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EFD SFW07
OUTLINE
Background Textile Wet Processing
Desizing Scouring Bleach Clean Up
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BACKGROUND
Increasing awareness for a cleaner and greener living standards Enforcement of stricter guidelines and rulings from various associations and Government bodies Challenges faced by Textile companies around the world alike Dyeing
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DYEING PROCESS
Desizing
Mebyo NHT
Garment
Scouring
Mebyo PT
Finishing
Bleach Clean Up
Mebyo HON
Dyeing
Megafix B-CPB
Soaping
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DESIZING
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DESIZING
Removal of starch used as size during weaving to prevent unleveled dyeing and poor batch-to-batch reproducibility Traditional Desizing Methods
Acidic: Sulphuric or hydrochloric acid Oxidative: Persulphate plus alkali bromite and alkali or
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DESIZING
Desizing with biocatalyst Advantages:
LESS chemicals involved ECO-FRIENDLY EFFICIENT in wide range temperature Specific, NO damage to cellulose fibres BETTER strength retention SOFTER fabric feel SHORTER process time EFD SFW07 7
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DESIZING
Mechanism:
Biocatalyst hydrolyzes -1,4-linkages in starch
HYDROLYSIS
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DESIZING
Test for degree of desizing
Tegewa Scale
Tegewa Rating: 1
Tegewa Rating: 7
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SCOURING
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SCOURING
Removal of impurities such as
Waxes Pectins Hemicelluloses Mineral salts
from raw cotton during the early stages of textile wet processing Prepares fabric treatments
Mercerizing Bleaching Dyeing
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subsequent
Printing Finishing
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SCOURING
Fabric Input
Scouring
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SCOURING
Advantages of bioscouring:
ECO-FRIENDLY (less harsh chemical caustic soda) LESS rinse water needed REDUCE effluent load REDUCE water consumption SAVE energy SAVE cost Fully RETAIN cellulose structure
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SCOURING
Wetting Test
Grey Fabric
Treated Fabric
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SCOURING
Measurement pH Temperature Residual pectin Weight loss Wettablility, drop test Brightness increase Bleach ability Dye ability Rinse water consumption Total diss solids (TDS) BOD COD Bioscouring 8 9.5 50 60oC (extract at 75 95oC) 22-30% <1.5% < 1 second + 1-5% points Same Same 35-50% 20-50% 20-45% 20-45% Alkaline scouring 13-14 95 100oC 10-15% 4-10% < 1 second + 5 -10% points Same Same 100% 100% 100% 100%
Source: Novozymes, 4 December 2006
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Basic Assumption fabric processed / day (tonne) Fabric cost per kg (USD) Liquor ratio Total water required (tonne) Total 20
Energy Saving Energy cost $1.00 1:7 140 Base temperature (oC) Scouring Temperature (oC) Temperature differential (oC) Steam required / 1 tonne water (kg) Total steam required (tonne) Total steam cost / day (USD) Steam cost saving / year2 (USD)
Alkaline Scouring
Bioscourin g
30 95 65 185.71 26 $410.801 -
Fabric Saving Weight loss cost Based on steam cost USD$15.80/tonne of steam 2 Based on 300 working days per year 3 Based on 4% fabric weight lost
4 1
Alkaline Scouring
Bioscourin g
Total fabric weight lost (%) Total fabric weight lost / day (kg) Total weight lost cost / day (USD) Weight lost cost saving / year2 (USD)
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BLEACH CLEAN UP
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BLEACH CLEAN UP
Removal of H2O2 residual ensure leveled dyeing Bleach Clean Up Alternatives
By rinsing only
Bleaching Rinsing Rinsing Rinsing Rinsing Dyeing
to
By reducing agent
Bleaching Rinsing
Reducing
Agent
Rinsing
Dyeing
With biocatalyst
Bleaching Rinsing
Biocatalys t
Dyeing
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BLEACH CLEAN UP
Advantages of using biocatalyst:
SAVE water
No rinsing required. Can proceed in the same bath with dyeing process
SAVE energy
No more hot rinse, cold rinse, hot rinse
SAVE time
As short as 10 min to complete the job!
SAFE
H2O2 complete removal dyestuff or textile materials without affecting
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BLEACH CLEAN UP
Bleach Clean Up with Biocatalyst
Temperature C - Adjust pH as desired for subsequent dyeing - Add biocatalyst - Check peroxide level
Bleaching
100 80 60 40 20
Bleach Clean Up
Dyeing
30
35
40
45
50
55
60
Time (min)
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BLEACH CLEAN UP
Water Usage in the Various B leach Clean Up Methods
4.5 4 3.5
No of Rinse B aths
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Minutes
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4 volumes
Batching Vessels
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DYE-Ocell
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Cost Comparison on Reactive Dyeing pre-bleached 100% Cotton ( Greenville, S.C. local currency)
Pad-batch cost $12.851 $19.052 $1.503 0 $33.40 $35.88 $39.77 $1.50 $40.00 $117.15 73.6% 67.6% 50.0% 100% 77.8% Total saving % Saving
1. Based on water & sewer cost of $2.58/1000 gals. 2. Based on steam cost $4.38/1000 lbs. of steam. Pad-batch includes extra drying. 3. Based on electric power cost of 5.0/kWh. Source: Cotton Inc 2003/TRI 4. Based on sodium chloride at 4/lb.
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