Bangladesh is one of the world biggest denim producers. Denim mills in Ashulia, Savar, Gazipur and Dhaka produce millions of metres of denim fabric every year for export garment factories and direct overseas buyers. Inspecting denim before it leaves the mill is not optional. International buyers require 4-point inspection with AQL 2.5 on all denim fabric going into their garment orders, and the penalty for a quality failure on denim is high because denim garments have long production lead times and the cost of a rejection is significant.
Yash Textile Machines makes a denim fabric inspection machine built specifically for the weight, tension, speed and cleaning requirements of denim. Our machine handles denim rolls from lightweight 7 oz chambray up to 14 oz selvedge denim, at inspection speeds up to 25 metres per minute.
Denim looks like woven fabric and technically is woven fabric, but the engineering requirements for inspecting denim are very different from inspecting standard woven fabrics like poplin or canvas. Here is why.
A standard denim roll from a Bangladesh mill weighs between 50 kg and 150 kg. Jumbo rolls used in some high-volume operations can reach 200 kg. A standard woven inspection machine is designed for rolls up to 60 to 80 kg. Put a 150 kg denim roll on a standard machine and the roll stand flexes, the fabric runs unevenly, and you get incorrect yardage readings. Our denim machine has a reinforced steel roll stand rated for rolls up to 200 kg with heavy-duty bearings that hold alignment under full roll weight throughout the inspection run.
Denim is a tightly woven twill with very low elasticity. It needs significantly more pull tension to run flat and smooth over the inspection table than lighter woven fabrics. If the tension is too low, denim droops and creates shadows that hide defects. If tension is too high, the fabric pulls against the roll stand and slips. Our denim machine uses a higher torque drive system with adjustable entry tension rollers to keep the fabric flat against the LED panel throughout the entire inspection run.
This is the detail most buyers do not think about until their first shift on a standard machine. Denim creates indigo dust and lint continuously during inspection. Without a cleaning system, this dust builds up on the LED light panel within the first 30 to 60 minutes of a shift and visibility drops significantly. Inspectors start missing small defects because the light quality is reduced. Our denim machine includes an integrated brushing and suction unit that cleans both the fabric surface and the light panel continuously during inspection so visibility stays consistent through the entire roll and the entire shift.
Because denim mills handle large volumes, inspection throughput is a capacity issue. Inspecting at 12 metres per minute as you would for a delicate fabric means your inspection department becomes a bottleneck at high production volumes. Our denim machine inspects at up to 25 metres per minute while maintaining the light quality and fabric tension needed for accurate defect detection.
Specification | Details |
Fabric types | All denim weights: lightweight chambray, standard twill denim, stretch denim, selvedge denim, printed denim, double-faced denim |
Inspection width | 44 inches to 72 inches standard. Wider widths available on request. |
Roll weight capacity | Up to 200 kg on reinforced roll stand |
Inspection speed | 5 to 25 metres per minute with variable speed control |
Light system | High-intensity LED panel with backlit and frontlit modes |
Cleaning system | Integrated brushing and suction unit for continuous lint and indigo dust removal |
Counter | Digital 4-point counter showing running defect points, total yardage and points per 100 square yards |
Defect marking | Fabric marking pen with auto-stop on user-set defect point threshold (optional) |
Output winding | Motorised output winder for even tension rewinding after inspection |
Drive | Variable frequency drive for smooth speed control across full speed range |
Yash Textile Machines supplies denim fabric inspection machines to Bangladesh with full export documentation, direct shipping to Chittagong port and post-installation support. Our machines are running at denim production facilities in Dhaka, Ashulia and Gazipur.
Email sales@yashtex.com or visit www.yashtex.com for a product catalogue and price quotation.
