Development of Antimicrobial Needle Punched Nonwoven Fabric For Various Technical Applications Final 10.07.2020

Development of Antimicrobial Needle Punched Nonwoven Fabric For Various Technical Applications
CHAPTER - 1
INTRODUCTION
1. Introduction
The demand for high performance textiles is continuously increasing, regardless of

their applications for apparel, home textiles, or outdoor applications. A suitability
of the application is mainly based on the functional aspects of a fabric, the
antimicrobial treatment on fabric can added value to different technical
applications.
Bacteria, fungi and dust mites can create various problems like odors, can cause
allergic reactions, stains on fabric surface due to bacterial growth. The microbial
growth is also very serious problem in outdoor applications of textiles like
awnings, tents, or lawn furniture and leads to discoloration and degradation.
Floorings, tufted carpets / automotive carpets, rugs are also a source for the
bacterial growth on surface. The fungi or bacterial growth can be seen on the moist
areas below the carpets or flooring materials and gives foul smell and sometimes it
reduces the serviceability of the product. Also the carpets, rugs, bathmats can hold
the dirt and moisture inside the structure or on the fibres that also can create bad
odours and surface staining with microbial growth.
The Needle punched Nonwovens with different GSM (for different applications)
will be developed by using staple Polyester fibers of 1.5 D, 3D, 6D denier. The
developed nonwovens will be subjected to chemical finishing of antimicrobial
agents to meet the requirements of the various applications like in shoe insole,
interlinings for jackets, automotive AC filter fabrics, milk & beverage filtration
application etc. Also an attempt will be made to make inherent antimicrobial
nonwoven by using inherent antimicrobial fibers.
An attempt will be made to explore the applications of the Zinc Pyrithone to make
antimicrobial needle punched nonwoven fabrics. This will restrict the bacterial
DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 1

growth over the fabric surface and a problem of bad odors in the cabin air filters
used in car & even in other various applications of nonwoven can be addressed
easily. With this development of antimicrobial nonwovens a bacterial development
over the fabric surface will be restricted and a problem of odors in various
applications of nonwoven can be addressed easily. (Applications of nonwovens are
like sleeping bags, jackets, automotive AC, shoe insoles, sleeping bag liners, milk
& beverage filtration application, floor carpets etc).
1.2 Problem statement based on Literature
Bacteria, fungi and dust mites can create problems and cause many different issues.
They mainly create an odors in mattress, automotive AC, floor carpets, shoe
insoles, cause allergic reactions also that can create stains on surface of upholstery.
An attempt will be made by developing antimicrobial nonwovens which can tackle
the problem.
1.3 Objectives
1. To synthesize Zinc Oxide / Zinc Pyrithone

2. Application of Zinc Pyrithone on needle punched nonwoven fabric for
achieving fungistatic& bacteriostatic characteristics for various applications
like automotive ac filters, interlining’s for jackets, sleeping bag liners, shoe
insoles, milk & beverage filtration application, floor carpets etc.
1.4 Scope
With this development of antimicrobial nonwovens a bacterial development over
the fabric surface will be restricted and a problem of odors in various applications
of nonwoven can be addressed easily. (Applications of nonwovens like sleeping
bags, jackets, automotive AC, shoe insoles, milk & beverage filtration application,
sleeping bag liners etc.)

CHAPTER - 2
LITERATURE REVIEW
2.1 Introduction
Nonwovens are sheet of fibres, or the continuous filaments or the chopped yarns of
any origin that have been formed into the web by any means and bonded together
by any means, except weaving or knitting. Nonwoven fabrics are mainly flat,
porous sheets that are made directly from separate fibers or from molten plastic or
sheet or web structures bonded together by entangling of fiber or filaments either
mechanically, thermally or chemically except by weaving or knitting and they
don’t require converting the fibers to yarn [1, 2].
Normally the nonwovens are manufactured at higher production rate and at lower
processing cost. The first commercial use of nonwovens was to replace the
expensive woven filters in automotive industry. The nonwovens have wide
applications and are classified on the basis of usage life time can be either durable
&disposable. Major applications includes sanitary napkins, caps, gowns, wipes,
apparel interlinings, padding and backing, agricultural applications, automotive
headliners and upholstery, filters for various applications, envelopes, thermal
insulation linings, house wraps, roofing products and geo textiles. The Filtration is
one of the most dynamic sectors for nonwovens due to their adaptability;
nonwoven materials play an important role in filtering both air and liquids.
Nonwovens plays vital role in filtration to improve indoor air quality & helps filter
the drinking water by removing viruses and bacteria. Nonwovens also play an
important role in medical applications like blood dialysis. [3, 4].
There can be chances of development of growing bacteria, fungi and dust mites
nonwoven structures, which can create problems and cause many different issues
like odors in various applications of nonwovens such as sleeping bags liners,
jackets liners, automotive air conditioner, shoe insoles, building and construction,
geo-textiles, mattress, disposable towels, bedding, upholstery, carpets, curtains,

pillows, acoustic insulation, military fabrics, tenting, carpets, thermal liners, caps,
jackets, work wear, sportswear, fleeces, architectural fabrics, awnings, canopies,
scrubs, automotive carpets, masks, window covering, filters etc.
As per World Health Organization, the allergens are the fourth most common
chronic illness globally. The bacteria, fungi and dust mites can get developed over
it and create different problems, like allergic reactions, odors, stains on the
upholstery used in cars. Microbial growth is also big problem with the outdoor
applications of the textiles, like, tents, lawn furniture, awnings and leads to
discoloration and reduces the life of the product.
The filters used in air conditioner in car also a possible surface on which bacterial
growth, can takes place, also at the time of the pollen season there are more than
3,000 different types of pollens in one milliliter of air. It’s very high load on the
the filter. Which is polluting the air inside the vehicle; people today suffer from
allergic reactions due to pollen, bacteria and mold fungi this can be big issue in
road safety because if the driver suddenly sneeze, there can be distraction for
approximately about two seconds and that restricts the ability of driver to respond
and the braking distance can be more than usual. For same the protection of the
driver and passengers against pollen and bacteria requires the use of efficient cabin
air filters for automotive application. [5].
The flooring, carpets and rugs can frequently be a source of unwanted microbes.
Fungi can grow in moist areas under carpets and create odours. Carpets, rugs,
bathmats can trap dirt and moisture within the fibres, leads to create odours and
staining on surface. Nonwoven finds applications across a wide range of end-use
applications as few examples below [6].
 Household: towels, bedding, upholstery, carpets, curtains, pillows etc.

 Commercial: window coverings, military fabrics, tenting, carpets etc.
 Apparels: caps, jackets, interlinings , sportswear, fleeces,
 Building construction: architectural fabrics, awnings, canopies

 Health & hygiene : masks, window coverings, beddings, air filters
Shalaby, S.E, et.al, carried out an experiment establishment of technological

Package for Production of Antimicrobial PET and PA Nonwoven Fabrics on Pilot
Scale, in that experiment Nonwovens was developed for testing the antimicrobial
activity for filtration and medical application. The hydrolyzed PET and regular PA
fibers were finished with antimicrobial substance on pilot level. The antimicrobial
properties of nonwoven PET and PA were studied. The produced nonwoven
fabrics appeared high antimicrobial activity. The physical properties of the
produced nonwoven fabrics were tested. The suitability of PET and PA nonwoven
fabrics are for air filters and surgical masks. [7].
2.2 Active Ingredients Used for Antimicrobial Fabric Treatment
In general, functional finishes usually need to be more durable than normally

expected. Antibacterial finishes are applied to textiles for three major reasons: to
control the spread of disease and the danger of infection following injury, to
control the development of odor from perspiration, stains, and other soil on textile
materials, also in order to control the deterioration of textiles, mainly for the
fabrics produced from natural fibers, caused due to bacterial growth. There are
many textile items for which antibacterial treatments are desirable. Antimicrobial
additives for textiles are selected based on the type of fibre, processing conditions
required and what kind of protection is needed such as antibacterial and/or
antifungal activity and wash durability. [8].
Chemical agents are generally used to control the growth of microorganisms on

textile fabrics. In fact, few chemical agents achieve sterility, and most of them
merely reduce microbial populations to safe levels. A common problem in
disinfection or bacteriostasis is the selection of an agent that will kill all organisms
in the shortest time without damaging the contaminated materials.

2.3 Antibacterial Fabric

The most common antibacterial additives used to treat fabric for end uses such as
apparel and home textiles are silver, silane quaternary ammonia compounds and
polyhexamethylenebiguanide (PHMB).These additives have good antibacterial
activity at low concentrations and excellent wash fastness. High concentrations are
typically required mainly for more antifungal or antibacterial properties are
required. [8].
2.4 Antifungal Fabric
Fabrics used for industrial or outdoor applications are often require antifungal
treatment & normally done by Isothiazolinone and thiabendazole, have good
antifungal properties but not effective against bacterial attack.
All the technologies have their pros and cons regarding the required degree of
antimicrobial effectiveness, along with the way they can be incorporated during the
manufacturing process. Single ingredient or product formulation will be suitable
for all the applications. The optimisation of different actives can lower overall use
of antimicrobial, which gives economical savings and most importantly, deliver
superior performance of the antimicrobial activity. Antibacterial agents should be
diluted exactly as per required antimicrobial activity. Solutions that are too weak
may be ineffective and too strong solutions can be dangerous when it comes in
human contact. Also it is very important that the antibacterial agent will make easy
contact with the microbes.[9, 10].
The anti-microbial agents used on fabric can destroy the bacteria and prevent the
breeding process. Nano silver colloids and nano silver treated nonwovens have
good bacteriostatic properties. Antibacterial treatment of nonwoven fabrics is
easily achieved by the nano silver colloidal solution. Nanotechnology is concerned
with various materials shows unique physical, chemical, biological properties, but
it is costly process and cannot be used for commercial products manufacturing.
This raises many issues about new materials for achieving specific functionality

and selectivity. Nano materials have excellent potential because of their potential
applications.
There are primarily two major types of antimicrobial routes available to the
nonwovens industry. These include either the non-leachable or leachable types.
Leachable antimicrobials are not chemically bonded with the fabric and can be
easily removed with moisture. Antimicrobials can increase the value and
performance of the nonwovens, but inherent antimicrobials can cause variety of
risks of environmental and toxicological concerns.
2.5 Applications of Antimicrobial Nonwovens fabrics
2.5.1 Mattress:
Microbial odors are associated with mattress is due to perspiration, dead skin and
organic matters. These problems are persistent because laundering of the mattress
is done less frequently. The major organisms associated with mattress are the
fungal organisms, but bacteria may cause problems under special conditions [11].
2.5.2 Flooring, carpets: Floorings, carpets and rugs can be normally source of
microbes. Fungi’s can easily grow on moist areas under soft flooring materials and
create musty odours. A carpet, rugs, bathmats holds dirt and moisture on fibres,
leading to odours and stains due to microbial growth on surface, when not properly
cleaned or dried.
2.5.3 Filtration: Filtration media normally prone to be a potential surface

microbial growth. The coating on surface causes reduction of filtration capacity;
also the filtrate quality can also be negatively affected by the presence of
microorganisms on the filter media [11, 12].
2.5.4 Building & construction:
With proper design and choice of materials the effects of microorganisms in most
civil engineering applications can be minimized. In most cases polypropylene

nonwoven fabrics are available for applications including rail road stabilization,
drainage liners, pond liners and erosion control. Microbial degradation of the
polypropylene fabrics will not happen but the microorganisms (bacteria and fungi)
can grow on the surface of these materials and affects the water transport property
of nonwovens.[12, 13].
2.5.5 Baby Diapers/Adult Incontinence Pads:
Antimicrobial treated nonwoven cover stock and baby diapers can minimize odor
associated with microbial breakdown of urine. Also it can help for effective in
control of microbes associated with mildew infections and diaper rash & more
hygienic product can be offered to the consumer.
Other Applications of antimicrobial nonwovens are,

 Sleeping bags lining &Jacket lining,
 Automotive AC filter,
 Shoe insoles,
 Milk & beverage filtration application,
 floor carpets, Automotive carpets
 respiratory protective materials
Prasad Upasani, et.al, carried out an experiment on zinc oxide nanoribbon (ZnO
NR)–multiwall carbon nanotube composite film was prepared by filtration
technique. The composite film displayed a strong antimicrobial property and
porous structure, which has potential application as an antimicrobial bandage
material. [12, 13].
The nano-scale particles can provide a narrow size distribution which is good for
uniform deposition on the material. Although the process of using solution
chemistry can be a practical route for the synthesis of nano-scale particles of many
materials, issues such as the control of size, distribution of particles, agglomeration

of the particle during and after synthesis and separation of these particles from the
reactant needs further analysis. [14].
During use, this surface bacteria transfers to textiles worn next to the skin. There,
in a warm, dark and moist environment, the bacteria breed, particularly after
aerobic activity. Sweat and sweaty clothes smell because it contains bacteria
effluent like ammonia. Anti-microbial agents in clothing can destroy these bacteria
and prevent the breeding process. However, anti-microbial clothing must strike a
balance to be both effective and safe. A migrating anti-microbial can destroy
everything it contacts, including the good and necessary bacteria needed for
healthy skin. The role is to destroy the bacteria in the clothing, stop the breeding
process but to leave the skin bacteria intact. [15] [16].
The nonwoven fabrics can be made antimicrobial easily by using nano-sized silver
colloidal solution. Nanotechnology can be used on various materials, with less
effect on physical, chemical, and biological properties of the fabrics due to their
nano size. This raises many issues about new materials for achieving specific
functionality and selectivity. Such multidisciplinary insights are stimulating
progress in nano bio-technology, and the emerging field of nanotechnology is
leading to new approaches in textile engineering [17,18].
Functional finishing of textiles are very much required of the technical textiles,
finishes imply chemical and mechanical processes that impart various performance
properties to fabrics that have not existed, for example, water repellency, water
proofing, abrasion resistance, flame resistance, or immunity to bacteria or fungi .In
general, functional finishes usually need to be more durable than normally
expected. Antibacterial finishes are applied to textiles for three major reasons: to
control the spread of disease and the danger of infection following injury, to
control the development of odour from perspiration, stains on textile materials and
to control the deterioration of textiles for fabrics made from natural fibers are
pronto be attacked by mildew.

Needle-punched nonwoven fabrics are the major filters in industry. The kinds of
needle-punched filter fabrics being produced recently are unique and more
particular than ever before. High temperature liquid filter fabrics made from
aramid or glass fibers. The needle-punched filter fabrics used for filtering blood.
However, polyester filter bags are what most of the companies in this field are
producing. Because a great deal of needle punching is involved in the filter
industry, medical products, and home furnishings fields, it is clear how sensitive
this industry is to increases in costs and interest rates. Most needle-punched fabrics
would be improved by high quality sanitation.
Chemical agents are generally used to control the growth of microorganisms on

textile fabrics. In fact, few chemical agents achieve sterility, and most of them
merely reduce microbial populations to safe levels. A common problem in
disinfection or bacteriostatic is the selection of an agent that will kill all organisms
in the shortest time without damaging the contaminated materials. The antibacterial
chemicals should always be diluted exactly as specified by the manufacturer.
Solutions that are too weak may be ineffective, and those that are too strong can be
dangerous for human contact. Also to be considered is the condition of the material
that is antibacterial.
Another very important consideration is whether the antibacterial agent will easily
make contact with the microbes. Heavy metals are usually toxic and very reactive
with proteins, particularly at sulfhydryl groups. Silver, for instance, is useful as an
antiseptic and disinfectant. The ability of microorganisms to grow in the presence
of metal content might result in specific mechanisms of resistance. Such
mechanisms include alterations of chemical structure or toxicity by changes in the
redox state of the metal ions. However, colloidal silver is much milder and less
toxic to humans than other inorganic materials [18, 19, 20].
With this development of antimicrobial nonwovens a bacterial development over

the fabric surface will be restricted and a problem of odors in various applications

of nonwoven can be addressed easily. (Applications of nonwovens like, jackets

liners, automotive AC filters, shoe insoles, sleeping bag liners, milk & beverage
filtration application, floor carpets etc.).

CHAPTER – 3
PLAN OF WORK
3. 1 introduction
The objective of present research work is to explore the possibility of application

of the Zinc Pyrithone to make antimicrobial needle punched nonwoven fabrics. To
address the problem of bad odors in the cabin air filters used in car & even in other
various applications of nonwoven.
Proposed Work
1 Selection of Raw Materials.
2 Synthesize of Zinc Oxides / Pyrithione
3 Development of nonwoven fabric byusing needle punching technique.
4 Testing of nonwoven fabric
5 Development of the antimicrobial nonwoven by pad – dry – cure method
6 Testing of developed nonwoven
7 Performance assessment and checking suitability for the desired application
8 Use ANOVA technique for analysis of results
9 Conclusion.

3. 2 Flow chart
Selection of Raw Material
Testing of Raw Material Properties
Synthesize Zinc Oxides / Pyrithione
Development of nonwoven fabric by needle punching technique &

development of antimicrobial nonwoven by Pad - Dry - Cure Method
Testing of developed product for performance characteristics
Statistical Analysis
Result and Discussion
Conclusion

3.3. Materials
a. Polyester staple fibre –
Polyethylene terephethalate is preferred textile fiber in many durable applications

of nonwoven for its ease of use and compatibility with other fibers. The various
deniers of the polyester fibre was taken from taken from M/S. DKTE CoE
Nonwovens
b. Modified/ inherent antimicrobial fibres:
From RIL, Mumbai (Only for comparison of cost & performance)
c. Antimicrobial chemicals:
Zinc oxide & Zinc pyrithione (or pyrithione zinc) is fungistatic (inhibits the
division of fungal cells) and bacteriostatic (inhibits the bacterial cell division)
properties.
Chemical structure: C10H8N2O2S2Zn & Solubility in water: 8 ppm (pH 7)
d. Method of application of antimicrobial chemical
Zinc Pyrithone is diluted to get the different strengths to apply on nonwoven

fabrics by PadDry Cure method
Zinc Pyrithon is mainly non-ionic in nature
Bath pH : 5.0-5.5
Bath Temperature : 30-40 ºC
Drying Temperature : 160 ºC for 2 min

3.4. Needle Punched nonwoven fabric Development
Needle-punching process
Nonwovens are produced by using four steps  raw material preparation web
formation  web bonding  finishing.
Web bonding is important process which decides the characteristics of the

nonwovens fabric, Web bonding can be classified under five groups; mechanical
bonding i.e needle punching, spunlace or hydro entangling, thermal bonding and
chemical bonding. The orientation of the fiber is important parameter which
affects on nonwoven fabric properties. Nonwoven has emerged as one such
structure offering wide applications in different sectors. Needle punched non
woven is a structure produced by interlocking of fibres accomplished by
mechanical needles.
The fibrous webs, mainly bulky, are produced by processes through carding, and
cross-lapping. Needle punching is the mechanical bonding method in which, the
interlocking of fibre and intermingling of fibers will be done by means of barbed
needles.
In the needle-punching process, the mechanical interlocking will be done by
thousands of barbed needles repeatedly punching on web. The web of fibers will
be fed to the needle loom. In needle loom consists of feed rolls, finger plate,
needle boards, needles, bed plate, stripper plate, and pair of delivery rolls.
Bonding takes place on the nonwoven web by the penetration of the barbed needle
into the web layers. In process of they make upward and downward motions the
needles travels through the holes present on the bed plate and stripper plate in
between the web will be held.
The barbed needles mounted on a board, with the upward and downward stroke
punches the fibres into the web. The web is trapped between bed plate and stripper
plate while needling process. The needles enter and leave from the web which is
supported by bed plate & stripper plate helps to remove web from needles. The

web is pulled out through the needle loom by delivery rolls and given for
subsequent process. The primary component of needle punching process is barbed
needle. In order to provide better bonding and mingling effect, the needle, barbs
and working blades play important role to punch the fibres to form peg on the
structure of needle punched nonwovens the in web and provides the mechanical
properties to the structure. Fig 3.1. Shows the schematic diagram of needle loom
on which needle punch nonwoven fabric is manufactured.
Figure 3.1 -Needling process
The needle punched non woven prepared by passing through the following steps –
Figure 3.2 - Manufacturing process of nonwoven fabric

Feeding:
Fibres were opened and spread on the floor for the preparation of fibres for
carding. The fibres were fed to carding machine in predetermined quantity by
electric auto scale controlled system.
Carding:
Fibres were fed into the carding machine. There the fibres are opened by the wires
points of the series of rotating cylinders and get aligned in parallel direction
(machine direction).A web is formed on card, which further given by doffer to the
cross lapper.
Cross Lapping:
The fibres webs were cross lapped several times by cross lapper to increase the
strength in cross direction. The number of layers depends on required GSM,
thickness and uniformity of non woven fabric.
Web Feeding:
The layered web fibres formed on cross lapper will be delivered to needle
punching loom by means of web feeding device. The web feeding mechanism
protects the layered web from deformation.
Pre-Needling:
The fibres will be mainly fed through number of needle punching looms. The pre-
needle punching is done to interlock the fibres entangle fibres in various layers
using low needle density. The process of the pre-needling is an optional process
but this process mainly improves the quality and provides better mechanical
properties to the needle punched nonwovens. The pre-needling process reduces
the web thickness; the mechanical strength is also gets increased and more
uniform structure can be manufactured by pre- needling the fabric.
Needle Punching:
The pre punched web of fibres will be subjected to further finishing punching
through other needle punching looms placed in series. The fabric gets needle

punched successively to get the fabric. The Needle punch nonwoven fabric
manufacturing process have, lower cost of production, low bulk density, porous,
better absorbency, less stiffness and better thermal insulation. The tensile and
tearing strength normally will be more in cross direction as compared to the
machine direction and vice versa in case of elongation. Stiffness is normally more
in cross direction as compared to the machine direction. Bending length depends
on compactness of fabric; more compact fabric provides more bending length.
Abrasion loss will be more in nonwoven fabric because it was made merely by the
entanglement of the fibres without any subsequent finish like resin coating which
could make it more abrasion resistant.
The mechanical properties of the needle punched nonwoven felt or fabric are
many depends on the processing parameters on needle punching line like, the
number needles and the barbs present on needles, type of needle, the punch
density, needling speed , depth of penetration, strokes and fiber types are other
important parameters. One of the most significant attribute of the needle punched
nonwovens fabric is their high porosity and high pore size distributions. The good
air permeability is also important property of needle punched nonwoven fabrics
for the use in filtration. Better dimensional stability, liquid and gas permeability,
good drape ability, easy mold ability, good acoustic and excellent thermal
properties, excellent mechanical properties make needle punched nonwovens
suitable to be used in various technical textiles applications and major applications
are like automotive application for acoustic and insulation, building construction,
home furnishing applications, geo-textiles, shoe insoles, blankets, solid / liquid
filters, thermal insulation.
The polysters fibres will be used for manufacturing the needle punch nonwoven
fabric. Needlepunch nonwoven fabric will be manufactured by using three basic
process carding, web formation and web bonding. Needle punch nonwoven fabric
will be manufactured on Trutzschler Nonwoven Machine shown in figure.

Figure 3.3: Needle punching machine (Courtesy – DKTE CoE Nonwoven)

Table 3.1: Process parameters of needle punch machine

GSM
Sr. Machine Parameter

50 100 150 200 250
No
1 EBO Drop down weight(g) 1000 1000 1000 1000 800
2 Carding Weight (g/m2) 24 24 37 38 36
3 Cross laying No. of layer 5 9 7 10 14
Line speed 1.44 1.3 1.23 0.75 0.55

ENL D
4 Needle stroke 492 479 450 270 182
Needle density 122.2 124.1 124.1 140.8 150.8
Line speed 2.3 2.11 2.1 1 0.76

ENL U
5 Needle stroke 522 482 534 195 189
Needle density 175.8 177.6 162.3 179 185.1
3.5 Synthesis of zinc Pyrithone

The chemical reaction in the presence of inert dilute salts can be used to prepare
inorganic particles such as ZnO. This process is solvent-less green route to nano
particulate ZPT, which is mainly produced by reaction of solid salts in the solid
NaCl, as follows:
The reaction of Zinc chloride: (ZnCl2) with sodium pyrithione monohydrate
(NaPT.H2O) gives Zinc Pyrithone ZnPT ).
Zinc Pyrithoneis mainly nonionic material, was then diluted to get the different
strengths to apply on nonwoven fabrics by Pad  Dry  Cure

The strength of antimicrobial chemical was tested as per antimicrobial test and it
was found that 15 gpl was optimum chemical concentration to make the fabrics
antimicrobial.
Process parameters:
 Bath pH : 5.0-5.5
 Bath Temp. : 30-40 ºC
 Drying: 160 ºC for 2 min
Figure 3.4: padding mangle

3.6 Design of Experiment

We have used Randomized Block Design. Five different GSM with three levels of
the different chemical formulations will be made. The optimum level of the
chemical concentration will be made on the specific GSM of fabric to meet the
requirements of the application. The Needle punched Nonwovens with different
GSM (for different applications) will be developed by using combination of
various staple Polyester fibers of 1.5 D, 3D, 6D denier. The developed nonwovens
will be subjected to chemical finishing of antimicrobial agents to meet the
requirements of the various applications like in shoe insole, interlinings for jackets,
automotive AC filter fabrics, milk & beverage filtration application etc. Also an
attempt will be made to make inherent antimicrobial nonwoven by using inherent
antimicrobial fibers.
Table 3.2 : Number of samples by DOE

Sr.no. Sample GSM Chemical levels
Sample A1 50 GSM 5 gpl
1 Sample A2 50 GSM 10 gpl
Sample A3 50 GSM 15 gpl
Sample B1 100 GSM 5 gpl
2 Sample B2 100 GSM 10 gpl
Sample B3 100 GSM 15 gpl
Sample C1 150 GSM 5 gpl
3 Sample C2 150 GSM 10 gpl
Sample C3 150 GSM 15 gpl
Sample D1 200 GSM 5 gpl
4 Sample D2 200 GSM 10 gpl
Sample D3 200 GSM 15 gpl
Sample E1 250 GSM 5 gpl
5 Sample E2 250 GSM 10 gpl
Sample E3 250 GSM 15 gpl

3.7 Testing
Initially we conducted some tests as per the ASTM standards to know the actual
fabric properties are as follows-
Table 3.3: Testing required
Sr. No. Testing parameter ASTM Standard & Instrument
1 Fiber Denier Microscopic method
2 Fiber Length ASTM D 3822 – 14 Grease plate technique
3 GSM ASTM 6242 (1 cm X 10cm fabric )
4 Thickness D5729-95 Digital Thickness Gauge
5 Air permeability ASTM D737-04 (TEXTEST FX3300 )
6 Strength ASTM C-1557 - Instron tensile tester
7 Tearing Strength ASTM D5035-95
8. Bursting Strength ASTM D3786 – 13
9. Antimicrobial reduction rate in the number of colonies
property (AATCC 100)
TESTING CARRIED OUT

The experimental tests have been achieved in the D.K.T.E’s center of excellence
(CoE) in nonwoven and D.K.T.E’s Physics lab. In order to study on nonwoven
fabric for air filter application, physical properties of needle-punch nonwoven
fabric samples & thermal bonded nonwoven fabric samples the following tests
were carried out.

3.7.1 Denier
The fiber denier calculated by using micron value. The micron value determines by
using microscope to get a diameter of the fiber in micron. The microscope is
shown in figure 3.5.
Figure 3.5: Microscope for diameter measurement
3.7.2 Fiber Length

As per ASTM D 3822 determine the fiber length using grease plate methods.
3.7.3 Fabric GSM
The nonwoven fabric GSM, calculated as per ASTM 6242 standards, i.e. mass per
unit area (areal density in grams per square meter). The specimen of the size 10X
10 cm was cut randomly from different places and weighted in electronic balance
with an accuracy of 0.001 g and an average of 5 readings was taken.
3.7.4 Fabric Thickness
Fabric thicknesses nonwoven fabrics were tested on fabric thickness tester

according to standard ASTM D5729 by using Digital Thickness Gauge – SDLATL
ATLAS (figure 3.6).

Figure 3.6: Digital Thickness tester
3.7.5 Air Permeability of Fabric
The air permeability of nonwoven fabric was tested by standard ASTM D737-04
test method on TEXTEST FX3300 air permeability tester (figure 3.7). The area for
testing was 38 cm2 and the applied pressure was 125 Pa. The air permeability of a
fabric is the volume of air measured in cm3 passed per second through 1 square
centimeter area of the fabric at a pressure of 1cm of water.
Figure 3.7: Air permeability tester

3.7.6 Tensile Strength (tensile strain at break %)

The tensile strength of nonwoven fabrics was tested on INSTRON TESTER
according to ASTM D5035-95 Standard, with 200 mm gauge length and speed
500mm/min. In the tests the samples of size 200x50 mm are placed between two
jaws. Ten readings were taken for each sample in both cross as well as machine
direction.
Figure 3.8 Tensile strength test
3.7.7 Tearing Strength (tear resistance)

The tear strength of treated nonwoven fabrics was tested according to standard
DIN-53128 methods. Tear strength was measured by Digital tearing strength tester
ESDEN LAB Italy. The fabrics sample size is 10 cm in length and 6.3 cm in width.
At the middle of the sample there is notch, where a notch with 2 cm in length was
produced. During the testing, this sample mounted in the sample holder and the
tear strength recorded while the pendulum falling down to tear the fabric sample.
Both machine as well as in cross direction the tear test was carried out.

Figure 3.9 Tearing strength test
3.7.8 Bursting Strength (bursting pressure)

Bursting Strength of nonwoven fabric is also a very important property. The test
for both treated as well as untreated needle-punch nonwoven fabric was carried out
on Digital Bursting strength tester AUTOBURST machine as per ASTM D3786 –
13. The fabric was placed over the holder and the motor was started, which bulged
the diaphragm outside towards the fabric and ultimately it burst the fabric. At this
time the reading was noted in Pa.
Figure 3.10 Bursting strength test

3.7.9 Antimicrobial property

Test was performed by AATCC-100 test method – for testing of Antibacterial
property of the fabric: Assessment
This is mainly a quantitative method for the testing of of degree of antibacterial
activity on fabrics.
Figure 3.11 AATCC-100 - Antibacterial Finishes on Textile Materials
The contact time selected for the test would be effective in significantly reducing
microbial counts during application.
This test is performed both with treated and untreated samples of the test material.
According to the AATCC 100 test method, 1 ml of microbial suspension at about
1000,000 CFU/ml will be inoculated on the fabric test specimen.
At a given time, bacteria’s are extracted with the help of a diluted neutralizer
medium.

This method is used mainly to test both bacteriostatic activity (inhibition of

multiplication) and bactericidal activity (killing of bacteria).
The hydrophobic characteristic of fabrics can affect the antimicrobial activity of
the textile material obtained by the AATCC 100 test method. Bacterial culture used
in this method: Klebsiella pneumoniae and Staphylococcus aureus.

CHAPTER 4
RESULT AND DISCUSSION
4. Introduction
The experimentation of this work was conducted as per the plan of work shown in
chapter 3. As per plan, various GSM of needle punch nonwoven samples are
manufactured on Truzschler nonwoven machine using 100% polyester fibres. The
manufactured needle punch nonwoven fabrics were treated chemically to make it
antimicrobial. The strength of antimicrobial chemical was tested as per
antimicrobial test and it was found that 15 gpl was optimum chemical
concentration to make the fabrics antimicrobial.
The fabric samples tested for various characteristics as per the ASTM standards.
4.1 Physical testing of fiber:
Needles punch fabrics, made up with 1.5D, 3D, 6D 100 % PET fiber. By using
above nonwoven technology various samples were produced with different GSM.
The table no.4.1 shows the properties of fibers used.
Table 4.1 - Properties of fibre
Sr.No Material Denier Staple Length

1 Polyester 1.5D 64 mm
2 Polyester 3D 64 mm
3 Polyester 6D 64 mm
4 PET Low melt 4D 51 mm
Figure 4.1 staple fibres

4.2. Grams per Square Meter (GSM) of Needle punch nonwoven fabrics
The nonwoven fabric GSM, calculated as per ASTM 6242 standards, i.e. mass per
unit area (areal density in grams per square meter).The specimen of the size 10X
10 cm was cut randomly from different places and weighted in electronic balance
with an accuracy of 0.001 g and an average of 5 readings was taken.
Table 4.2 Grams per Square Meter (GSM) of Needle punch nonwoven fabric
Sr. GSM of Nonwoven Fabric

% Difference
no. Sample untreated treated
A1 51.02 55.87 8.68
1 A2 51.7 57.71 10.41
A3 51.5 59.71 13.75
B1 101.02 107.65 6.16
2 B2 102.1 113.35 9.93
B3 101.08 120.13 15.86
C1 151.2 164.21 7.92
3 C2 153.6 173.14 11.29
C3 152.8 183.21 16.60
D1 204.04 226.14 9.77
4 D2 203.15 237.29 14.39
D3 202.84 249.31 18.64
E1 254.01 278.13 8.67
5 E2 253.12 283.15 10.61
E3 253.26 294.21 13.92

350
300
250
200
Axis Title
150
100
50
0
A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3
treated 51.02 51.7 51.5 101.0 102.1 101.0 151.2 153.6 152.8 204.0 203.1 202.8 254.0 253.1 253.2
untreated 55.87 57.71 59.71 107.6 113.3 120.1 164.2 173.1 183.2 226.1 237.2 249.3 278.1 283.1 294.2
Figure 4.2 Grams per Square Meter (GSM) of Needle punch nonwoven fabric
4.3. Thickness of Needle punch nonwoven fabrics
Fabric thickness is an important quality of fabric. It is an important determinant of

many fabric parameters and properties e.g. cover factor, porosity, air permeability
etc. and it gives information on its warmth, heaviness of/or stiffness in use. In
practice the thickness measurements are rarely used as they are very sensitive to
the pressure used in the measurement. Averages of 15 readings of thickness for
each sample are considered in Table 4.3.
Table 4.3 Thickness (mm) of Needle punch nonwoven fabrics
Sr. Thickness of Nonwoven Fabric in mm

% Difference
A1 0.81 0.78 3.70
1 A2 0.83 0.80 3.61
A3 0.80 0.78 2.50
B1 1.02 0.97 4.90

2
B2 1.09 1.01 7.34

B3 1.06 0.98 7.55
C1 1.20 1.15 4.17
3 C2 1.22 1.17 4.10
C3 1.19 1.13 5.04
D1 1.43 1.35 5.59
4 D2 1.39 1.32 5.04
D3 1.40 1.34 4.29
E1 1.71 1.59 7.02
5 E2 1.77 1.62 8.47
E3 1.68 1.59 5.36
2
1.8
1.6
1.4
1.2
Axis Title
1
0.8
0.6
0.4
0.2
0
Treated 0.81 0.83 0.8 1.02 1.09 1.06 1.2 1.22 1.19 1.43 1.39 1.4 1.71 1.77 1.68
Untreated 0.78 0.8 0.78 0.97 1.01 0.98 1.15 1.17 1.13 1.35 1.32 1.34 1.59 1.62 1.59
Figure 4.3.Thickness (mm) of Needle punch nonwoven fabrics
4.4. Tensile Strength of Needle punch nonwoven fabrics

From the following Table & Figure, we can conclude that after antimicrobial
treatment the tensile strength of needle punch nonwoven fabric decrease in both
machine as well as cross direction.

These results may be because of the low melt fibers in the fabric melts after drying
process due to this they are unable to contribute to the strength of the fabric.
From the statistical analysis of the data we can conclude that antimicrobial
treatment affects on the tensile strength of needle punch nonwoven fabric in both
machine and cross direction but the difference is insignificant.
Table 4.4 Tensile Strength (N) in Machine Direction of Needle punch nonwoven
Sr. MD Tensile strength of Nonwoven Fabric (N)

% Difference
no. Sample Treated Untreated
A1 174.15 167.13 4.03
1 A2 172.04 165.9 3.57
A3 171.39 162.59 5.14
B1 258.00 249.75 3.20
2 B2 256.38 245.3 4.32
B3 259.10 246.28 4.95
C1 381.03 366.47 3.82
3 C2 388.76 370.04 4.82
C3 387.66 369.78 4.61
D1 445.87 423.17 5.09
4 D2 447.54 421.89 5.73
D3 446.55 426.1 4.58
E1 510.45 488.9 4.22
5 E2 509.87 484.79 4.92
E3 511.15 490.48 4.04

600
500
400
Axis Title
300
200
100
0
Treated 167.1 165.9 162.5 249.7 245.3 246.2 366.4 370.0 369.7 423.1 421.8 426.1 488.9 484.7 490.4
Untreated 174.1 172.0 171.3 258.0 256.3 259.1 381.0 388.7 387.6 445.8 447.5 446.5 510.4 509.8 511.1
Figure 4.4 - Tensile Strength (N) in MD of Needle punch Nonwoven Fabrics
Table 4.5 Tensile Strength (N) in cross direction of Needle punch nonwoven
Sr. CD Tensile strength of Nonwoven Fabric (N)

% Difference
no. Sample Treated Untreated
A1 294.32 287.16 2.43
A2 293.40 284.32 3.09

1
A3 294.10 283.15 3.72
B1 368.34 356.64 3.18
2 B2 370.12 358.16 3.23
B3 369.34 360.17 2.48
C1 432.15 421.89 2.37
3 C2 436.87 426.1 2.47
C3 438.56 424.88 3.12
4 D1 576.12 559.57 2.87

D2 579.23 564.98 2.46
D3 572.36 566.55 1.02
E1 742.01 730.82 1.51
5 E2 744.56 735.64 1.20
E3 738.12 728.65 1.28
800
700
600
500
Axis Title
400
300
200
100
0
Treated 287.1 284.3 283.1 356.6 358.1 360.1 421.8 426.1 424.8 559.5 564.9 566.5 730.8 735.6 728.6
Untreated 294.3 293.4 294.1 368.3 370.1 369.3 432.1 436.8 438.5 576.1 579.2 572.3 742.0 744.5 738.1
Figure 4.5 - Tensile Strength (N) in CD of Needle punch Nonwoven Fabrics
4.5. Tearing Strength of Needle punch nonwoven fabrics

From the following Table & Figure, it is clear that after antimicrobial treatment
tearing strength of needle punch nonwoven fabric decreases.
Due to the pad – dry – cure process the fabrics are subjected to the heat while
drying & curing that may lead to breaking of the thermally fused low melt fibre
bonding with the regular polyester fibres. That reduces the contribution to bonds to
the tearing strength.

From the statistical analysis of the data we can conclude that antimicrobial
chemical treatment affects on the tearing strength of needle punch nonwoven fabric
in both machine and cross direction but the difference is insignificant.
Table 4.6 Tearing Strength- Tear Resistance in Machine direction (N) of

Needle punch nonwoven
Sr. Tear Resistance in Machine Direction (N)

Untreated treated % Difference
no. Sample
A1 37.11 34.90 -6.34
1 A2 38.45 36.22 -6.16
A3 35.12 32.60 -7.73
B1 43.54 40.66 -7.08
2 B2 42.12 39.12 -7.67
B3 44.45 41.89 -6.11
C1 48.12 45.12 -6.65
3 C2 46.63 43.25 -7.82
C3 49.36 45.97 -7.37
D1 56.58 52.36 -8.06
4 D2 55.11 51.39 -7.24
D3 58.39 54.32 -7.49
E1 66.36 62.40 -6.35
5 E2 69.33 64.78 -7.02
E3 63.79 58.96 -8.19

80
70
60
50
Axis Title
40
30
20
10
0
Treated 37.1 38.4 35.1 43.5 42.1 44.4 48.1 46.6 49.3 56.5 55.1 58.3 66.3 69.3 63.7
Untreated 34.9 36.2 32.6 40.6 39.1 41.8 43.1 42.5 44.2 52.3 51.3 52.3 62.4 61.2 58.9
Figure 4.6 Tear Resistance in Machine Direction of Needle punch nonwoven
Table 4.7 Tear Resistance in Cross Direction (N) of Needle punch nonwoven
Sr. Tear Resistance in Cross Direction (N)

% Difference
A1 37.11 34.90 -6.34
1 A2 38.45 36.22 -6.16
A3 35.12 32.60 -7.73
B1 43.54 40.66 -7.08
2 B2 42.12 39.12 -7.67
B3 44.45 41.89 -6.11
C1 48.12 45.12 -6.65
3 C2 46.63 43.25 -7.82
C3 49.36 45.97 -7.37
4 D1 56.58 52.36 -8.06

D2 55.11 51.39 -7.24
D3 58.39 54.32 -7.49
E1 66.36 62.40 -6.35
5 E2 69.33 64.78 -7.02
E3 63.79 58.96 -8.19
90
80
70
60
Axis Title
50
40
30
20
10
0
Treated 57.9 56.3 59.5 62.9 62.3 63.5 66.1 65.3 66.9 69.5 71.5 70.2 74.6 76.7 75.1
Untreated 54.9 53.2 56.6 59.6 58.4 60.8 63.1 63.2 63.9 66.3 69.3 67.3 71.4 72.7 71.9
Figure 4.7 - Tearing strength-Tears Resistance in Cross Direction of Needle

punch nonwoven fabrics
4.6. Bursting Strength of Needle punch nonwoven fabrics

From the following Table & Figure, we can conclude that bursting strength of
needle-punch nonwoven fabric decreases after antimicrobial treatment. This may
be due to the pad – dry – cure process the fabrics are subjected to the heat while
drying & curing that may lead to breaking of the thermally fused low melt fibre
bonding with the regular polyester fibres. That reduces the contribution to bonds to
the tearing strength.

From the statistical analysis of the data we can conclude that chemical treatment
affects on the bursting strength of needle punch nonwoven fabric but the difference
is insignificant.
Table 4.8 -Bursting strength-bursting pressure (kPa) of Needle punch nonwoven fabrics
Sr. Bursting strength-bursting pressure (kPa)

% Difference
A1 287.95 283.95 -1.41
1 A2 284.26 281.26 -1.07
A3 285.69 281.69 -1.42
B1 367.63 363.63 -1.10
2 B2 362.3 357.3 -1.40
B3 363.54 359.54 -1.11
C1 410.78 405.23 -1.37
3 C2 412.36 408.12 -1.04
C3 414.59 409.56 -1.23
D1 533.48 525.48 -1.52
4 D2 548.54 538.54 -1.86
D3 545.98 538.98 -1.30
E1 594.83 587.83 -1.19
5 E2 590.21 584.21 -1.03
E3 592.65 585.65 -1.20

700
600
500
Axis Title
400
300
200
100
0
Series1 287.9 284.2 285.6 367.6 362.3 363.5 410.7 412.3 414.5 533.4 548.5 545.9 594.8 590.2 592.6
Series2 283.9 281.2 281.6 363.6 357.3 359.5 405.2 408.1 409.5 525.4 538.5 538.9 587.8 584.2 585.6
Figure 4.8 - Bursting Strength- Bursting pressure (kPa) of Needlepunch

nonwoven fabrics
4.7 Antimicrobial property: AATCC-100
Figure 4.9: Assessment of antibacterial textiles - AATCC TM100; Untreated

(left) and treated (right) textile sample

Figure 4.10: Assessment of antibacterial textiles - AATCC TM100; Untreated

(left) and treated (right) textile sample

CHAPTER 5
CONCLUSION AND FUTURE SCOPE
5.1 Conclusion
The synthesized zinc pyrithone based antimicrobial needle punched nonwoven

fabrics were developed and based on the statistical results and significantly proved
by using ANOVA with regression for both untreated and antimicrobial treated
nonwoven fabric. Following conclusion can be drown based on the results,
 Zinc Pyrithone can be synthesized and formulations can be made for

applications on nonwovens.
 After antimicrobial chemical treatment the gram square meter (GSM) of needle-
punch nonwoven fabric increases with reference to the add-on of chemical but
the difference is not significant.
 The thickness of needle-punch nonwoven fabric decreases significantly due to
Pad  Dry  Cure process. Due to nipping arrangement in pad – dry – cure
process, the thickness of needle punched nonwovens reduces.
 After antimicrobial treatment the tensile strength, tearing strength & bursting
strength of needle-punch nonwoven fabric in machine and cross direction
decreases but the difference is not significant.
 The mechanical properties of the nonwoven fabric do not get affected
significantly, that makes this Zinc Pyrithone based chemical suitable for the
treatment on polyester fibre.
 Zinc Pyrithone based chemicals can be used as a cost effective chemical to
make the nonwovens antimicrobial for various applications.

5.2 Future Scope
 The properties of the nonwoven fabric do not get affected significantly, that
makes this Zinc Pyrithone based chemical suitable for the treatment on
polyester fibre.
 Further this chemical can be used as a low cost & feasible solution for
making fabrics suitable for various applications like in Geo-textiles, medical
textiles etc.

CHAPTER 6
REFERENCES
1. https://www.edana.org/discover-nonwovens/what-are-nonwovens. Retrieved on
07/07/2019
2. R.L.Gotipamul, P.M.katkar, S S. Borikar, Prospects of nonwovens in apparel
industry, Indian Textile Journal, December, 2012.
http://www.indiantextilejournal.com/articles/FAdetails.asp?id=4864. Retrieved
on 08/07/2019
3. Russell SJ (2006) Handbook of nonwovens. Woodhead Publishing Series: 544
4. International Nonwoven Journal, Volume 8 No. 2,1999.
https://www.jeffjournal.org/INJ/inj99_1.pdf
5. European Committee for Standardization. EN 13537, ―Requirements for
Sleeping bags‖. Brussels: CEN,July 2002.
6. https://ultra-fresh.com/antimicrobial-applications/antimicrobial-fabric-
treatment/Retrieved on 08/07/2019
7. Shalaby, Saad, M., Balakocy, N., Ibrahium, Establishment of Technological
Package for Production of Antimicrobial PET and PA Nonwoven Fabrics on
Pilot Scale, International Journal of Engineering Research and Technology.
ISSN 0974-3154 Volume 11, Number 6 (2018), pp. 867-880
8. R. Rathinamurthy and G. Thilgavathi, Effect of Antimicrobial Finish on Odor
Control Properties of Apparel Fabric, JTATM, Vol.9, Issue –I, 2014
DKTE Society’s Textile and Engineering Institute, Ichalkaranji. Page 45

9. http://www.aegisasia.com/wp,content/uploads/how_antimicrobial_treatment_ca
n_improve.pdf Retrieved on 08/07/2019
10. S. Radika, P.Deepika Nandhini, K. Archana, Design and Development of Shoe
Insole for Diabetic Patients, International Journal of Innovative Research in
Science, Engineering and Technology, Vol. 3, Issue 4, April 2014, Page 11535-
11541
11. Fatma RANGCHI, Simultaneous antimicrobial, water and blood repellent
finishing of disposal nonwovens using ctab and fluorochemical, TEKSTIL ve
KONFEKSIYON 2/2009, Page 128-132.
12. Prasad Upasani, T.V. Sreekumar, V.G. Gaikar, Neetu Jha, Preparation of
ZnO/MWCNT/PP Composite Film and its Application as Multifunctional
Protective Film, POLYMER COMPOSITES—2016, 1-14
13. Prasad Upasani, T V Sreekumar, V G Gaikar and Neetu Jha, Preparation of
ZnO nano ribbon–MWCNT composite film and its application as antimicrobial
bandage, antibacterial filter and thermal IR camouflage material, Bull. Mater.
Sci., Vol. 40, No. 4, August 2017, pp. 865–876
14. http://www. SurfMod5-abs.html. Retrieved on 08/07/2019
15. Liquid concentrate for the preservation of cosmetic and pharmaceutical
productshttps://patentimages.storage.googleapis.com/af/90/ab/4bbb7667aedf63/
EP1393713B1.pdf. Retrieved on 08/07/2019

16. HoonJoo Lee, Sung HoonJeong, Bacteriostasis of Nanosized Colloidal Silver
on Polyester Nonwovens, TRJ, Volume: 74 issue: 5, page(s): 442-447, Issue
published: May 1, 2004
17. http://www.Nano silver fights infections.htm. Retrieved on 09/07/2019
18. http://www.physorg.com. Retrieved on 09/07/2019
19. http://www.Nano Silver kills microbes - EPA up in Arms - Health Supreme.htm
Retrieved on 08/07/2019
20. http://www.Stabilizing antimicrobial nanosilver on a natural porous plant
material.htmRetrieved on 09/07/2019

CHAPTER 7
PAPER PUBLICATION
Earlier Paper Published if any
Sr. No Paper Journal Status

1 Antimicrobial International Published in ,
Nonwoven Technical Journal for International
Textiles Scientific Research Journal for
& Development Scientific Research
(IJSRD) & Development
(IJSRD), Volume
.07, Issue 12, March
2020, Pages: 908-
910
2 Development of International under publication
Antimicrobial needle Journal for
punched Nonwovens Scientific Research
for Technical Textiles & Development
applications (IJSRD)

CHAPTER: ANNEXURE – I
Anova: Single Factor for GSM
SUMMARY
Groups Count Sum Average Variance
Column 1 15 2286.44 152.4293 5488.162
Column 2 15 2603.21 173.5473 7236.025
ANOVA
Source of Variation SS df MS F P-value F crit
Between Groups 3344.774 1 3344.774 0.525735 0.474422 4.195972
Within Groups 178138.6 28 6362.093
Total 181483.4 29

Anova: Single Factor for Thickness
SUMMARY
Column 1 15 18.6 1.24 0.102429
Column 2 15 17.58 1.172 0.08456
ANOVA
Between Groups 0.03468 1 0.03468 0.370932 0.547407 4.195972
Within Groups 2.61784 28 0.093494
Total 2.65252 29

Anova: Single Factor for Tensile Strength (MD)
SUMMARY
Column 1 15 5319.945 354.663 16345.83
Column 2 15 5078.57 338.5713 14774.36
ANOVA
Between Groups 1942.056 1 1942.056 0.12481 0.726521 4.195972
Within Groups 435682.6 28 15560.09
Total 437624.7 29

Anova: Single Factor for Tensile Strength (CD)
SUMMARY
Column 1 15 7249.603 483.3069 27087.89
Column 2 15 7088.68 472.5787 27019.79
ANOVA
Between Groups 863.2071 1 863.2071 0.031907 0.859518 4.195972
Within Groups 757507.5 28 27053.84
Total 758370.7 29

Anova: Single Factor for Tearing Strength (MD)
SUMMARY
Column 1 15 754.46 50.29733 117.2025
Column 2 15 703.9349 46.92899 101.0557
ANOVA
Between Groups 85.09286 1 85.09286 0.779745 0.384738 4.195972
Within Groups 3055.616 28 109.1291
Total 3140.709 29

Anova: Single Factor for Tearing Strength (CD)
SUMMARY
Column 1 15 998.91 66.594 40.05003
Column 2 15 953.2749 63.55166 39.43681
ANOVA
Between Groups 69.41875 1 69.41875 1.746673 0.196993 4.195972
Within Groups 1112.816 28 39.74342
Total 1182.234 29

Anova: Single Factor for Bursting strength
SUMMARY
Column 1 15 6594.79 439.6527 13725.49
Column 2 15 6510.97 434.0647 13361.37
ANOVA
Between Groups 234.1931 1 234.1931 0.017292 0.896321 4.195972
Within Groups 379215.9 28 13543.43
Total 379450.1 29

Research student Guide Dissertation Committee Chairman
Director H.O.D.

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Development of Antimicrobial Needle Punched Nonwoven Fabric For Various Technical Applications

The demand for high performance textiles is continuously increasing, regardless of

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 1

1.2 Problem statement based on Literature

1. To synthesize Zinc Oxide / Zinc Pyrithone

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 2

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 3

 Household: towels, bedding, upholstery, carpets, curtains, pillows etc.

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 4

 Health & hygiene : masks, window coverings, beddings, air filters

Shalaby, S.E, et.al, carried out an experiment establishment of technological

2.2 Active Ingredients Used for Antimicrobial Fabric Treatment

In general, functional finishes usually need to be more durable than normally

Chemical agents are generally used to control the growth of microorganisms on

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 5

2.3 Antibacterial Fabric

2.4 Antifungal Fabric

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 6

2.5 Applications of Antimicrobial Nonwovens fabrics

2.5.3 Filtration: Filtration media normally prone to be a potential surface

2.5.4 Building & construction:

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 7

2.5.5 Baby Diapers/Adult Incontinence Pads:

Other Applications of antimicrobial nonwovens are,

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 8

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 9

Chemical agents are generally used to control the growth of microorganisms on

With this development of antimicrobial nonwovens a bacterial development over

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 10

of nonwoven can be addressed easily. (Applications of nonwovens like, jackets

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 11

The objective of present research work is to explore the possibility of application

1 Selection of Raw Materials.

2 Synthesize of Zinc Oxides / Pyrithione

3 Development of nonwoven fabric byusing needle punching technique.

4 Testing of nonwoven fabric

5 Development of the antimicrobial nonwoven by pad – dry – cure method

6 Testing of developed nonwoven

7 Performance assessment and checking suitability for the desired application

8 Use ANOVA technique for analysis of results

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 12

Selection of Raw Material

Testing of Raw Material Properties

Synthesize Zinc Oxides / Pyrithione

Development of nonwoven fabric by needle punching technique &

Testing of developed product for performance characteristics

Result and Discussion

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 13

a. Polyester staple fibre –

Polyethylene terephethalate is preferred textile fiber in many durable applications

b. Modified/ inherent antimicrobial fibres:

From RIL, Mumbai (Only for comparison of cost & performance)

d. Method of application of antimicrobial chemical

Zinc Pyrithone is diluted to get the different strengths to apply on nonwoven

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 14

3.4. Needle Punched nonwoven fabric Development

Web bonding is important process which decides the characteristics of the

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 15

Figure 3.1 -Needling process

Figure 3.2 - Manufacturing process of nonwoven fabric

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 16

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 17

DKTE Society’s TEI Ichalkaranji M.Tech. Textiles _S Y _June 2020 Page 18