, there will be no chemical reaction.
4. If remained C6H1005, cotton fiber is at pH 3~4 and wet condition, the chemical reaction will start.
5. Heat tumble dry process will make chemical reactions faster and finally, cotton fibers will be burned at high temperature.
6. Once the chemical reaction is completed through a tumble dry, some cotton fibers will be burned and taken away.
NaOH -> Na++ OH-, H+ + OH- -> H2O (Water, neutralization)
7. With the decrease of H+, they become water, and the neutralization process is done.
8. Burned cotton fibers will be washed out during the neutralization and rinse process.
Preparation for Bulk
1. It is very important to use fabric without softener or hydrophilic softener in the fabric mill. Some softener blocks dyestuffs on the fabric surface and dyestuffs will not be absorbed. Usually, it appears uneven dye effects like dye spot.
2. It is also very important to conduct a blanket test before cutting the fabrics. To learn blanket procedures, click here.
3. Fabric, style construction, accessory, and graphics are very important in garment wash and dye.
For the cost, the garment weight is important because the recipe is based on O.W.G. (on the weight of goods).
4. If there’s a zipper, you must wrap the zipper with the same fabric. If you wrap zipper, there will be some undyed area, which needs tolerance for garment dyeing & washing.
5. It is easy to get needle hole issue especially fabric is too thin. To learn more about the needle hole issue, click here.
6. Burnout requires a wide Shadeband for color shade & effect. Shade is related to fabric and washing. The effect relies on washing.
7. Burnout spot is the most common issue during bulk production. That is related to fabric and washing.
The burnout line effect also commonly happens during bulk production. That is related to sewing construction and washing.
8. Fabric for burnout is CVC always. Usually the garment weight increase after washing. However the garment weight decrease after washing because acid burns cotton.
9. Regarding the fabric dye route, poly side dye is recommended to avoid quality issues. If you want to learn more about burnout wash with cotton side dye fabric, click here
10. Hole issue is more common with burnout wash as cotton parts fall apart. Polyester becomes loose and easy to get holes where...
- Thick and thin fabric meet
- Embroidery
- Slit
- Back neck tape
- Wherever it’s sharp, snaps, grommet
11. For the same reason, this wash easily get skewness and measurement issue. If you want to learn more, click here.
12. Thread color changes after acid wash. It requires several times of binder in thread dyeing.
13. After several times of laundry, the garment becomes damaged and worn out easily.
Pictures
1. Shadeband
2. Heavy Wash Effect
3. Burnout Line Effect
4. Pocket Issue
5. Thread Color Change
6. Burnout Spot
7. Uneven Effect #1
8. Uneven Effect #2
9. CSD DYE Crocking Issue
10. Hole Issue