TEXTILE PRETREATMENT

Muhammad Moosa AR Khan, SDC Muhammad Awais Imran, SDC BS, MS Textiles,IRC Indus University, Pakistan

INTRODUCTION
As the name suggest word pre-treatment mean, before treatment It is a set of processes to prepare fabric for coloration and finishing

OBJECTIVES OF PRETREATMENT
Uniform whiteness Uniform Absorbency Removal of seed husks Good Tegewa (removal of Sizes) Surface smoothness Dimensional stability Less loss in DP value Environmental friendly and ecological

Why pretreatment?
Pretreatment is important !!! 70% of problems during dyeing and finishing is caused by pretreatment.

PRETERATMENT SCIENCES
Mechanical Shearing Mending

ThermoMechanical Singeing

Chemical

Physicochemical

Desizing Scouring Bleaching

Mercerization

SEQUENCES OF WOVEN PRETREATMENT

1 2 3

Mending

Shearing Singeing

4 5

Desizing

Scouring Bleaching
Mercerization

6
7

SEQUENCES OF KNITTING PRETREATMENT

1 2

Shearing
Mending Scouring Bleaching Bio Polishing

3
4 5

GREIGE INSPECTION (A Practical Approach)

MENDING
Brushing The purpose of brushing is to remove the short and loose fibers from the surface of the cloth. Brushing is mainly done to fabrics of staple fiber content. Brushing before cropping minimize pilling.)
Shearing Shearing is an operation consists of cutting the loose strands of fibers from either surface of a fabric with a sharp edged razor or scissors.

FAULTS IN FABRIC
Normal fabric VS faulty fabric

Knot in fabric

OBJECTS FOR MENDING EXAMINATION

Double pick
Miss pick

OTHER FAULTS
Bad Selvedge Burl Mark Drawbacks Dropped Pick End Out Jerk-in Knots Mixed End (Yarn) Mixed Filling

OTHER FAULTS
Open Reed Slub Smash Soiled Filling or End Stop Mark Thin Place Holes Drop Stitches Loop Distortion

SINGEING
Singeing comes from verb singe which mean to burn off Singeing is a thermo-mechanical process to burn out protruding fibres, surface fibres 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; Protruding fibre ends sticking out of the textile yarns and/or fabrics.

BURNING SCIENCE
Conduction

Modes of heat transformation

Convection

Radiation

What is flame? What is fire? Characteristics of Fire?

Fire & Flame

Fire is a mixture of hot gases. Flames are the result of a chemical reaction, primarily between oxygen in air and a fuel, such as wood or propane. In addition to other products, the reaction produces carbon dioxide, steam, light, and heat. If the flame is hot enough, the gases are ionized and become yet another state of matter: plasma.

Why fibers burns or melts? Fiber heat capacity Pyrolysis

PYROLYSIS

Pyrolysis is a thermochemical decomposition of organic material at elevated temperatures without the participation of oxygen. It involves the simultaneous change of chemical composition and physical phase, and is irreversible. The word is coined from the Greekderived elements pyro "fire" and lysis "separating Pyrolysis refers to transformation of a substance by the action of heat. At temperature of pyrolysis (Tp), both thermoplastic and non-thermoplastic fibres decompose (pyrolyze) into lower molecular weight fragments.
The chemical change, which begins at temperature of pyrolysis, continues through the temperature of combustion (Tc)

PYROLYSIS
Cotton has an exothermic pyrolysis as once it has been ignited it continues to burn by virtue of its own energy which is being released. Polyester has an endothermic pyrolysis as it requires a steady supply of energy to allow the burning process to continue. Polyester ignites at a temperature of 480-500 C, while it starts melting at 250-260 C. For the singeing of polyester fabric or yarns, thermal energy must be supplied in a shock form, and the pyrolysis must be like an explosion, so that the polyester protruding fibres ignite rather than melting. Otherwise, molten beads of polyester may be formed

SINGEING
The aim : a smooth and fiber-free surface The smooth surface obtained exhibits the following improved properties in the textile fabric: clearer visualization of the particular textile fabric, reduced soiling with subsequent processing, more stable fabric appearance in the dyeing with plain colors due to reduced diffuse light reflection, sharp contours to the printed pattern with print fabrics, anti-pilling finish obtained, especially with fabrics made of polyester or cotton/polyester.

Singeing Systems
Singeing Systems: There are two types of systems in singeing, viz., Direct and Indirect. 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. In an alternative improved system, the fully combusted hot flue acts directly on the protruding fiber ends. Indirect Singeing System: In this system, the heat, in the forms of diffused infra-red radiations, produces amore even singeing effect. Owing to the indirect character of the singeing effect, this system is quite suitable for fabrics having wavy selvedges, such as those occurring in the case of fabrics coming out from shuttle-less types of looms.

Plate Singeing Machine

Plate-Singeing m/c: The main parts of plate singeing m/c -i) Two copper plate
ii) Fire clay. Copper plates are set up on the fire clay which is heated with farness (gas and oil or oil jet). At first the fabric opening with guide roller is passed over the plate with drawn roller. When the plate was red heated with farness, copper plates drawn with draw roller which speed 135-225 m/min. Projecting fibres is burnt contact with heated plate. In this process, one side of fabric is singed.

WHY & WHY NOT Plate singeing

Advantages:
Very suitable for back filter in finishing process. A certain amount of lusture is produce due to friction between the fabric & hot surface of curved plate. Improved lusture. Uniform singeing. More effective in case of valvet & pile fabric.

Disadvantage:

control of the plate. Only one side of the fabric is singed. Discontinuous process so more time taken. More labour cost Not uniform singeing in stitch portion. Strength decrease.

Very difficult to maintain the proper heat

 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.. If the singeing of both sides of the fabric is required, then two cylinder are employed, one for each side of the fabric. This type of machine is particularly suitable for the singeing of velvets and other pile fabrics.

ROTARY SINGEING

Roller singeing
This is more improved process than plate singeing m/c process. In this process, the fabric is singed one side also by heat but not red heat. If the fabric is singed by red heated roller, the heat is not even for this the result is not good.

ROTARY SINGEING

Why &why not Cylinder singeing

Advantage:
The surface temp of cylinder is more uniform than plate singeing m/c. This method is very suitable for valvet & pile fabrics. Uniform singeing. Lustre increase.

Disadvantage:

Only one side of the fabric is singed. Due to over use, small tinny groove created on the cylinder. Local cooling may arise on cylinder due to contact between cold fabric & cylind

GAS SINGEING

With this treatment fuzz and fiber ends are burnt off in order highlight the fabric weave. The distance from burner to fabric at horizontal position 1.5-4mm.

FLAME SINGEING
This is the most commonly used process for woven fabric. The burners are usually supplied with a suitable mixture of gas and air. Source of gas are-Coal-Petrol-Natural gas. This m/c may be single or Duoble burner. In double burner, fabric is singed the both side

MECHANISM
At first fabric is drawn onto the guide roller then brushing is done on both side of fabric such that, flying and projecting fiber stands sufficiently. Then fabric is passed over the burner. The burner should be adjusted with the width of the fabric. Height of the flame depends upon the fineness or coarseness and speed of the fabric. After singeing the fabric is immersed in the water or de sizing/ Cold Bleach Tank to prepare next process.

SINGE-DESIZE

 The fabric speed is the actual singeing speed. The usual speed ranges from 75m/minute to 150 m/minutes.
The energy output for the desired flame intensity ranges from 25000 to 100000 K calories per hour. Burner length ( usually 200mm more than the fabric width) 1600mm is the most common fabric width and hence 1800 mm becomes the most common burner length

An automatic burner extinguishing device for any untoward breakdowns and passages. An automatic igniting system for burners,
An arrangement to conduct singeing of one surface of the cloth or both the front and back face of the fabric when so desired.

In this type of a machine, one cloth surface comes twice in contact with the flame of the burners or both the cloth faces can be singed once

SINGEING PARAMETERS
Following parameters are of most importance during singeing process: Machine Speed Flame Intensity: (is the amount of energy released per unit time/per unit area of primary flame front. It is used to evaluate the effectiveness of the fuel.)[1] Flame Colour Burner Position Flame Distance from Fabric Surface Efficient and accurate gas-air mixtures : (produces flames of superior controlled character)

FLAME INTENSITY
Together with the supply and control units for gas-air mixture, burners comprise the most important part of any singeing machine. The flame of the singeing burners is based on the amount and the outlet speed of the gas-air mixture leaving the burner slots. Besides having high thermal energy, flame also has considerable mechanical energy. All the thermal and mechanical energy of the flame is directed onto the fabric during singeing. The temperature of the flame at the mouth of the burner is intensity n the range of 1250 to 1300C. The speed of the flame at the burner outlet may be between 15 and 35 meter per second. The flame intensity usually lies between 5 and 20 mbars.

FLAME COLOUR
the blue to green region of the spectrum below about 565 nanometers, accounting for the bluish color of sootless hydrocarbon flames.

SINGEING RESULTS

BURNER ANGLES
Burners are the heart of all Singeing Machines. Practically there are three burner positions:
Onto free guided fabric (Position 1)

Onto water cooled roller Tangential singeing

(Position 2) (Position 3)

Onto free guided fabric

Flame meets right-angle onto dense woven fabric freely guided between 2 rollers, recommended for natural fibres and blends weighing more than 125g/m

Onto water cooled roller

Flame meets right-angle onto the fabric bended over a water cooled roller. Recommended for fabrics of temperature sensitive fibres, those of open-weave, blended ones weighing less than 125g/m

Tangential Singeing
Flame passes tangentially over the fabric bended over a water cooled roller recommendable for fabrics which cannot tolerate direct exposure to flame and for repair of filamentation

MAIN PARTS OF SINGEING M/C

Process Sequence with in Singeing Machine

Cotton and Cotton Blend fabrics are passed through different process on Singeing Machine Pre Brushing and Cleaning Singeing (Through Burners) Post Brushing and Cleaning

1. Beating 2.Brushing 3.Brushing and Beating

Pre Brushing and Cleaning

Purpose Well prepared and cleaned fabric is a precondition for good singeing Working Principle 1. Fabric heavily vibrates due to the beating bars. Dust, fibres and other residues get loosened and are extracted 2. Fibres sticking to the surface get lifted by the brush segments presenting it in such a way that they easily can be singed-off.

Post Brushing and Cleaning

Purpose Cleaning after singeing is as well of importance, impregnating liquor remains cleaner Working Principle Same as Pre Brushing

Why & why not Gas Singeing?

Advantages: 1. Uniform temperature ensure to proper singeing. 2. Both side of the fabric can be singed. 3. As the process is continuous, there is no hamper in production. 4. After singeing, fabric are cleaned in water / de sizing tank, hence all sparks are easily removed 5.Standard process. 6. Ideal singeing. 7. The fabric in inter-stitches of warp and weft are singed

Disadvantages
1. Dirty burner can produce spot on the fabric. 2. The process is not suitable for synthetic fabric. 3. Due to in consistent of fabric speed, it may be burnt.

. GAS SINGEING

1 = gas; 2 = combustion air; 3 = calibrated opening; 4 = premix zone; 5 = open jet gas injector; 6 = observation port; 7 = turbulence ring; 8 = special glass fiber exit via stuffing box; 9 = signal converter (converting the optical into an electrical signal); 10 = pin diaphragm for limiting combustion air quantity; 11 = ignition plug; 12 =plug-in connection for ultra-violet flame detector; 13= special glass fiber entry side; 14 = special ultra-violet glass fibers

KUSTER SINGEING

KNIT SINGEING

Singeing machine for tubular knit goods [Dornier singeing]

ESSENTIAL CONDITIONS FOR GOOD SINGEING

Following are three essential conditions for good singeing: 1. A flame with high mechanical & thermal energy to quickly burn thermoplastic protruding fibres (e.g. polyester) without any molten beads formation 2. A homogeneous flame with uniform mechanical & thermal energy to result in uniform singeing 3. An optimal flame/fabric contact time to neither result in incomplete not over-singeing

Common problems in GAS singeing and their causes

A. Incomplete Singeing

Too low flame intensity Too fast fabric speed Too far distance between the fabric and the burner Inappropriate (i.e. less severe) singeing position Too much moisture in the fabric incoming for singeing. If the fabric incoming for singeing has too much moisture in it, a significant amount of thermal energy will be used up in evaporating the fabric moisture rather than burning the protruding fibres, resulting in incomplete singeing. B. Uneven Singeing Across the Fabric Width Non-uniform moisture content across the fabric width Non-uniform flame intensity (uneven flame height) across the fabric width Uneven distance between the burner and the fabric This may be due to misalignment or improper setting of the guide rollers Uneven smoke evacuation over the burners

Common problems in GAS singeing and their causes

C. Uneven Singeing Along the Fabric Length Non-uniform moisture content along the fabric length Non-uniform flame intensity along the fabric length Change in fabric speed during singeing Change in the distance between the fabric and the burner along the length D. Horizontal Singeing Stripes Rollers with an un-centered rolling action Sudden fabric tension increase E. Vertical Singeing Stripes Total or partial blockage of flame outlet

Common problems in GAS singeing and their causes

F. Over-singing or Thermal Damage of the Fabric Too high flame intensity Too slow fabric speed or too long contact time between fabric and flame Too close distance between the fabric and the burner or too deep penetration of the singeing flame into the fabric Inappropriate singeing position G. Formation of Small Beads of Molten Material Insufficient energy supply, when the thermal energy is not supplied quickly enough to be able to ignite the thermoplastic fiber rather than melting it.

Possible causes of defects of gas singeing and its precaution

Care should be taken on gas singeing 1. If any anticeptic /anti mildew agents, (ZnCl2 or MgCl2) in size ingredients, then singed fabric produce spot which result, uneven in processing.ZnCl2+H2OZnO + 2 HCl .So fabric must be free from those agents. 2. Burner should be cleaned, otherwise singed fabric will be faulty and as a result stripe found during dyeing. 3. Speed of fabric must be consistent with the flame height, otherwise fabric may be burnt. 4. Synthetic blend must operate carefully otherwise shrink in flame and beet formed and during dyeing uneven dyeing. 5. Fabric may be burnt due to power failure. Automatic gas must stop the power failure. 6. Fabric must be evenly dried before singeing.7. The singeing may not be even due to folding of selvedge

Flame Singeing Both side can be singed Uniform temperature maintain No extra lusture is produced Very suitable for Dyeing & Printing Brush is used for proper singeing. No decay

Roller Singeing One side can be singed Uniform Temperature cannot maintain Extra lusture produce, due to friction between fabric & surface Not suitable for dyeing & printing Brush is not used for proper singeing.
Plate may decay due to friction

Plate Singeing One side can be singed Uniform Temperature cannot maintain Extra lusture produce, due to friction between fabric & surface Not suitable for dyeing & printing Brush is not used for proper singeing.
Plate may decay due to friction

 Nowadays Singeing serves as the final finish also to improve the glaze of smoothness of the finished product. Singe Finish

SEM Image of a typical 'Singe Finish' (100 X Magnification)

Improves abrasion resistance of media where dust impacts on needlefelt. The singeing process removes protruding surface fibres by using a flame that melts back fibre tips which in turn consolidates the fibrous needlefelt surface. The molten polymer does not impede airflow at all but the resultant finish provides a tough abrasion resistant media surface.

Glaze
This type of finish is recommended for demanding situations in dry filtration as well as liquid filtration where large areas of fibres are welded together to form a smooth, unbroken finish on the collection surface of the felt.

SEM Image of a typical 'Glaze Finish' (100 X Magnification)

Depending on the specific end use requirements, Webron Marling offers the following types: Light & Medium Glaze for: Fine dust applications Improved particle collection efficiency Good dust release

 Heavy Glaze for: Liquid filtration applications where high efficiency and smooth release surface is required Difficult dust situations where good filter efficiency is more important than gas flow rate Superglaze This revolutionary finish was developed in response to our customers' requirements for enhanced filtration properties in demanding dust situations. Superglaze, thanks to its extra smooth surface offers superior dust release in a variety of applications. The benefits of this finish can be listed as follows: In many applications effective surface filtration helps P to be kept low over a longer period of time in comparison to media with a conventional surface finish Good level of air permeability, which is equivalent to that of a singed finish media, offers flexibility in a whole host of industrial applications Cost effective Smooth surface of Superglaze media prevents the formation of dust globules Can be applied to needlefelts manufactured from Polyester, Polypropylene, Acrylic and PPS fibres

Singeing Has Contribution to The smart Finishes

Super Glaze SEM Image of WML Superglaze (50 X Magnification)

Dust agglomeration is a common problem with filter media whose collection surface lacks effective mechanical finishing

REFERENCES
http://www.bocindustrial.co.uk/bocindustrial/technical/glos sary/a.asp http://www.ft.tul.cz/depart/ktc/dokumenty/pte/1PTE%20In troduction.pdf 1. http://www.osthoff-senge.com/ 2. http://www.swastiktextile.com/ 3. http://www.lindauer-dornier.com/english/index.htm 4. http://www.menzelus.com 5. http://www.menzel.net 6. http://susiram.in 7. http://www.gayatri-engg.com 8. http://www.jfletcher.co.uk 9. http://www.ssm.ch 10. http://www.ritespa.it