Polly Industries - Sustainable Chemical Solutions

[pollyindustries]

Chemical Finishing of Textiles

As we know textile finishing determines the final appearance and aesthetic qualities of the fabric. Finishing processes include processes designed to change the optical, tactile, and mechanical strength properties of the textile. This involves the application of chemical compounds or finishing auxiliaries to a textile material to achieve the desired fabric property.  Textile finishing is the final stage in changing the quality of fabric. It is done in terms of appearance, handling, and functionality by mechanical and chemical means. This sector comprises operations such as the textile industry’s processing unit, which is a high-cost, energy-intensive, and hazardous chemical-demanding process.

Here sustainability is a critical aspect. It addresses many problems provided by the textile industry in terms of regulating the use of water, electricity, hazardous chemicals, and so on. Chemical finishing in a sustainable manner may be accomplished using environmentally friendly techniques. Finishing Techniques that are Eco-Friendly:

1.      Antimicrobial finish derived from natural ingredients.

2.      Plasma completing processing.

3.      Nanotechnology implementation.

4.      Ultrasound-based finishing.

5.      Sustainable UV technology.

Traditional textile chemical finishing processes have a harmful impact on the environment. So, the need for long-term solutions is growing by the day. Most environmentally friendly techniques, such as plasma technology, nanotechnology, and UV technology, are being used in the textile sector.

As a result, with the developing idea of sustainability, sustainable dyeing and finishing techniques in the textile industry have received a lot of attention.

Here we go through a Polyester dyeing. Polyester fiber is hydrophobic in nature, and it is characterized by a compact physical structure. Water-soluble dyes are not suitable for dyeing polyester. Dyes of low molecular weight are suitable. Disperse dyes are only suitable for dyeing polyester. Disperse dyes have substantivity for one or more hydrophobic fibers e.g., cellulose acetate, nylon, polyester, acrylic, and other synthetic fibers. Polly Industries provides customers with a wide range of polyester dyeing chemicals:

1. Polly-DFT - It is a versatile Non-Ionic Dispersing Agent which imparts anti-static properties to the polyester/polyester blends. It is also an excellent emulsifier and has various applications in the dyeing process.

2. Polly-DHTP- It is a Non-Ionic Auxiliary for Level Dyeing of Disperse Dyes. It is useful at high temperatures and imparts excellent emulsifying (for oleic, stearine, and oils and waxes of both mineral and vegetable oils). It has detergency and anti-static properties. It prevents limestone formation. It has fiber lubrication properties.  It is miscible with common vegetable and mineral oils, stable to hard water and metallic ions; compatible with weak alkalis, and hydrolyzed by strong acids.

3. Polly-AIO - It is an all-in-one Reduction Clearing Agent. It keeps the dyeing mixture at acidic pH. It also imparts excellent dyeing, an excellent reductive effect in acidic dye baths during the cooling stage. It removes unfixed dispersed dyes from polyester, nylon, wool, natural silk, and cellulosic fibers.

4. Polly-DAN - It is a modified condensation product based on sulphonic acid salts. Anionic in nature. High-performance non-staining. Dispersing agent. High-temperature resistance in exhaust dyeing systems; boasts of in-built dispersing action on polyester oligomer by eliminating lower rub-fastness in package dyeing and simultaneously clears oligomer residues in machines. It is stable under a wide pH range and also ensures optimum brightness and color clarity in pale shades with fluorescent optical whiteners. It maintains high dispersing efficiency. It is suitable for one-bath polyester-cellulosic and polyester-wool blends. It is low foaming and effective at low concentrations.

5. Polly-GSL- It is a cost-effective green substitute of Acetic Acid used for providing an efficient pH system in all stages of wet processing and neutralization of 100% cotton. It also enhances hard water stability etc.

[pollyindustries]

Textile Desizing: Challenges

Sizing has been considered an 'invention of the devil' because it is the main source of many processing problems. Size paste is added to the grey fabric in a weaving preparatory process to reduce frictional properties, decrease yarn breakages and improve weaving efficiency. The sizing agents can be divided into two main types:

a) Natural sizing agents- which include native and degraded starch and starch derivatives, cellulose derivatives and protein sizes.

b) Synthetic sizing agents- which include polyvinyl alcohols, polyacrylates, and styrene-maleic acid copolymers.

Starch-based sizing agents are commonly used for cotton yarns because it is economical and gives satisfactory weaving performance. Other products are also used, alone or in combination with starch sizes when the higher cost can be offset by improved weaving efficiency. Some auxiliaries are also used.

The desizing procedure depends on the type of size. Therefore, it is necessary to know what type of size is on the fabric before desizing. So this is easily determined by appropriate spot tests.

The sizing material present on warp yarns can resist dyes and chemicals in textile wet processing. It must therefore be removed before any further wet processing of the fabric.

Different methods of desizing are:

a)      Enzymatic desizing

b)     Oxidative desizing

c)      Acid steeping

d)     Rot steeping

Desizing with hot caustic soda treatment

The most used methods for cotton are enzymatic desizing and oxidative desizing. Acid steeping is a risky process and may result in the degradation of cellulose while rot steeping, hot caustic soda treatment, and hot washing with detergents are less efficient for the removal of the starch sizes. Enzymatic desizing consists of three main steps:

Application of the enzyme---digestion of the starch ---- removal of the digestion products.

The common components of an enzymatic desizing bath are as follows:

·        Chelating agent

·        Salt

·        Surfactant

·        Optical brightener

·        Amylase enzyme

·        pH stabilizer

Enzymatic desizing offers the following advantages:

·        No damage to the fibre

·        No usage of aggressive chemicals

·        Wide variety of application processes, and

·        High biodegradability

Disadvantages of enzymatic desizing include:

Lower cleaning effect towards other impurities, no effect on certain starches (e.g. tapioca starch), and possible loss of effectiveness through the poisonous enzyme. Every problem has a cause and a remedy for it. So here are some of the problems that occur in enzymatic desizing, their causes, and countermeasures to prevent those problems.

1.      Incomplete desizing

CAUSES:

·        It is caused due to inadequate enzymes.

·        It is caused due to inappropriate desizing baths.

·        It is caused due to inappropriate desizing bath pH

·        It is caused due to insufficient fabric pickup.

·        It is caused due to poor enzyme activity.

·        It is caused due to incompatible wetting agent.

·        It is caused due to deactivation of the enzyme due to the presence of metals or their contaminations.

·        It caused due to insufficient digestion time.

REMEDIES:

·        Using a sufficient amount of enzyme in the desizing bath.

·        Appropriate temperature should be maintained.

·        Optimum pH should be maintained

·        Optimum squeeze pressure and wetting agent should be used.

·        Good quality of enzymes must be used

·        Compatible wetting agent must be used.

·        Use soft water or to use an appropriate sequestering agent.

·        Optimum digestion time.

 2.      Uneven desizing (widthways)

CAUSES:

·        It is caused due to uneven pad pressure (across the width).

·        It is caused due to non-uniform pad temperature.

·        It is caused due to non-uniform chemical concentration in the bath.

REMEDIES:

·        By maintaining uniform squeeze pressure

·        Uniform bath temperature.

·        Uniform chemical concentration.

 3.      Uneven desizing(lengthways)

CAUSES:

·        It is caused due to uneven pick-up (along the length).

·        Drying of outer layers of the batch.

·        Temperature variation during digestion.

REMEDIES:

·        Uniform pick-up along the fabric length.

·        Covering the batch with polythene or other suitable sheet or by keeping the batch rolling.

·        Covering the batch with polythene or other suitable sheet or by keeping the batch rolling.

 4.      Uneven desizing(random)

CAUSES:

·        Poor wetting agent.

·        Inappropriate bath temperature.

·        Foaming in the bath.

·        Improper use of defoamer.

·        Uneven liquor distribution during padding.

·        Non-uniform washing after desizing.

REMEDIES:

·        Use of effective wetting agent.

·        Optimum bath temperature.

·        Use of appropriate defoamers.

·        Uniform liquor distribution during padding.

·        Thorough and uniform washing after desizing.

At Polly Industries, we take care of all these aspects which engineering the formulations of our chemicals. Our products provide various advantages and the benefits are very well time-tested at hundreds of processes.

POLLYZYME-15 - Highly effective; safe on fabrics; Alpha-amylase-based desizing agent; imparts 100% removal of size, ensures efficiency in dyeing, printing, and finishing.

 POLLY-THERMO - Highly effective; Stable at high temperatures; safe on fabrics; Alpha-Amylase based desizing agent; imparts 100% removal of all types of starch including PVA, polyacrylic acid and CMC; ensures efficiency in dyeing, printing and finishing