2nd International Conference - Science for BusinessInnovation for Textiles, Polymers and Leather

Łódź, 2016

Fibrilised Cereal Straw as a New

Raw Textile Material

Zdzislaw CZAPLICKI 1) , Stanislaw STRZELECKI 2) , Boguslaw Wozniak 3)

1) Institute of Natural Fibres and Medicinal Plants, Poznan,Poland2) Research Institute of Textile Machinery, POLMATEX CENARO, Lodz, Poland3) The Institute of Leather Industry, Lodz, Poland

1. Introduction

Functional properties of straw were the inspiration for the development in

the Lodz branch of the Institute of Natural Fibres and Medicinal Plants the

innovative technology of its processing, by modification of its form while

maintaining its properties [3-6]. The point of technology [3] consists in

subjecting the cereal straw to different partial operations, which result in

the breakdown into the fibrous mass. The resulting straw fibers are

further enriching to afford possible processing on conventional textile

machinery.

Patents

The issue about fibrilising wheat straw is also the subject of patents [1], [2].

According to the patent [1] the cereal straw is cut into lengths of 5-10 cm. It is then

washed, softened, cleaned and mechanically processed into the fiber product.

According to the patent [2] a method for fiberizing cereal straw in the form of

chopped is characterized in subjecting the grain and chaff to the action of hot

water in the temperature range from 40 to 70 0C at stabilizing by the addition of

water steam. Hydrothermally treated cereal chaff is next fibrilised between the

discs of the defibrator discs at the supply of fresh water at a temperature ranging

from 40 to 60 0C. The resulting mass is added to the wood pulp in a ratio of 1: 1,

and the resulting new mass is formed into sheet plates.

A method of the fibrilising of cereal straw shown in U.S. Patent [3] is

significantly different from the patents [1] and [2].

2. Material research and equipment

The research material was a cereal straw (rye) after cutting off the end of the

completion of spikes. The length of the cut portion of the straw was approx. 20

cm. Cereal straw without ears was subjected to a ultrasonic washing in the

machine made by company "POLSONIC" - sonic14.

Fibrilising process was carried-out on a specially prepared laboratory device

equipped with belt card clothing (fibrilising).

3. Process of the fibrilising of cereal straw

The fibrilising process consists of a series of partial operations including:

preparing straw for processing, removal of straw pectin and impurities,

calendering straw and mechanical fibrilising.

3.1. Preparing of straw for processing

It includes the removing of straw ears and their residues as well as the cutting of

straw into sections corresponding to the length of the ultrasonic bath tub (Fig. 1).

Fig. 1 Sample of cereal straw

3.2. Removal of straw pectins and impurities

Straw segments are placed in an ultrasonic washing machine and processed in the

washing bath containing the soda and soap. The washing temperature is 60-80 0C.

The washing time amounts to 30 min. After washing, the material is washed twice,

once in the water of temperature 60-80 0C and once again in cold water (Fig. 2).

Fig. 2 Ultrasonic washing

device Sonic 14 (1) and a

container (2) with straw

12

3.3. Calendering of straw

The straw removed from the ultrasonic washing undergoes the removing of water

without drying and is subjected to the calendering. During calendering process it

follows the removal of excess moisture from the material, flattening the straws and

degradation of so-called bends, i.e. connections of the sections of circular cross-

section .

3.4. Mechanical cottoning

It involves exposing a thin layer of

straw (after calendering) to the

action of tape card cloting on a

special device (Fig. 3). The result

is a splitting of the straws into

single fibers which are

characterized by significant

flexibility (Fig. 4).

Fig. 3 Laboratory device for the

straw fibrilising

3.4. Mechanical cottoning (cont.)

Fig. 4 Sample of fibrilised cereal straw

4. Finishing of produced fibrilised straw cottoning

4.1. Enzymatic cottoning

It consists in the treatment of cotonin produced in a mechanical way by the solution

of the enzyme preparation called "Pektopol". Cotonning takes place in a water bath

comprising in one dm3 the volume of 2 g of preparation KDK and 15 g / kg fiber of

"Pektopolu". The bath temperature is 55 0C and time processing is 60 min.

4.2. Texturing

The wet cottoning made by mechanical or enzymatic process is twisted into the

rope (Fig. 5). After drying at ambient temperature or preferably in a drying chamber

the rope spins up and loosens the fibers contained therein (Fig. 6).

4.3. Wetting

Textured fiber from the fibrilised straw is subjected to the wetting by spraying with

the solution of a typical moisturizing agent (grease) in an amount of up to 15% by

weight of the fiber and followed by the storage in a sealed container for a period of

approx. 24 hours.

Fibrilised straw, twisted in a rope

Fig. 5 Fibrilsed straw, twisted in a rope

Fibrilised straw after texturing

Fig. 6 Sample of fibrilised cereal straw after texturing

5. Test results

Item Parameter description Unit Values

1 Linear mass of straw before fibrilising texa 986

2 Linear mass of straw after fibrilising texb 109

3 Coefficient of variation Vtexa % 9,78

4 Coefficient of variation Vtexb % 14,8

5 Degree of the fibrilising of cereal straw texa / texb - 9

Table 1 Linear mass of straw before and after fibrilising process

Upholstery mats

The upholstery mats can be used, when piled up, for the production of mattresses. Mats

made from coir are used for making artificial lawns. They are also used in the manufacture of

upholstered furniture.

Fig. 7 Upholstery mat (30% fibrilising cereal Fig. 8 Upholstery slab (50% cereal

straw and 70% coir fibre). straw and 50% coir fibre).

6. Technical and economic benefits

The source of technical and economic benefits resulting from the use of the

technology of fibrilising is the low price of wheat straw. Relatively expensive

fibrilising operations are still lower than the cost of purchasing and processing of

comparable coconut fibers. An important aspect of the issue is also possibility of its

application in the processes of acquisition and processing of cottoning from

fibrilised straw the machines and equipment used in the processing of domestic

natural fibers. National limitations of flax and hemp cultivation cause that a

significant number of machines and equipment for their processing remains unused.

The economic effects resulting from the application of fibrilising technology, are

mainly:

- reduction of the price of raw materials to manufacture products with the

participation of coconut fiber;

- limiting of the imports of coconut fibers;

- make productive of significant amounts of cereal straw currently destined for the

combustion;

-new products involving fibrilised cereal straw: warming mats, disinfection mats and

mats for production of mattresses in the furniture industry.

7. Conclusions

1. Original method of cereal straw fibrilising was developed. Fibrilised cereal

straw due to its properties could be used in significant quantities in the textile

industry, mainly in technical products (warming mats, disinfectants, mattresses,

etc.).

2. The method of the fibrilising of cereal straw and manufactured products with its

content will be original in the world and represents a significant improvement in

the field of innovative technologies.

3. Developed technology of the fibrilising of cereal straw as well as its use in

technical textiles can solve the problem of rational and economic use of natural

raw material.

The method of the fibrilising of cereal straw was presented at four international

exhibitions of inventions (Brussels, Seoul, Romania and Warsaw), and obtained

diplomas and medals (1 gold and 3 bronze) and the special award.