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MERCERIZATION
MERCERIZATION
By
Prof.K.B.Krishna Kumar
PRESENTATION DETAILS
• This presentation has been devided into:
• INTRODUCTION
• ADVANTAGES OF MERCERIZATION
• CLASSIFICATION OF 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 DYE ABSORPTION
– EFFECTS ON MOISTURE REGAIN
PRESENTATION DETAILS contd..
• WHAT HAPPENS AFTER MERCERIZATION ?
• CONDITIONS OF MERCERIZATION
– HANK MERCERIZATION
– CHEESE MERCERIZATION
– SINGLE END MERCERIZATION
PRESENTATION DETAILS contd…
– TOW MERCERIZATION
– WARP MERCERIZATION
– CHAINLESS MERCERIZATION
– CHAIN MERCERIZATION
– BATCH MERCERIZATION
– ADVANTAGES & DISADVANTAGES OF CHAIN
MERCERIZATION
– CHAIN AND CHAINLES MERCERIZINF MACHINES &
THEIR COMBINATION
– COMPARISION OF CHAIN AND CHAINLESS M/C’S
* IMPORTENCE OF WASHING
PRESENTATION DETAILS contd….
• ALTERNATIVE SOURCES TO CAUSTIC SODA
• CONCLUSIONS
INTRODUCTION
• Alakali treatments of COTTON has been found
to be very advantageous to the processor.
• A number of alkali treatments like Desizing,
Scouring, Caustic padding , Causticization,
Mercerization etc. are being carried out on
COTTON using NaOH by the processor.
• The effectiveness of these treatments depends
on the penetration of the NaOH. However, the
viscosity of NaOH poses, the problem of
penetration to the processor.
INTRODUCTION cntd…
• Merecer observed that treatment
OF COTTON with NaOH
increases the Dye Exhaustion and
fixation and Horace observed that
treatment with NaOH by
preventing shrinkage the fabric
becomes more lustrous.
INTRODUCTION contd…
• Of all the treatments, treatment with NaOH of a
specific concentration, for a specific period under
control is known as Mercerization
• is of considerable importance, wherein the
concentration is 48-52° Tw and the time is 30-40 sec.
either under control or without control commonly
referred as
• Tension Mercerization ( treatment under tension/
Control)
• Slack mercerization ( Treatment without tension/
Control)
Advantages of Mercerization
• The mercerization has the following advantages:
• Improving luster
• Improvement in CRA
• The wide range of treatment methods can approximately be broken down into the
following divisions. Parentheses denote established terminology.
• a) Yarn mercerization
• Batch:Hank mercerization
Cheese mercerization
• Continuous:Single end mercerization
• Tow mercerization
Warp mercerization
• b)Knit Mercerization
Open mercerization
Closed mercerization (Round mercerization, tubular knit mercerization)c)
• Cloth mercerization
Chainless mercerization (Roller mercerization)
Chain mercerization (Stenter mercerization)
Batch-up mercerization
CLASSIFICATION OF MERCERIZATION PROCESS
contd…
• 2. Classification according to the marcerizing conditions
• a)Water content
Dry mercerization
Wet mercerization
• b)Tension
Fixed-length mercerization
Tension mercerization
Tensionless mercerization
• c)Alkaline concentration
Low-concentration alkaline mercerization
High-concentration alkaline mercerization
Two-step mercerization
• d)Temperature
Ambient-temperature mercerization
High-temperature mercerization
Low-temperature mercerization
CLASSIFICATION OF MERCERIZATION PROCESS
contd…
• 3. Classification according to timing
a. Gray mercerization
b. Pre-dyeing mercerization
c. Post-dyeing mercerization
•
• 4. Classification according to the number of treatments
Single mercerization
Double mercerization
•
• 5. Classification according to the type of alkali used
a. Caustic soda mercerization
b. Ammonia mercerization
• 6. Other
a. Alkali pad-dry method
b. Alkali pad-steam method
WHAT HAPPENS TO COTTON DURING
MERCERIZATION ?
• Convolutions disappear
• Time of Treatment
• Tension applied
• Temperature
• Impurities of NaOH
PARAMETERS CONTD…
Effect of Concentration
• After swelling reaches its greatest point, NaOH
thoroughly penetrates the interior of the micelle, and a
reaction between the alkali and the micelle occurs,
completing the generation of alkali cellulose I.
•
• From 18-22°Bé, the range displaying the greatest
degree of swelling, to around 24°Bé, the cotton hair
first contracts momentarily, and then swells again, and
at 24°Bé or above a second swelling peak was
observed. These observations cannot be disregarded
as baseless occurrences.
PARAMETERS CONTD…
The longitudinal changes of a single scoured cotton hair in a single caustic soda
• The concentration of NaOH versus the shrinkage of cotton hairs and cotton fabrics
Cotton hair under physical restraint, that is, made into a yarn or a woven fabric
that restrains the hair's freedom due to twisting and to crossing of twisted yarn,
when treated with an alkali, displays different behavior because the shrinking
and swelling displayed originally cannot occur due to the constraining forces.
Cotton hair under physical restraint, when converted into a yarn or a woven
fabric restrains the hair's freedom due to twisting and to crossing of twisted
yarn, when treated with an alkali, displays different behavior because the
shrinking and swelling displayed originally cannot occur due to the constraining
forces.
It is reported by H. Flecken that even for the same type of yarn, the behavior
of single, double and triple yarns display differences, as does the shrinkage of
woven fabric and hairs
PARAMETERS OF MERCERIZATION CONTD….
• 4. Luster increases
• 5. Stiffness increases
• 6. MR increases
• 7. Soiling decreases
• 8. % Exhaustion increases
WHEN MERCERIZATION CAN BE CARRIED OUT ?
• After Desizing
• After Scouring
• Finally washing off of the traces of alkali from the treated fibres.
CONDITIONS OF MERCERIZATION contd…
Cellulose undergoes
• Chemical
• Physico-Chemical
• Structural
• Time,
• Tension and
• Washing conditions
Formation of different celluloses on
structural modification
• yarn that has been hank mercerized and then dyed for
finishing into solid-color fabrics can result in a barre
effect.
• Other problems relate to yarn breakage, yarn overlap, and yarn skewing.
•
• In general, this method of treatment requires two-fold yarn with a yarn count less
than 60, and it is unsuitable for the treatment of yarn with fine yarn counts higher
than this. In general, this method of treatment requires two-fold yarn with a yarn
count less than 60, and it is unsuitable for the treatment of yarn with fine yarn counts
higher than this.
TOW MERCERIZATION
• Normally, 400 or so yarns are wrapped around a beam or a ball with a warper and 8
to 10 of these beams or balls are set in a stand. Yarn is unreeled from the balls or the
beams at the same time and lined up in ropes made with light twisting, which are
mercerized continuously in a manner similar to that of roller mercerization of fabric.
• The equipment used in this method looks like a row of soapers, and each treatment
bath is driven separately, tension on the yarn is controlled, and the shrinkage due to
swelling during absorption of the alkali and the level of strain after this can be
adjusted freely.
• This type of equipment can produce a large amount of yarn of consistent quality and
so this method is suitable for the production of mercerized yarn for use in knits, and
the treatment of fine yarn that is two-fold yarn with a yarn count of around 100-110 is
also possible.
• One problem concerning the type of equipment used is the separation of the yarns in
the rope after it is dried at the conclusion of the mercerization process, and the way
in which the yarns are unwound is very important for ensuring the smoothness of the
operation.
•
WARP MERCERIZATION
• While tow mercerization involves the treatment of a
lot of yarn lined up in rope-form, in warp
mercerization yarn is wound onto a beam and fed
into a machine with the same system as in a slasher-
sizing machine. Mercerization takes place with
sheets of separate threads, and the machinery used
can be exactly the same as that in tow mercerization.
• Thus, in the warp-beam method and the tow method,
only the handling is different.
• problem, however, is that during treatment the
breakage of a single thread can lead to major
difficulties, and so if the yarn is not of very good even
quality, industrial implementation of this method is
difficult.
Chainless Mercerizing Machine
• This method of mercerization involves running fabric through a
number of rollers without the use of a clip stenter is also called
roller mercerization.
• The machine used has a number of stainless rollers, or
stainless and rubber rollers, of a relatively-large diameter tiered
zigzag in close contact to each other inside a long trough, with
the lower tier designed to submerge in alkaline solution for
mercerization.
• The absorption of alkaline solution and fabric swelling take
place as fabric sequentially glides through the surface of these
rollers, and, although this movement from roller to roller in close
contact with them reduces the widthwise contraction to a
minimum, the resulting fabric expansion remains within a limited
range, thus displaying the mechanism of mercerization at fixed
length.
Chainless Mercerizing Machine contd.
• Still, for the growing cases of carrying out alkali reduction for
the polyester side of cotton/polyester blends to achieve both the
mercerization of cotton and the alkali reduction of polyester in a
single treatment, the application of this cold batch method is
particularly interesting as a device that can combine the two
separate stages which would otherwise raise facility problems.
BATCH MERCERIZATION MACHINE
MERCERIZATION UNDER TENSION
DISADVANTAGES OF CHAIN MERCERIZING
• Uniformity
• Higher productivity
1. Lower swelling
5. Costlier
THEN –
HOW TO DO HOT MERCERIZATION?
• Yes, it is possible.
• Hot mercerization can permit an elimination of scouring or
rather simplification or in other words combined process of
scouring and mercerization, which can be carried out under
the following conditions;
• Prograde Process
• in this process the yarn is treated with liquid ammonia at
its boiling point of -33oC for less than a second, followed
by immersion of yarn under tension in hot water for about 0.1
second to produce a 40% increase in tensile strength,
improved luster etc.
• The drying cylinders reduce the moisture content of the material below the humidity,
while the cooling station takes care of the cooling of the material.
• Then the material pases into actual treatment chamber whre it is impregnated with liquid
ammonia in a trough.
• The treatment chamber is kept under slight vacuum to prevent ammonia from escaping.
• Finally it is squeezed off in a padder and the ammonia is driven off in two felt calanders.
In this heat treatment 90-95% of ammonia is recovered. The rest which is chemically
bound to the cellulose is removed in a steaming compartment consisting of a pre-
dwelling zone and a steaming zone. The entering and take off compartments are sealed
by locks.
Sanforset Process
• An after dwelling zone and take off zone complete the process.
• 1. Less pollution
• 2. Higher productivity
• Higher shrinkage
• Lower luster
• Very costly
•
• Ammonia recovery even though not a problem with
the machinery developed, leakages will do great
harm to the personnel working.
MERCERIZING OF KNITTED GOODS
• The world-wide demand for knit goods is growing. Knitted
fabrics are increasingly being used for outer and underwear
and are also enjoying greater acceptance amongst various
consumers.
• The very fact that knitted fabrics are being used for outerwear
explains the higher demands placed on the quality as well as
the appearance of the fabrics in order to meet the ever-
changing fashion trends.
• Although most processing of knitted fabrics today is carried
out in tubular form, the need to process in the open width form
is becoming increasingly necessary in order to satisfy the
quality requirements.
• This PRESENTATION deals with the various machine
concepts being offered by Benninger for the open width
processing of knitted fabrics.
MERCERIZING OF OPEN WIDTH KNITTED GOODS CONTD..
• This means that tensions exerted by the machinery on the fabric must be
kept to a minimum.
• This is the reason for the special design of the entry to the range which
consists of a centre driven unwinding arrangement.
• The low tension and gentle treatment is also ensured by the ratio metered
AC drive. Each drive position can be adjusted up or down by 20%.
MERCERIZING OF OPEN WIDTH KNITTED GOODS CONTD…
• The fabrics are impregnated in a short impregnating zone followed by dwelling in the
chainless section of the machine.
• The dwelling zone is followed by a vertical return pin chain / stenter section, where the
fabric is uniformly stretched during the gradual removal of the caustic content.
• This means an initial stabilization of the fabric already begins in the chain zone
followed by further stabilization in the chainless section of the machine.
• The combination of the chain and chainless principles ensure the dimensional stability
of the knitted fabric. The dimensions set during the processing are fixed and
memorised permanently.
• The results after mercerising on the BEN -DIMENSA are representative of the final
product and any deviation can be corrected immediately in the stenter frame.
MERCERIZING OF OPEN WIDTH KNITTED GOODS CONTD….