Through the ages countless attempts have been made to alter the fiber, sometimes with a specific end use in mind and other times just as pure research. This causes the fibers to swell, and their cross-section changes from kidney-shaped to round. The characteristics of these fabrics are given in Table 1. fabric is washed and neutralised. If mercerization of material (yarn/fabric) is carried out in grey state i.e. Drying machine with contact drying system in which exit humidity control is carried out with Pleva equipment and which consists of 20 cylinders that work with steam. This gives the seersucker effect. Improving to the touch THE ADVANTAGES OF THIS PROCESS ARE: Effects of the chain mercerization of cotton fabric 14. Mercerized fabrics however Tensile strength with caustic soda concentration: Higher the fiber lengths lower the twist. Pad Chain Mercerizing Machine 2.... CARDING Carding is the process in which sliver is formed from lap by carding m/c. These charges are shown in the following figure. This test is done by using a microscope. Higher strength is obtained after the process sequence due to: In this study, fabrics, that were woven by using 20/1 Open-end 100% cotton thread and three different weaving pattern, were chosen. (2013) K. Kaushik et al. which go in to NaOH solution. Mercerization is an alkali treatment process that is used to reduce lignin, hemicellulose, wax and oils that are present on the surface of fibers . No need of padding mangle or chain (stenter). 13, 270-277 (1978). The results that are smaller than this value have a statistically significant effect. Reaction heat is emitted when mixing the process lye. Thesis also discuss the change of trend, design and style among times and know about how a technical person developed quality of product. Deconvolution occurs or convolution twist becomes less. High flexibility to treat small and medium fabric batches (production speed up to 35 – 40 mt/ 1’). Luster and strength of the fabric increases for mercerizing process. Its effects of mercerizing liquor should be permanent. relatively circular when mercerised. Ideally Chemistry laboratory and beaker, measuring tape, pipette, titration apparatus, etc. Temperature of the mercerization solution. The advantage of the counter current principle over co-current principle is that a relatively small volume of wash liquor of high concentration is obtained in the former. The fiber starts out as a projecting hollow sheath and each night a new layer of cellulose is laid down on the inside of the sheath until about thirty layers are built up. Tension mercerization:- This type of mercerisation is used to increase the luster of a fabric. It was observed that three different fabric samples processed at three different time and conditions indicated the best unshrinking values under dry mercerization conditions and decreased shrinkage values on warp direction with increasing of processing time. Hence, mercerized cottons, unless stretched too much, are generally considerably stronger than untreated cottons. The reason for that is that the fabrics gather a little bit in drying. colour of the dyed cloth is brighter and deeper. As in the case of barium activity number, the moisture also increases with decreases in the temperature of mercerization at a given sodium ion concentration. The properties of the fibre change by swelling. Describe BAN test in detail. stage of process sequence. In this test light is The liquor is usually heated by closed steam coils. If the fabric is fully mercerized, the spots will not be evident; on the other hand, if the fabric is not mercerized or of a low degree of mercerization, dark spot will be evident. As Compared with cold impregnation the swelling behavior is considerably better and has a positive influence on the dimensional stability. The temperature of the solution must be uniform. Cellulose-I (natural formation) cannot convert fully into cellulose-II (after mercerization formation). It is seen that moisture regains increases almost linearly with barium activity number. The process lye is continually circulated and the temperature and concentration monitored. The Mercerization involves exposing cotton to sodium hydroxide. The important facts to remember are: Fiber is the fundamental unit in either yarn or in cloth. We observed the best results at the conclusion of the trials again with wet process. Crystal lattice is altered and tends to increase absorbency. 1 is a simple and direct method for determining the replication of the degree of mercerization. Contact of the cloth impregnated with strong NaOH solution with air (carbon dioxide) produces sodium carbonate, which hinder swelling (if re-used untreated). Improved dimensional stability & physical compactness. The space required for machine installation is reduced to the minimum and the costs of investment are lower compared with the machine working with chain, If put in line with a continuous washing range, the mercerizing machine does not require any extra maintenance, Excellent results with possibility to adjust the temperature and the concentration of caustic soda as pleased according to the results required, Possibility to adjust the tension of fabric in warp while in weft, during the impregnation the fabric is kept in tension by the compression of rolls, Changes in dimensional stability when considered values for both alkali concentration and temperature were low is very little. * Ammonia recovery problem, leakages can be dangerous to the personnel involved. barium activity number should be 120-130 for a bleached fabric. Available –OH group increase which contribute dye affinity. Higher-end fabrics may be double or triple mercerized for added benefits .effective mercerization requires attention to variables such as caustic soda strength, dwell time (feed rate), temperature, and neutralization. Two guide rollers are arranged parallel and horizontally or vertically. Lowe (source: Wikipedia). unmercerized cotton fibre have an elliptical cross-section, while it becomes It should able to reduce the surface tension of water. The process is continuous. Dye absorption increases with the increasing caustic soda concentration up to 13%. Tension pulleys are present due to variation of tension. As seen in Table 7, the P values of plain weave, twill and dobby weave fabrics in the resistance to shrinkage of the weft appeared to be 0.000. Mercerizing is done after bleaching operation. The exit humidity of the fabrics was measured with humidity measurement device in a controlled way. The effect of different mercerization techniques on tactile comfort properties of woven cotton fabric has been studied. However, not all shades require the same The first washing is with hot water and then cold water. When goods are mercerized using hot mercerizing liquors, the goods can be stretched to a greater degree than when they are applied cold. A homogeneous swelling is produced in mercerization at 60°C, but the shrinkage in the fibers changes with the changing of the application time, thus stabilization will also change. In the dobby weave, an improvement of 25 – 65% was observed in the direction of the weft as it was observed in plain weave and twill. We observed the best results at the conclusion of the trials with wet process. So that the impregnation becomes properly. The improved lustre of mercerised cotton is due to the production of nearly circular cotton fibres under tension. However the P value of dobby weaves fabric appeared to be 0.190, which is higher than 0.050 in the process time period interaction, so process time period interaction does not have a statistically significant effect on the resistance to shrinkage of dobby weave fabric. For cotton knit dyeing; mercerizing is done before dyeing. As the next pictures show, there is a difference in the cross section of the fibre before and after mercerization. De Boer JJ, Borsten H (1962) An Empirical Relation for the Degree of Penetration of a Mercerization Solution into a Cotton Yarn. Mercerization A third process often used with cotton fibers is mercerization, which changes the physical structure of the cotton fiber and thereby its physical properties and appearance. If temperature and concentration of caustic soda increase up to a certain limit the tensile strength of cotton increases. Low pressure steam is admitted into the chamber, which impinges on the fabric, gets condense and removes the alkali efficiently. As seen in Table 9, 60 – 70% improvement was seen in the direction of the warp compared to the raw fabric. Also, affinity for absorption of dye increases along with chemical reactivity. One of the known fiber properties of cotton is its softness. by. good lusture property and mercerized effect as the degree of hydophilicity is Kidney shaped becomes almost circular (oval shaped) in X-section. desizing in detail with its advantages and disadvantages. 2002). 1996). The invention relates to a method that a mercerized cotton fabric is colored in deep tone with reactive dye, which comprises that: 1) the cotton fabric can be pretreated by being added with bicyclic oxides and weak base in room temperature, and then the cotton fabric can be added with cyclodextrin of 0.5 percent to 9 percent(o.w.f) for further processing while being implemented … Mercerization is a process applied to cotton yarns or fabrics which gives to the cotton fiber a silk-like luster, a somewhat greater strength than that of ordinary cotton, and a greater affinity for dyes. 52°Tw are not much sensitive. Simultaneously two fabrics can be mercerized. This gives a large volume of dilute NaOH solution, which cannot be discharge into the drain for economy and pollution point of view. Then the fabric is dried washing in cold water. textile processing . On the other hand in low twist yarn alkali enter easily and luster will be also good. Mercerization is carried out on yarns, fabrics or … The faster the processes of mercerization, the better are the results of stability in the direction of the weft. However, flexibility decreases since the links among macromolecule chains, crystallites and fibrils are even stronger. The fabrics that have the properties in Table 1 were passed from the mercerization machine according to the plan below and they were tried. As a result mercerizing will be better and luster increases. 10th IFATCC congress, Barcelona, may 1975) and referred to by C. Duckworth and L.M. Appearance is improved through increased luster, a deepening of the color and the production of a transparent look, the feel of the fabric is improved through a resulting soft hand and improved smoothness, and strength and elongation are also improved, along … The mercerization treatment also appeared to … This has led some to present a pessimistic view of the media, to emphasize the ascendancy of ‘infotainment’ over ‘serious’ reportage and analysis of politics. To summarize the benefits of hot mercerization: Essentials mercerization involves treating of cotton material with strong NaOH solution and washing it off from the material. yarns due to sizing. The resistance to shrinkage values gave better results as the time period for application increased in the direction of the warp. Mercerization is therefore an expensive chemical procedure. Hence along with caustic we have to add some wetting agent. Traditional final washing (in multibox washer). Steam chamber                  : Accumulation type. The technical data and the prescription are as follows: Prescription                       : 35 ml/l H2O2 50%, 15 ml/l NaOH 480Be, 2 ml/l     Gemsol WA, 2 ml/l Rohstoff ST-OS, 1 ml/l SevalinD. On further swelling, the section rounds off and the major axis of the ellipse is at least 25-30% greater than the fiber width of the corresponding collapsed fiber. Mercerization is a process in which textiles (typically cotton) are treated with caustic soda (NaOH) solution to improve properties such as fiber strength, shrinkage resistance, luster, and dye affinity. In almost every sort of fabric in which silk is used, mercerized cotton is also employed. At the time of his invention, he was a chemist in a large calico printing plant. The yarn of hank form is placed on the guide rollers whilst they are close together.  Squeezing to lower lye content is possible with hot mercerizing. Mercerizing is done after bleaching operation. Six measurements were done on each sample according to the standard of BS EN 26330 and the average of them was taken. Mercerization Conditions and Characterized by NIR FT Raman Spectroscopy in Combination with Multivariate Analytical Methods Heléne Almlöf Ambjörnsson,a,* Karla Schenzel,b and Ulf Germgård a Carboxymethyl cellulose (CMC) is produced commercially in a two-stage process consisting of a mercerization stage followed by an etherification stage. Two for one twister (TFO) At the yarn stage, TFO renders improved evenness, strength and elongation the material. Complete fiber cleanliness is not easily achieved. The fabrics were made to absorb the dyestuff and chemicals in pad-batch painting machine and which works with single dipping and wringing method, and they were rotated during the fixed period in order to avoid filtration at the rotation stations. mercerization and commoditization. The lye bath has been kept purposely small and under it there is one single lye tank integrated into the machine. Each mangle is arranged to provide either a single or double immersion in the caustic liquor and two squeezes. prof.k.b.krishna kumar presentation details this presentation has been devided into: introduction advantages of mercerization classification of mercerization what happens during mercerization parameters of mercerization effect of concentration effect of drying effect of teparature effect of tension temparature vs shrinkage shrinkage effects on lustre effects on … Bleaching process was carried out in a Mega-Bleach, which has two pre-washing Chambers, a Flexnip in which the solution is made to absorb to the fabric, a steam chamber which is appropriate for accumulation type working and four washing chambers at its exit. When the fashions dictate a great vogue in silks, then mercerized cotton likewise leaps forward. When mercerized the walls of the lumen come closed to Length wise shrinkage of fabric occurs which minimize the weak links in the fabric. AT WHICH STAGE CELLULOSE CAN BE MERCERIZED? The recommended mercerizing condition is to mercerize at 15% caustic soda solution at 10-20 ํC for 30 seconds. … Properties of Cotton. Dyeing properties increase as mercerization carried out under decreasing tension. Generally it depends on concentration of caustic soda, temperature, impregnation, fabric structure etc. Alternatively, the fabric (with about 10°Tw NaOH solution) may be passed through a recuperator where some more NaOH is recovered. The machines and equipments used in the processes were as follows: Firstly, burning and desizing processes were applied on the fabrics. So washing is very important after mercerization and its condition carefully should be maintained. Mercerization and liquid ammonia treatment were shown to improve the dyeability of all three fibers. The method was developed in the 19th century by John Mercer and H.A. Then pre-finishing was carried out on the fabrics by applying the conditions and prescriptions indicated below before the mercerization process. Mercerized cotton is at the present time a direct competitor of silk in a great number of ways, both as an imitation and as a substitute. Weave reports of the fabrics used in this study are shown in Figure 3. It is necessary then that mercerized yarns and fabrics should be signed in order to achieve greatest gloss or luster. Cotton mercerizing is the most popular operation. The fabric is entered in the bath of caustic soda solution with two down rollers. None of the imitations of silk has been more widely adopted than mercerized cotton. mercerization is not optimum reason being the grey fabric lacks in the concentration of a solution in terms of °Tw (Twedell). Other observation are analysis the management system and get a clear concept on production planning, costing, marketing techniques etc. Increases above 27%, tensile strength falls rapidly. After mercerization of cotton, its tensile strength increases up to 10-50%. These fabrics have medium weights and approximately same construction. Tensile strength is higher when caustic concentration is 45-54°Tw and temperature is 17°C. sample is mercerised. However, this finishing process has numerous benefits. Mercerize definition, to treat (cotton yarns or fabric) with caustic alkali under tension, in order to increase strength, luster, and affinity for dye. In addition, the lye volume is kept very low. The main benefit of using 100% mercerized cotton crochet thread is the luster and vibrance you get. Merecerization treatment for cotton yarn fibers is very essential process to increase the luster, tensile strength and enhancement their dyability. Mercerizing is an important operation for cotton finishing achieving a resistant silk shine and good handle without all the fundamental processes being understood. For example wash liquor may be used (1) for the preparation of NaOH solution (for use in bleaching) by passing chlorine gas into it, (2) in kier boiling, (3) in dyeing vat dyes of cotton, (4) in mercerizing itself by concentrating (evaporation of water in evaporators). Should be available at an economical price. The C. I. The recuperator consists of a cast iron chamber containing two sets of guide rollers, the top row begin driven. Maximum luster is obtained when the tension is just sufficient to bring the material back to its original dimension. Some advantages of this mercerization over grey On the other hand, solutions of sodium hydroxide whose concentration is about 29% (wt/vol), i.e. The primary and secondary alcohols in the cellulose are acidic in nature. Hence a gain in lusture. However, when goods are processed under tensions which are too great, dye sorption and affinity are decreased because the internal fiber structure is collapsed. After washing they were dried in drum drier and their shrinking percentage values were measured. The yarns are washed by means of spraying unit and squeezed. The samples are washed, dried and compared visually or using a spectrophotometer. US1482076A US616606A US61660623A US1482076A US 1482076 A US1482076 A US 1482076A US 616606 A US616606 A US 616606A US 61660623 A US61660623 A US 61660623A US 1482076 A US1482076 A US 1482076A Authority US United States Prior art keywords fabric thiocyanate treatment alkali solution Prior art date 1923-02-02 Legal status (The legal status is … Hence we usually go for alkali The more uniform swelling gives, with dyed goods, a more equal appearance. Fabric Mercerising Machines: There are three types of fabric mercerising machines: 1. But the silk-like luster that we now look for in mercerized cottons had not yet been developed. In addition, other changes that occur in the fiber include increased surface roughness, enhanced wettability, and decreased moisture absorption. This dependency is such that the resistance to shrinkage values increases as the period of holding increases. * Evenness and uniformity of swelling is comparatively better. In commercial mercerization process, the strong NaOH is washed out of cotton by hot water. Under the low tariff of the Democratic administration from 1893 to 1897, European mercerized cottons were introduced into America, and American manufacturers presently began to produce the same sorts of goods for home consumption. List the main advantage of superwash wool: b. In grey mercerization, a large amount of impurities find their way in mercerization liquor. In this investigation, a selection of three common yarn patterns (2/9.5, 984 and 3/8) was subjected to different mercerization experiments under factory conditions, to optimize the caustic soda concentration for highest quality and economic impact. THE CONDITION OR CONSIDERABLE POINTS FOR MERCERIZATION. for chemical tests. But in our topic on Ammonia Mercrization. Cross section of mercerized cotton fibers becomes larger and assumes perfectly circular forms as shown in Figure 1. Then the fabric is washed properly with cold water. Sick mink appear to rise from the dead in Denmark. Another characteristic feature is the untwisting (deconvolution) of the cotton hair. That is, the sodium hydroxide that is concentrated this much, penetrates inside the micelles (crystallites) and a structure called hydrate cellulose emerges. The scoured and bleached cotton fabric is passed through a padding mangle containing 55°-65°Tw the NaOH solution at 18°C for 2-3 min with tension. The main purpose of the degumming process are to remov... What is Mercerization and Effect of Mercerization. These alterations increase sorption, tensile strength and luster of fibres. As the next pictures show, there is a difference in the cross section of the fibre before and after mercerization. This may be eliminated by adding calculated quantities of lime. The actual degree of mercerization must be established by using other qualified tests. Mercerizing also gives cotton cloth increased tensile strength, greater absorptive properties, and, usually, a … He went on to list a number of these changes, one of which was that caustic soda caused the fiber to swell, become round and straighten out (but it did not impart any change in luster). The epoxy resin (LY556) and the corresponding hardener (HY 951) are mixed in a ratio 10:1 by weight as recommended. the twedell meter. The technical data and prescriptions are as follows: Prescription             : 2.5 g/l Torozym NT, 2 g/l Schnellnetzer KE, 1 g/l, Speed                                    : 70 m/min, Table 2: The properties of the chemicals that were used in removing dressing, Table 3: The properties of the chemicals that were used in the bleaching process, Burner position                   : Vertical – double side, Burner distance                  : 8 mm, pH                                           : 6 – 7, Temperature                       : 60 – 65°C. It is an ultimate reference for textile students and professionals. We see the best results at the conclusion of the trials with dry process. Larger dimensional stability of the articles 3. Also This process increases the dyeability of the fabric but does However, at lower concentration at30°C, the treated cotton does not show any barium absorption, but the moisture regain increases, due to the differences in the molecular size of barium hydroxide and water, Table 11: Moisture regain values of cotton yarn mercerized at different temperature. A ratio of dyed to undyed fibers can then be used to determine the degree of mercerization. Five NaOH concentrations were used, i.e., 0, 5, 10, 15, and 20 wt%. One of the finishing operations that change the physical and characteristic properties of cotton fiber and the most important of these is mercerization. Some advantages of this mercerization over grey stage are: 1. Mercerization, in textiles, a chemical treatment applied to cotton fibres or fabrics to permanently impart a greater affinity for dyes and various chemical finishes. it also gives the cloth a better resistance to multiple washings, keeping the colours bright and unchanged over time. Shrinkage of the fabric is much less than that occurring in the cold process. No selvedge to middle differences occurs with the DIMENSA. hydrophilicity. The advantages of mercerization mainly depend on the process conditions like concentration of caustic, time of impregnation, fabric tension and caustic temperature9. (c) Name various tests of mercerization. It should enable the alkali to swell the cotton fiber rapidly. They were mercerized according to the plan indicated in Table 5 by using fabric mercerization machine at 60°C and 30°Be NaOH. We know that an As seen in Table 6, all the P values of plain, twill and dobby weave fabrics occurred 0.000 in terms of statistical significance in resistance to shrinkage in the warp except for the process time interactions of the dobby weaving fabric. Mercerization is the treatment of cotton yarns, fabrics and knit goods with cold, strong caustic soda liquor under tension. This causes the fibers to swell, and their cross-section changes from kidney-shaped to round. Colors may be applied which dye the ordinary cotton faintly while giving the mercerized figures a very full, deep color. Although both of them take place in mercerization, 75% is on linking’s side through the force of pull. They were successful in keeping the fabric from shrinking, but what was their surprise, on taking the cloth out of the caustic and washing it, to find that it had a beautiful, silk-like luster! In the measurements, the fabrics were marked with permanent marker with 35*35 cm gaps (in the direction of wefts and warps) and they were washed in the washing machine at 60°C. THE LUSTER OF MERCERISED COTTON DEPENDS ON VARIOUS FACTORS: Cotton fiber is a long chain polymer of glucose residue. However it is recommended that a standard swatch be calibrated so that the actual desired degree of mercerization can be assured. Faster caustic soda penetration speedier swelling, High swelling uniformity no ring mercerizing, Maximum squeezing action at in feed squeeze, Lower investment cost through shorter impregnation sections. There are arrangements of squeezing rollers are guide rollers in each boxes. Speed                                   : 60m/min. Greater tension necessary to prevent shrinkage. Mercerisation is an industrial process involving sodium hydroxide for cotton yarns or fabrics to increase the lustre and dyeability. The In 1890 Horace Lowe was granted a British patent in which he claimed that by applying Mercer’s caustic soda process to cotton yarn or fabric under tension a resultant high luster (a result of the light reflection off the smooth, round surface) was imparted to the fiber. It should not discolor the fiber permanently. Its use is now widespread in a great number of fabrics, as the sole textile in some cases, as the warp in others, as filling in still others. THE REACTIONS THAT TAKES PLACE IN MERCERIZATION: Since concentrated sodium hydroxide (operational solution that includes chemicals) is used in mercerization process, the reactions that take place with the cellulose fibers are intermolecular reactions. Not until the later eighties did mercerization become practical, and then for two reasons. The fabric enters the washing unit (of chain type of mercerizing machine) with sodium hydroxide solution of 55° Tw strength. 1. In this type, the fiber untwists and swells which causes the lumen to become rounder. Then the remainder of the acid is removed from the fabric by washing. As seen in Table 8, 50 – 60% improvement was seen in the direction of warp compared to the raw fabric. The following are the The properties of the fibre change by swelling. Most commonly used concentration is 21-22%. A simple test can be made by first spotting an undyed fabric with a 30% sodium hydroxide solution. The reason for that is that, they gather a little bit in drying. By repeated mercerization-etherification steps, DS values above 1.5 can be obtained, and it has been reported that Kulicke prepared CMC samples with a DS of between 0.7 and nearly 3.0 by a slurry procedure with isopropanol (Kulicke et al. At the time Mercer introduced these processes, the British cotton trade showed no interest in any of it and it all sat in obscurity for about forty years. of the fibre lumen the strength increases. The possible variations in finish may be made even more numerous by the dyeing process. Temperature           : In cylinder drier machine at 140°C. No change was observed in the direction of the warp depending on the time period. The recovery of caustic is some easier as impurities to some extent are removed by desizing. In industry, wetting agent is referred as mercerizing oil. Most of the goods were imported from Germany. The warps first pass through 2-4 boxes, where they are boiled in a suitable solution of dilute caustic soda and T.R.oil sequestering agent may be used. The yarn must be mounted evenly on the rollers.

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