Hairy fibre removal system using singeing & enzyme wash

Hairy Fiber Removal System Using

Singeing & Enzyme Wash

Name : MAZADUL HASAN SHESHIRID: 2010000400008Batch: 13th Batch (Session 2009-2013)Department: Wet Processing Technology Email: [email protected]: www. Textilelab.blogspot.com Southeast UniversityDepartment of Textile Engineering

PREPARED BY ©right

SOUTHEAST UNIVERSITYSchool of Science and Engineering, Department of Textile Engineering

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Textile A textile or cloth is a flexible woven and knit

material consisting of a network of natural or artificial fibres often referred to as thread or yarn.


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Modern TextileModern textile means the revolution of textile machineries. The invention of power loom, and roller printing machine, Stenter machine, Compactor machine increase the quality of fabrics. It also saves time Of production.


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Treatment of fabricIn order to impart the required functional properties to the fiber or fabric, it is necessary to subject the material to different types of physical and chemical treatments. For example, wash and wear finish for a cotton fabric is necessary to make it crease-free or wrinkle-free. In a similar way, mercerizing, singeing, flame retardant, water repellent, waterproof, anti-static and peach finishing achieve various fabric properties desired by consumers. For example-


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Flow chart of wet process for knit fabric

Grey fabric inspection

Loading in the machine

Scouring

Bleaching

Enzyme Wash


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Flow chart of wet process for woven fabric:

Grey fabric inspection

Sizing

Desizing

Scouring

Bleaching


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Hairiness of Fibre and removal system:

In the textile industry, loose fibres protruding on the surface of textile goods are singed or enzyme wash to remove them.


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Flow chart of Hairy fibre removal system:


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WHAT IS SINGEING ?


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Singeing is designed to burn off the surface fibres from the fabric to produce smoothness. The fabric passes over brushes to raise the fibres, then passes over a plate heated by gas flames.


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Why singeing and what is being singed?


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During the singeing process, fibers which are not tied in threads or in the cloth are burned or turned to gas through the action of thermal energy, normally by means of a flame. This means that a fabric surface is achieved which is virtually free of hairs and fibers.


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The verb singe literally means to burn superficially. Technically, singeing refers to the burning-off of:

• Loose fibres not firmly bound into the yarn and/or fabric structure;

• Loose yarns not firmly bound into the fabric structure;


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Singeing Objectives & advantages:• Singeing of a fabric is done in order to obtain a clean fabric

surface which allows the structure of the fabric to be clearly seen. • Fabrics, which have been singed, soil less easily than un-singed

fabrics. • The risk of pilling, especially with synthetics and their blends, is

reduced in case of singed fabrics. • Singed fabrics allow printing of fine intricate patterns with high

clarity and detail. • The risk of skitter dyeing with singed articles dyed in dark shades

is considerably reduced, as randomly protruding fibers are removed in singeing which could cause diffused reflection of light.


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Singeing System:There are two types of singeing system are found.


Direct Singeing System: The action of burning away the protruding ends of the fibers is brought about by the direct action of the flame ensuing from the gas burners.

Direct Singeing Includes:

1. Knit fabric singeing• Gas singeing• Cylinder singeing• Blade singeing

2. Woven fabric singeing• Gas singeing• Plate singeing• Roller singeing


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Indirect Singeing System:In this system, the heat, in the forms of diffused infra-red radiations, produces a more even singeing effect.

Indirect Singeing Includes:• Infra-red ray burning system(both for woven & knit

fabric)


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Why Knit Singeing Is Done?In case of knitting process normally singing is not done. Because the purpose of singing like removing of having fibres from the fabric surfaces is done in here by using enzyme . But simply in some special cases like processing of viscose knit singing is done. An enzyme-based process was applied in finishing viscose fabrics, which are very susceptible to pilling because of individual loose fibres ends which protrude from surface, and impurities and fuzzes.


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Knit singing machine:Normally the machine which is used to removing the hairy fibres of the fabric as a alternative of enzyme is known as knitting machine. The main purpose of this machine is to remove the protruding fibres from the fabric surface.

• The name of our reference machine is Osthoff-Senge in Fakir Knitwears Ltd.


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Gas Singing MachineFinishing of knit-goods commonly was effected in tubular form until recently. But there is a clear tendency in the industry to process knits more and more in open-width form. There are significantAdvantages such as

• improved quality • reduced losses • lower production cost


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The essential features of the DOUBLE-JET burner :• Equal distribution of the mixture by means of a series of expansion

and compression chambers.• Uninterrupted flame band achieved by exit of the gas-air mixture

from two parallel slot nozzles.• Generation of a homogenous flame by ideal combustion of the gas-

air mixture within the combustion chambers formed of molded ceramic bricks.

• Generation of a highly concentrated, high-energy flame: the prime requirement for singeing textile materials of natural, regenerated and synthetic fibers.

These properties clearly distinguish the DOUBLE-JET burner from conventional burners, in terms of reliability, precision, performance, capacity, and energy consumption.


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Singeing Position


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1. Singeing onto free-guided fabricThis is the most intensive singeing position with highest efficiency. In this position, the flame bounces onto the free-guided fabric at right angles.


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2. Singeing onto water-cooled rollerIn this position, the flame bounces at right angles onto the fabric while the fabric passes onto water-cooled guide roller. This position avoids the penetration of the flame into the fabric. The flame does not pass through the fabric, and because of the fabric passing onto water-cooled roller, any thermal damage of temperature-sensitive synthetic fabrics is avoided.


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3. Tangential SingeingIn this position, the singeing flame falls on the fabric tangentially. The flame touches only the protruding fibres without having any significant contact with the main fabric body. This position is usually recommended for very light weight and sensitive fabrics as well as fabrics with broken filaments.


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ESSENTIAL CONDITIONS FOR GOOD GAS SINGEING• Following are three essential conditions for good singeing:• A flame with high mechanical & thermal energy to quickly burn thermoplastic protruding

fibres (e.g. polyester) without any molten beads formation• A homogeneous flame with uniform mechanical & thermal energy to result in uniform

singeing• An optimal flame/fabric contact time to neither result in incomplete not over-singeing.

IMPORTANT CONSIDERATIONS DURING GAS SINGEING• The flame should more bluish (less yellowish) to give the maximum temperature.• Recommended flame should Control and maintain the length and angle of contact,

depending on the fabric construction, thickness, weight, heat sensitivity, etc.• Fabric speed should be regulate according to the fabric construction/thickness/weight etc..• The flame should be set to cover just a little more than the fabric width. This will ensure

conservation of energy.• Guide rolls next to the flames or the guide rollers on which flame is directed in case of heat-

sensitive fabrics should be cooled, generally by cold water circulating through the guide rollers. Otherwise they could become red hot and scorch the fabric.


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Common problems in GAS singeing and their causes:-• Incomplete Singeing• Uneven Singeing Across the Fabric Width• Uneven Singeing Along the Fabric Length• Horizontal Singeing Stripes• Vertical Singeing Stripes• Over-singing or Thermal Damage of the Fabric• Formation of Small Beads of Molten Material

Advantages of gas singeing:-• Both side of fabric is singed in gas singeing m/c.• Uniform temp can be controlled. • In gas singeing, brush is used which stands the lying projecting the fibers.• Plates not decay on gas singeing machine.• The fabric in interstices of warp and weft can be singed.


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What is an Enzyme?


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Enzymes are proteins, composed of hundred of amino-acids, which are produced by living organisms.

• Each enzyme is a made of a sequence of amino acids (like pearl on a string, picture 1) folded into a unique three-dimensional structure that determines the function of the enzyme.

• Only a small part of the enzyme participates in the catalysis of biochemical reactions: the active site (picture 2). Enzymes are therefore very specific (e.g. cellulose can only degrade cellulose).


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Types of enzymes that can be used in cleaning products:• Proteases act on soils and stains containing proteins. Examples are collar & cuff soil-lines, grass,

blood.• Amylases remove starch-based soils and stains, e.g. sauces, ice-creams• Lipases are effective in removing oil / greasy body and food stains• Cellulases provide general cleaning benefits, especially on dust and mud, and also work on garments

made from cellulosic fibers, minimizing pilling to restore color and softness

Benefits of enzymes:• Active at very low levels (1 to 2 ppm, and sometime even below 1 ppm)• Highly specific, • Active at low temperatures, from 60°C to as low as the "30-40°C range"• Highly biodegradable• Wash at varying pH levels, from mild to high alkalinity;• Retain laundering performance in the presence of chemicals such as bleach; builder, surfactant,

etc….• Soften fabrics;• Brighten their colors;• Improve whiteness;• Remove fatty stains at low wash temperatures;


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There are two process of Enzyme Wash:

1. Before Dyeing 2. With Dyeing


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BEFORE DYEING PROCESS


For Any Medium Color:

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• Detergent + Wetting Agent• Sequistering + Anticreasing + Sabilizer

Di-Mineralization

• Caustic• Hydrozen Per Oxide

Scouring & Bleaching

• To controll PH at 4.5Addition of Acetic Acid

• Temp-55°C• PH-4.5• Run Time-60 min

Enzyme Wash

• Temperature risi to 80°C to i activate the Enzyme Temperature Controll

Dyeing

Rinsing

Unload


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For Black Color:• Detergent+Wetting Agent• Anticreasing Agent+Sequestering AgentDi-Mineralization • Acetic Acid• Bio-Engyme-At Temp.-55°C & Ph-4.5Enzyme Wash

Dyeing

Draining

Rinsing

Unload


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For White Color:

•Detergent + Wetting Agent

•Anticreasing Agent + Sequistering Agent

Di-Mineralization

•Wetting Agent + Anticreasing Agent

•Caustic + Hydrozen Per Oxide

scouring & Bleaching

•Brightener

Dyeing

•To controll PH at 4.5

Addition of Acid

•Temp-55°C

•pH-4.5 , Run time-60 min

Enzyme Wash

Drain WAsh

Unload


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With dyeing Process:


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For Black color:•Detergent+Wetting Agent•Anticreasing Agent+Sequestering AgentDi-Mineralization

• Acetic Acid•Bio-Engyme-At Temp.-60°C & Ph-6.5-7Enzyme Wash +

Levelling

Dyeing

Draining

Rinsing

Unload


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FOR TURQUOISE COLOR:•Detergent + Wetting Agent•Anticreasing Agent + Sequistering Agent

Di-Mineralization

•Wetting Agent + Anticreasing Agent•Caustic + Hydrozen Per Oxide

scouring & Bleaching

• 6.00-7.00

Check PH

• Retrocell PL-ECO• Temp:60°C, PH-6.00-7.00

Enzyme Wash

Levelling

•Brightener

Dyeing

•To controll PH at 4.5

Addition of Acid

•Temp-55°C•pH-4.5 , Run time-60 min

Enzyme Wash

Drain WAsh

Unload


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Woven Singeing


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If a fabric is to have a smooth finish, singeing is essential. Singeing is a dry process used on woven goods that removes fibers protruding from yarns or fabrics. These are burned off by passing the fibers over a flame or heated copper plates. Singeing improves the surface appearance of woven goods and reduces pilling. It is especially useful for fabrics that are to be printed or where a smooth finish is desired. Pollutant outputs associated with singeing include relatively small amounts of exhaust gases from the burners.


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Woven singeing can be done in three process.

1. Plate singeing machine2. Rotary-cylinder singeing machine3. Gas singeing machine


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1. Plate Singeing Machine:In this type of singeing machine, the cloth passes over and in contact with one or two heated curved copper plates. The thickness of the plates ranges from 1 to 2 inches. The heating of the plates is done by a suitable burning arrangement of gas mixed with air. The plates are heated to bright redness and the cloth passes over and singeing is done in contact with these plates at a speed ranging from 150 to 250 yards per minute.


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2. Rotary-Cylinder Singeing Machine:In this type of singeing machine, the cloth passes over and in contact with a heated rotary cylinder made of copper or cast iron. The rotary cylinder has internal firing and revolves slowly so that constantly a fresh surface of the roller comes in contact with the cloth. The direction of rotation of the cylinder is opposite to the direction of the fabric so that the protruding fibres or nap of the fabric is raised.

Fig: Line diagram of rotary-cylinder singeing machine


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3. Gas Singeing Machine:In this type of singeing machine, the fabric passes over a burning gas flame at such a speed that only the protruding fibres burn and the main body of the fabric is not damaged by the flame. This is the most common type of machine used for singeing fabrics as well yarns .

Fig. 3. Principle of gas singeing machine.


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Advantage of Woven SingeingGoods which are to be mercerized are signed to

maximize the luster.In fabrics of polyester and cellulosic fiber blends singeing

is the best method to control pilling, sometimes double singeing is done to minimize the pilling.

Unsigned fabrics are soiled easily.


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Some of the precautions to be taken in considerations during singeing:-


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The fabric to be singed should be dry as wet fabric tend to scorch more readily than dry.

Uneven singeing may cause streaks on fabric or bubbles when the fabric is finished.

Stopping the machines may cause bars on the fabrics.The fabric should not contain any acid releasing

salt,which may release acid on heating and tender the fabric.

Hairy fibre removal system using singeing & enzyme wash

Engineering

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