Recent Techniques In Textile

Wet Processing

Aravin Prince .P., M.Tech (Textiles)

Lecturer/ Apparel Technology

S.S.M.I.T.T, Komarapalayam

aravinprince@gmail.com

+91-9790080302

What is Textile Processing..?

It has four basic process

Preparatory

Dyeing

Printing

Finishing

Testing

Preparation

The ultimate goal of any preparation process is to

produce fabric that is clean and rid of all impurities

that interfere with dyeing and finishing.

Fabric preparation is the first of the wet processing

steps

Desizing

To remove the sizing material from the textile

material (yarn/ fabric/ garment)

Scouring

To remove natural impurities from natural

fibers.

To remove added impurities from man made

fibers

Bleaching

To remove natural coloring matter from fiber

structure

Mostly used hydrogen peroxide; we can use

this to all type of fibers

What Is “Dyeing”…..?

The pleasure derived from imparting colour

to clothing has existed since the time of the

earliest civilisations;

A world of fashion without colour is

impossible to imagine. Coloration processes

produce the most visible results of all the

finishing operations carried out during the

preparation of textile goods

What Is Printing….?

Textile printing is the most versatile and

important of the methods used for introducing

colour and design to textile fabrics.

Considered analytically it is a process of

bringing together a design idea, one or more

colorants, and a textile substrate (usually a

fabric), using a technique for applying the

colorants with some precision.

What is finishing…..?

This facilitates production of attractive

ready-to-sell textiles intended to fulfil

requirements for specific use.

This includes all processes which help to

maintain the value or increase the value of

the textile material.

Textile finishing therefore makes textile raw

material usable by creating properties with a

useful effect.

Recent

Techniques……?

Ultrasonic Assisted WetProcessing

Digital printing Technology

Nano Technology

Bio-Technology

Plasma Technology

Ultrasonic Assisted WetProcessing

Ultrasound energy is sound waves with

frequencies above 20,000 oscillations per

second, which is above the upper limit of

human hearing.

The ultrasonic waves can be generated by

variety of ways. Mostly it is produced by

piezo-electric and magnatostrictivetransducers

Mechanisms:

Increasing swelling of fiber in water.

Reducing glass transition (Tg) temperature

of the fiber.

Reduce the size of the dye particles. It helps

to enhance the transport of the dye to the

fiber.

Applications It degraded starch followed by ultrasonic desizing could

lead to considerably energy saving as compared to conventional starch sizing and desizing.

The scouring of wool in neutral and very light alkaline bath reduces the fiber damage and enhance rate of processing.

It is more beneficial to the application of water insoluble dyes to the hydrophobic fibers.

Among the textile fibers, polyester is structurally compact fiber with a high level of crystallinity and without recognized dye sites.

Ultrasonic waves accelerate the rate of diffusion of the disperse dye inside the polyester fiber.

Benefits

Energy savings by dyeing at lower temperatures and

reduced processing times.

Environmental improvements by reduced

consumption of auxiliary chemicals.

Increased color yields.

Enzymatic treatments supplemented with ultrasonic

energy resulted in shorter processing times, less

consumption of expensive enzymes, less fiber

damage, and better uniformity treatment to the

fabric.

Digital Printing

Digital printing, the most advanced technology in

textile printing is an emerging new technique.

Digital printing in simple terms is the process of

creating prints generated and designed from a

computer, as opposed to analog printing, which

requires printing screens.

Among the various approaches for digital printing

including electro photography, ink jet has gained a

very significant place in the field of innovative

printing techniques.

Mechanism Printing Machine

Nano Technology

Nano Technology…… The concept of Nano tech was first developed in

1930,that time it is called as bottom science.

The term Nano arise from 1970‟s only.

The term „Nano‟ comes from a Greek word „Nanos‟

which means „Dwarf‟.

Dwarf means abnormally small.

1nm = 10-9m

It is about 75000 to 100000 times smaller than the

diameter of the human hair.

This technology that can work at the molecular level,

atom by atom to create large structures with

improved molecules organization by controlling

shape and size at the Nano scale.

Application of Nano Technology

in processing

Nano dyeing

Nano finishingHydrophobic finish

Self cleaning effect

UV-protection

Anti-Microbial

Anti-Pollen

Odour fights finish

Flame retardant

This nano finish originally named as “Nano care”& marketed by “Nano Tex”

Hydrophobic surface can be produced mainly in 2 ways

1. By creating rough structure on a hydrophobic surface

2.By modifying a rough surface using materials with low surface energy

Flurocarbon finishes constitute an important class of hydrophobic finish

Hydrophobic Finish

U-V Finish

Rayleigh‟s scattering theory predicts that in order to

scatter UV radiation between 200 and 400 nm, the

optimum particle size will be between 20 and 40 nm.

A thin layer of titanium dioxide is formed on the

surface of the treated cotton fabric which provides

excellent UV-protection; the effect can be maintained

after 50 home launderings.

Treated cotton Un treated cotton

Anti Microbial Finish It is a well known fact that the growth of bacteria and

microorganisms in food or water is prevented when stored in silver vessels due to antimicrobial properties

Silver ions have broad spectrum of anti microbial activities

The method of producing durable silver containing antimicrobial finish is to encapsulate a silver compound or nano particle with a fiber reactive polymer like poly (styrene co-maleic anhydride)

Instead of perfume , we may use thermo sensitive pigment, thermal storage materials or pharmaceutical preparation in the inner core

The treated yarns showed effective antimicrobial activity against various bacteria, fungi

Silver nano particle

Anti-Pollen Finish

Miyuki keori co of Japan is marketing anti-pollen fabrics

The smoothness of the finish on the surface and the anti-static effect does not let pollen or dust to come

close

This finish is given by the polymer which have anti-static or electro conductive composition

Eg. Fluroalkyl –( meth acrylate polymers.)

It is used in coats blouses, gloves,& etc

Odour Fight Finish

A Taiwanese nanotech firm Greenshield has created underwear using nanotechnology that fights odour

This underwear fiber release undetectable negative ions &infrared rays that destroy odour -causing bacteria

The negative ions inhibits the reproduction of bacteria

Far infrared rays causing all the individual atoms being vibrated at a higher frequency which speeds up the metabolism & the elimination of wastes

Tourmaline –a natural mineral emits negative ions

when low level radiation comes in contact with

oxygen, co2 & water molecules in the air-promotes

electrolytic dissociation

This nano finish can eliminate

99.99% of bacteria,

90% of odour,

75 % sticky moisture

Flame- Retardant Finish

Nyacol nano technologies, has been the worldleading supplier of colloidal Antimony pentoxidewhich is used for flame retardant finish on textiles

It contain colloidal antimony pentoxide withhalogenated flame retardants . The ratio of halogento antimony 5:1 to 2:1

10 parts of nycol in 1550 parts of aqueousdispersion, with pH7 and add 40 parts of H2O andsufficient ammonia add for bring out pH9,mix thiswith 50 parts of rubber latex and spray to the Non-woven material

Characteristics of

Nano finished Textile materials

Their protective layer is difficult to detect with the

naked eye.

Saving time and laundering.

This technology embraces environmental friendly

properties.

The crease resistant feature keeps clothing neat.

Nano processed products are toxic free

Garments are good looking and more durable than

ordinary material

Manufacturing cost is low, adding value to the

products.

BIO TECHNOLOGY

Bio Technology

Bio-technology is not a single technology, rather it

is a group of technologies.

It shares two main characteristics-working with

living cells and their molecules and having a wide

range of applications that can improve our lives.

Bio-technology is the one “using organisms or their

products for commercial purposes”.

Enzymes

Enzymes come from a Greek word “Enzymos” which means „in the cell‟ or „from the cell‟.

Enzymes are proteins, composed of amino acids, which are produced by all living organisms. These are responsible for number of reactions and biological activities.

Enzymes not only work efficiently and rapidly also biodegradable.

Enzymatic Desizing Desizing using enzymes is the most effective and

widely used method for the removal of Starch.

Starch liquefying enzymes are directly used in required quantity under controlled condition of pH and temperature.

Amylase enzyme from Malt extract were first used to degrade starch-based sizes for cheap and effective desizing.

Two categories of amylase

i. α-amylase

ii. β-amylase

The α-amylase attacks the starch randomly and

form Dextrins. It is very rapid in action and

produce simple water soluble sugars.

The β-amylase converts starch into maltose

and it is slower in the rate of action

Bio-scouring

Cotton scouring using alkaline which requires harsh chemicals and high temperature leads to high cost.

Bio-scouring is an effective alternative to chemical scouring. Cottonase T enzyme is widely used for scouring which reduces the need for high energy consumption.

It is versatile, economically viable and eco-friendly to cotton scouring.

Bleach Killing

In bleaching, especially with hydrogen peroxide, the reactive dyes are very much sensitive to residual peroxide.

The residual peroxides are converted into water and Oxygen by using the enzymes which shows better results than traditional method.

Reaction takes place at 30-400 C and pH 5.5-7.5 for 15 min

Enzymes like Peroxidases, Glucose oxidases, etc are used.

Bio-washing This process is removal of surface dyes from

fabrics.

Neutral stable cellulase enzyme is used for bio-washing.

This enzymes replaces the pumice stones .

It is produced from humicola isolans.

It is leading to decolourisation without loss in fabric strength.

This enzyme acts at pH of 6

Bio-polishing

It is a finishing process of cellulosic fabrics and

garments.

This process is improving surface of the material .

This process is also called enzymatic singeing .

Bio-polishing with acid cellulose effectively reduces

fabric fuzz and pilling on denim materials.

NORMAL COTTON FABRIC BIO POLISHED FABRIC

Plasma Technology

Plasma Technology…?

Plasma is often called the "Fourth State of Matter,"

the other three being solid, liquid and gas.

A gas becomes a plasma when the addition of heat or

other energy causes a significant number of atoms to

release some or all of their electrons.

The remaining parts of those atoms are left with a

positive charge, and the detached negative electrons

are free to move about.

Those atoms and the resulting electrically charged

gas are said to be "ionized." When enough atoms are

ionized to significantly affect the electrical

characteristics of the gas, it is a plasma.

Applications

Mechanical Properties

Electrical Properties

Wetting (hydrophilic)

Hydrophobic

Uv-protection

Flame-retardancy

The plasma modification of polymeric materials

used as textiles, membranes, non-woven,

composites, and so on, is able to optimize a lot of

interesting properties.

Mechanical Properties

Material: e.g. cotton, other cellulose-based polymers

Treatment: e.g. oxygen plasma

Crease-resistance

Material: e.g. cotton, wool, silk

Treatment: e.g. dipping in N2-plasma

Fabric Cross Section Possesing Cut Resistance For Cotton

Electrical Properties

Antistatic finish

Material: e.g. rayon

Treatment: e.g. plasma

consisting of chloro-

(chlormethyl)dimethylsila

ne

Antistatic Protection

two layer fabric construction

three layer fabric construction

Hydrophobic & Hydrophilic Finish

Improvement of wetting

Material: e.g. PA, PE, PP, PET PTFE...

Treatment: e.g. O2

Hydrophilic treatment serves also as dirt-repellent and antistatic finish.

Hydrophobic finish

Material: e.g. cotton, cotton/PET,

treatment: e.g. per fluorocarbon-plasma

Water-repellent finished cotton/polyester fabric.

plasma treated.

Oil repellency on plasma treated cotton/polyester fabric.

UV-protection Material: e.g. dyed

cotton/polyester

Treatment: TiO2 plasma

Flame-retardancy Material: e.g. PAN,

Rayon, cotton

Treatment: e.g. phosphorus containing monomers

PLASMA TREATMENT FOR UV PROTECTION

PLASMA TREATMENT FOR FLAME RETARDENCY

Advantages

It increases abrasion resistance of cotton materials

It increases dyeing speed

It gives anti-shrinking

It gives anti-dirty

It gives hydrophilicity to polypropylene bonded fiber fabrics

It gives liquid repellency

Conclusion

Thus the Ultrasonic, Digital Printing , Bio ,Nano &

Plasma technology replaces traditional method with

more advantages such as

Replacing harmful chemicals

Require less effluent treatments

Low cost and less energy consumption

No damages to materials

superior quality of the product

In feature , one can expect to see many more

developments in textiles , based on above

technology‟s

Aravin prince .Periyasamy M.Techaravinprince@gmail.com

+91-9790080302

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www.textileinfo.com