This helps to understand different types of techniqes, machines and production capacities and capabilities of laser machine when it comes to garment manufacturing/washing industry because laser is the latest sustainable system to do lot of dry processes for garments such as whisker, hand sand, PP spray, destruction, acid wash effects etc. and many more. This ppt helps to review these techniques using laser machine.

1. LASER MACHINE STUDY FOR EGYPT PLANT
Introduction, Advantages & Disadvantages, Renowned Manufacturer
Brands, Machine Arrangements, Execution Capabilities,
Recommendations, Production Capacities
By: Sachith Samarasinghe (2023.03.15)

2. What is Laser?
LASER is light amplification by stimulated emission of radiation. Laser is an electromagnetic
radiation, produced by the atoms due to energy states are changed in some materials. The
atoms promoted to higher energy states emit laser in the form of light. Subsequently, this
laser is being amplified in a suitable lasing medium with the help of mirrors and delivers from
the equipment as a stream similar to light.
Ring Dye
Yarn Yarn
Ring Dye
Laser Output
Laser Output

3. Why Does Plant Need Laser?
• Plant doesn’t have dry process unit. Laundry is still incomplete. With Laser, our plant will
become a ‘fully fledged laundry’ with increased capabilities and capacities.
• Laser opens the opportunity to enter a wider global market. This leads to more business
opportunities as well as sub-contracting options during dry seasons for plant.
• Rejection rate with laser dry process is negligible compared to that of manual dry processing
which is about 0.5% - 1.0% on average.
• Laser is the future. Sustainable, no waste, increasing living expenses in Egypt makes laser the
perfect solution for the automation of manpower-based dry operations.
• Plant has a very compact space. Laser is ideal for space saving dry operations.

4. Advantages & Disadvantages of Using Laser
• Highly Consistent operation. Less or no defects over manual execution.
• Zero water usage. No wastes (no sandpaper, whisker boards etc.)
• 24 hours non-stop production.
• Multiple parameters can be changed and adjusted at the same time.
• Cost & time effective (Ex: No scaling of whisker boards)
• More production with less workers (Approx 2000pcs/day/operator/machine).
• Smooth execution of designs with intricate dry details such as high-definition whiskers.
• Can execute wire tie, acid wash, PP sponge effects. Also, double dyeing + laser fixing for printed effects.
• Quick change between different designs almost in no time.
• Avoid chemicals such PP, Good for Worker health & safety. Marketing tool for sustainable execution.
• One machine for many operations (whisker, chevron, grinding, Knee-star, hot-spot, Scratch-mark, drilling,
grinding, hole, heavy body grinding etc.)
• Less pilling tendency and less hairiness on hand sanded area.
• Good for markets with highly varying demands for dry process. Zero turnaround time and same layout.
• Less damage to the local area of the fabric and hence physical strength tests give better readings.
• Confined and limited workspace is enough over manual operation.
• Laser execution can be performed on any fabric but most suitable for laser compatible ring dyed fabrics.
Advantages Disadvantages
• High CAPEX (Can go for installments).
• Operators need a special training and skills.
• When executing damages with weft yarn
exposure, some designs need manual blow-off
of unremoved warp yarn which will cause open
weft yarn to show cast differences between
blue, white and tint cast.
• Same laser intensity isn’t ideal for all damage
shapes and sizes. If not adjusted to proper
values, garment may catch fire or design
overburn/underburn may occur.
• Special laser resistant threads (dual-duty) must
be used for garments when laser is done, to
withstand the heat.
• Correct and timely maintenance is required.
• Some laser-executed designs would still require
manual touch.
• Extra costs of UPS, Air-conditioned room.
• Some garments need to be ironed before laser.
• Vertical machine cannot execute jackets, skirts,
T-shirts, Kids garments etc. (But flat bed can do
all these)

5. Laser Machine Manufacturers in the Market
Jeanologia
Spain
VAV
Turkey
Macsa id
Spain
Tonello
Italy
Arges
Turkey

6. Machine-Bed Arrangements
Flat + Vertical (Single Head)
Flat-Bed (Single Head) Vertical (Double head)
Good for any: Jeans, skirts, jackets, T shirts etc. Good for jeans without whiskers running close to crotch. High output rate Only one bed is usable at a time, either the flat bed or vertical

7. Some Laser-Laundry Facilities in Egypt….
Location: Port Said, Egypt
No. of Machines: 34
Brand: Jeanologia, Spain
Location: Al Obour, Egypt
No. of Machines: 23
Brand: Jeanologia, Spain

8. Execution Capabilities - Standard
Laser File Final Garment Multiple Laser Files Final Garment
Final Gmt
Laser File
Laser File
Final Garment
Camo Effect Local Area Used Look
Laser File
Final Gmt
Full Laser

9. Execution Capabilities - Special
• What if a laser beam could be used for fixing colors instead of erase them from garments?
• Garment Flash Print is a patented* process specifically made for the garment treatment that involves the use of laser systems.
• ZETAFLEX ZL SPECIAL, the core of this process, is a special resin developed to create infinite original effects on ready-to-dye,
already dyed or denim garments.
• Suitable to be used in combination with ZETACOL F pigments, it allows to create infinite decorations on garments using laser
technology.
Garment Flash Print Process

10. Execution Capabilities - Special

11. Recommendation for Washing Plant
JEANOLOGIA COMPACT SUPER

12. Jeanologia EIM

13. Potential Average Production Capacities with Laser at Plant
Front: Whisker + Local Abrasion
Back: Back Pocket Local Abrasion
Light – Medium Intensity
1600pcs/SH* machine/20 hours
Front: Whisker + Local Abrasion
Back: Back Pocket Local Abrasion
High Intensity
1200pcs/SH machine/20 hours
Front: Full-Body Acid Wash Effect
Back: Same as front
Medium Intensity
800pcs/SH machine/20 hours
Front: Whisker + Loc. Abr. + Damage
Back: Back Pocket Local Abrasion
Medium Intensity
1000pcs/SH machine/20 hours
This slide contains general data to get a rough understanding only.
SH = Single head, double flat bed standard compact super machine