An in plant training at

Bombay Dyeing and Mfg. Co. ltd.

Presented By
NIKHIL S. SHAIWALE
VJTI (VII L.T.C.)
MATUNGA, MUMBAI 400 019
1) Mercerization (the actual process)
2) Conventional Merceriser & Problems faced
3) Concept of Hot mercerization & parameters
4) Benefits of hot mercerization
5) Benninger Mercerisers
6) Padless chain merceriser
7) Comparative description of the machines
8) Specialties of the design and machine
9) Disadvantages and advantages
 Mercerization is a treatment of cotton fiber under tension
with about 280-290 gpl caustic at low temp (RT instead of
low temp) for 45 to 60 seconds.
 Gives excellent luster and drape with considerably increased
dye uptake.
 The machine consists of a trough containing caustic through
which cotton fabric is padded.
 Machine speed is set according to dwell time required. (dwell
time = loop length/speed of machine in mpm)
Problems faced
 Difficulty in achieving reproducible results. (Due to RT
variation)
 Poor mercerization at yarn core resulting poorly dyed core of
yarns in fabric.
 More consumption of utilities.
 Low production speeds (Due to larger dwell time)
 A mercerization process carried out at 60-70˚ C.
 Affinity of caustic towards cellulose decreases.
 At this temperature, caustic has low viscosity.
 Cotton yarns swell more slowly allowing the diffusion of lye upto yarn
core.
 Core gets mercerized achieving core mercerization.

Hot mercerization – parameters

 Concentration:- The concentration of the caustic lye should be strictly
controlled between 28 – 30˚ Be as rise or fall in conc. does not achieves
the desired result.
 Temperature:- The temperature must be controlled in a range of 60 - 70˚ C.
 Dwell time:- The dwell time required is 25-30 seconds.
 We will discuss the merceriser from following point of view.
 Design
 Important parts
 Utility consumption
 Parameters
 Variation according to process
 The merceriser can process both heavy and light varieties
while processing.
 The sequence of processing is impregnation -> dwell time ->
stabilization -> washing.
 This one has better control over shrinkage both weft wise and
warp wise.
 Impregnator: For impregnation.
& Timer: For dwell timing
 Stabilizer: For stabilization and recuperation

 C.R.P. (caustic recovery plant): For recovery of the caustic

from wash liquor.

IMPREGNATOR
 Hot 28° Be caustic is sprayed through pipes in the
gap between engraved and hollow rubber roller.
 This saves the unnecessary amount of caustic and
low amount allows rapid change in concentrations
according to the quality.
 The overflowed caustic liquor is recirculated with
recirculation pumps. And thus this also adds to
saving of the caustic lye.
TIMER
 This compartment is same as the impregnator. But
the caustic is not sprayed on the fabric. This
compartment is only used to give a dwell time of
25 to 30 seconds.
RECIRCULATION
PUMP
Impregnator concept
Stabilizer
 In this unit the fabric is stabilized i.e. caustic conc. is lowered

in this zone to 8˚ Be. making the fabric stable .

 Also in this unit steam is employed to achieve the temperature

of about 85˚ C. This further lowers the affinity of caustic

towards fabric to serve easy removal during washing.
CRP
 In this plant caustic from wash liquor is recovered by means
of evaporation technique to recover about 95% of pure caustic
recovery. It delivers the caustic of about 35˚ Be.
These are the important sections of the machine. The parts are
mentioned below which are present in these sections.
 Engraved roller & Rubber coated rollers (small and big)

 Baumy sensor

 Chain

 Extracta compartments
 Engraved roller has a engravings on its surface which ensures firm
grip & yarn slippage.
 Baumy sensor : it sences the concentration of caustic

Rubber coated hollow

roller
The chain is the most important part of this merceriser which
enables weft wise control over shrinkage.
Pins & water sprayers
 The roller arrangement is unique that is sequence of rollers is
engraved steel roller and rubber roller.
Caustic lye
RC:- Rubber coated roller
RC RC RCS. Small rubber coated roller
RC
S. Steel:- Engraved roller
steel steel steel steel

 The liquor lies between engraved steel roller and hollow

rubber roller.
 Reduced power consumption due to Hollow rollers
 The arrangement of rollers reduces the amount of caustic to
the considerable extend.
 Better & faster control over concentration (Low amt of
processing caustic).
 Less labour handling and minimal stoppages.
 Counter current washing has been provided.
 Low consumption of lye, water and electricity (up to 30% less
lye consumption).
 The range is totally automated. Thus once the values are set
rest of the parameters are governed by a computerized system.
 Increased efficiency due to heat exchangers
 The advantages of these hot mercerization ranges
are as follows-
1. Uniform core mercerization is achieved.
2. Controlled temperature ensures excellent shade
reproducibility.
3. Dwelling time is theoretically reduced upto 20-25
seconds giving higher productivity.
4. Upto 30% less consumption of lye, water and electricity.
 The disadvantage of this process is that it gives
poor luster as compared to cold mercerization.
Difference between the chain &
chainless principle.
 This process gives core mercerization.
 Also the dwell time is reduced from 45-60seconds to 25-30
seconds.
 This increases higher production speeds thus higher
productivity.
 Also the temperature is strictly maintained at 60˚C thus giving
excellent shade reproducibility.
 This gives enhanced luster uniformly.
Thank you for your patient co-operation.