1

UTTAR PRADESH TEXTILE TECHNOLOGY INSTITUTE

SOUTERGANJ, KANPUR (UTTAR PRADESH)
(Earlier known as Government central textile Institute)

A
Training Report
On
Fabric Wet Processing Machine & Process
(MI industries Private Limited , Aligarh Uttar Pradesh)

Submitted to: Submitted by:

Prof. Rakesh Kumar Srivastava Vishal Singh(Textile Chemistry)
(Textile Chemistry Department) 3rd Semester (2100440609004)

Department Of Textile Chemistry

(UPTTI KANPUR)
2021-22
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Preface

Training in business organization infuses among students a sense of critical analysis of the
real managerial situation to which they are exposed. My institution has given me opportunity
through this program to be aware of and cope with fast rate changing technology,
management policies, quality and productivity. This is a bold attempt to bridge the gap
between the “world of work” and “studies imparted in the institution”.
This training enable us to apply theoretical knowledge to practical situations, appreciate the
sense of responsibility, importance of discipline, punctuality and the psychology of a worker
and their habits which make us more professional and near to the world of technology and
team work. Industrial training bring out better citizens, better technocrats and better
diplomats out of us.
We were lucky to get an opportunity to work in one of the premier private sector industries,
i.e. MI INDUSTRIES PVT LIMITED ALIGARH The purpose of this training is to gain knowledge
about the industry, methodology, procedures, norms, and also to see the environment of the
industry. I have also focused during the training period on learning about machineries
installed, processing, mechanism and construction of processing devices. We have attempted
to describe both the mechanical and process parameters, as well as the underlying chemistry
behind each process. The major focus in describing the underlying chemistry is the
fiber/chemical interaction; however, where possible, I have provided a brief review of the
appropriate chemistry behind the various classes of chemical auxiliaries. Each part of the
book is subdivided into a part that describes equipment and a part that describes unit
operations. Some attempt is made to describe the stages in sequence, one that a typical
greige fabric may follow. Each dye house has its own character, depending largely on the type
of equipment and type of fabric it processes.
Fabric preparation has been subdivided into singeing, desizing, scouring, bleaching,
mercerizing, and heat setting. Further dyeing of fabric is covered with optimum parameters.
Finishing is broken down into chemical and mechanical. Chemical finishing covers those
treatments that alter the performance of the textile fabric where the chemical is the major
component of the change. Mechanical finishing refers to certain types of mechanical devices
that physically alters the fabric.
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Acknowledgement

We extend our heartfelt gratitude to MI INDUSTRIES PVT LIMITED ALIGARH for recruiting us
in this illustrious Summer Training Program. I Have worked in the concern of 45 days and
prepared my industrial training Report. Under the guidance of training officers, I analyzed
various aspects of Production. This has helped in boosting up my confidence and
determination, Which will help me to face any situation in years to come. FOUR WEEKS
(28Days) training was a great venture where we were reincarnated as a technical Novice. We
were really thankful to all the staff members and working hands in the mill who helped us
generously and assisted us through every bottleneck Guiding us to attain a dexterous
knowledge in textile dyeing sector.We also feel sincere and earnest appreciation for valued
supervision and Guidance from:

Mr. Sanjay katiyar

Mr. Balkrishna panigrahi
Mr. Amarnath chaturvedi
Mr. Sunil shukla
Mr. Rahul pandey
Mr. Masum reza
Mr Ganga prashad mehata
Mr. D.N. Mandal
Mr. S.S. Tiwari

Moreover, we thank Mr. Aditya Prakash to be supportive and nurturing throughout the
training
program.
We finally thank you Mr. ASHUTOSH SHUKLA(Unit Head) for helping us during the whole
journey.

Thanking You. MI Industries Aligarh

(UTTAR PRADESH)
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INTRODUCTION

MI Fabrics was established with the sole idea of delivering the

highest quality fabric for the upper-segment of the garment
industry. The ultra-modern textile mill has the ability to
deliver fabrics including cotton, viscose, modal, polyester,
spandex, tencel, and blends. MI focuses on having the leading
men, machinery, & material to achieve our goal of highest
quality fabrics. Our focus on quality control and assurance
while manufacturing ensures that we manufacture high
quality products while reducing defects at the source.
MI Fabrics’ textile products include bleached, dyed, and
printed
fabrics. Our extensive infrastructure and technical team
enables us to manufacture diversified textile products. Our
research and development facilities with a constant focus on
improvement ensures that our quality standards stay up
todate allowing us to stay ahead of the quality curve.

Our production processes, standard operating practices, and

quality assurance is aligned to manufacture quality fabric
every time. MI Fabrics stateof the art sampling and testing
facilities provides good sample to bulk Reproducibility.
Further, highly controlled procedures enable bulk
Reproducibility time and time again. Our NABL certified
physical & wet laboratory ensure standardized result Testing.
Strong testing procedures and the latest testing equipment
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ensure That our results correlate with other independent

testing facilities.

Context

Departments.
1. Grey fabric
2. Bleaching
 Singeing
 Desizing
 Scouring
 Bleaching
3.Mercerization
4.Dyeing
5.Finishing
6.Dyeing Lab
7.Physical lab.

MI INDUSTRIES CERTIFICATION
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Major areas of process & quality control in wet processing

- Grey Inspection.
- Singeing.
- Desizing. Raw Materials Processed Materials
- Scouring.
- Bleaching.
- Mercerizing.
- Dyeing.
- Printing.
- Finishing.
- Final Inspection.
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SINGEING OPERATIONS

Object: To remove loose and hairy fibre.

To obtain a smooth surface.
In order to import a clearly define & sharp design.
To improve better appreance.

Machine Name: Singeing Machine.

Make : osthoff Senge

ABOUT OSTHOFF SENGE-

 Osthoff singer is equipped with 2 double jet burners , to
singe both side in one pass.
 Heating medium all types of gas.
 Flame intensity adjustable in a wide range.
 Distance flame fabric steplessly adjustable.
 Singeing parameters to be set manually or program
controlled .
 Slow and high speed system.
 Brushing system.
 Computer touch control display.
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Key Features :
 Applicable for different types of fabric.
 Sequencing unit.
 Automatic flame width adjustment.
 Four singeing positions, centreing devices, flat rollers,
counter rotating scroll rolls.
 Double-jet burner.
 Complete PLC machine with chemical dosing.
 Comes with an optical scanning device
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Check point Required Check Durations

Gas Pressure 2 kg -3kg Daily every lot
Air Pressure 2 kg-3 kg Daily every lot
Guider Pressure 0.5- 2 bar On every lot
Water Daily

Details of singeing m/c

Osthoff Senge
42327 Wuppertal Germany
Bj 2014
Mod:- VP99-H
No:-7186
Serial No:- 6899
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DESIZING UNIT

Osthoff Senge (Singeing cum Desizing Range)

Object Of Desizing:

To process to remove the size material applied in weaving section and increase the
absorbency power of the fabric is called resizing.

PROCESS DESCRIPTION OF MACHINE:

1.Fabric inlet section- grey fabric are directly feed into the inlet of singeing machine
where the fabric is passed over some free roller guider and expended to ensure open
width with entry here there is a controller pannel to control fabric speed.

2.Cleaning unit -1: fabric passed in cleaning unit fabric cleaned by brusher .
3.Singeing unit:after passing cleaning unit then fabric comes into contect of flame for
4.Cleaning unit 2: after singeing unit then fabric comes into brushing for cleaning .
5.Desizing unit: finally the fabric is passed thow desizing unit it’s content dezinging
liqour for desizing wetting agent squesting agent enzyme acetic acid is required.
After desizing fabric comes into batching unit & rotation for 8-12 hour.

Chemical for desizing

Enzyme: enzyme can make soluble the sizing chemical in Water.

Wetting agent: it is use to increase the wettibility of textile Substrate & dye in water is
easy to penitration and obtain smooth Paste.
Sequesting: It is used to minimize the impact of hardness of the Water.
Soaping agent: it is used to antifomic agent and increase the penetration of wetting
agent.

Chemical Name (in market)

Felosan RGN – detergent

BEIXON Q. – sequesting,Despersing agent
BEISOL SED. – desing agent, enzymes
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BEISOL PR0. – Enzyme

How to test desized material (Starch based size):

To test the presense of sizing material i.e starch based sizing material in the fabric
iodine test is conducted. In which the fabric is spotted or treated with  Iodine solution
Iodine dissolved in an aqueous solution of potassium iodide, which reacts with the
starch and produce a bluish-purple-black colour. If there is no starch the colour may be
brownish-yellowish.  In the below figure, it is explained that if the iodine solution is
added in the solution ( which you want to know whether there is a starch or not) if there
is a starch then you may get purple/bluish colur solution. If there is no starch the colour
remain same. 

TEGEWA solution is also used for the identification of starch.  For making this solution
potassium iodide 10 g of KI (100%) in 100 ml of water is added with 0.6358 g of iodine
(100%) and shake this well to disslove iodine crystals. Then make it up to 800 ml using
distilled water and finally make it up to 1000 ml with ethanol.

Factors of Size removal Efficiency :

 Type and amount of size applied.
 Viscosity of the size in solution.
 Ease of dissolution of the size film on the yarn.
 Nature and the amount of the plasticizers.
 Fabric construction.
 Method of desizing, and.
 Method of washing-off.

Some Sizing Materials :

Starch: Corn,
Potato,
Sago,
CMC (Carbon Methyl Cellulose),
CMS (Carbon Methyl Starch)
Natural gums: Locust bean,
Tragacanth .
Synthetic sizes: PVA,
PAN,
PVAC, etc.
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Classification of Enzyme :

Mainly two types of enzymes. Such as:

Animal enzymes: Example: Viveral, Novofermosol, Degomma, Waste pancreas, Clotted blood,
Liver, etc.
Vegetable enzymes:
There are two types vegetable enzymes.
a) Malt extract enzymes: Example: Diastafor, Diastase, Gabahit, Maltoferment, Maltostase
etc.
b) Bacterial enzymes: Example: Rapidase, Biolase, Arcy etc.

Condition for Enzymatic Desizing :

Enzymes Conc. g/l Temperatures(°C) pH Value

Malt Extract 3-20 50-60 6-7.5

Pancreatic 1-3 50-60 6.5-7.5

Bacterial 0.5-1 60-70 5.5-7.5

Preparation of the desizing mixture:

Agents should be added:
Water
Wetting agent
Salt
Acid/Alkali
Enzyme.
First, salt and wetting agent are added than enzyme.
2. Saturation: Fabrics containing starch as sizing materials are difficult to wet out. So, it is
mandatory that the mass of fiber and size be saturated to approx. 100% wet pick up.
3. Digestion: It means the process of converting starch to soluble materials. In a continuous
process, fabrics are run through a steamer and conversion is accomplished during the
steaming time available. In case of J-box, temperature range is 60 C to 90 C and time is 15 to
20 mins.
4. Washing: When desizing has been completed, it should be relatively easy to remove the
short chain sugar as they are water soluble.

Main controlling points:

 Temperature
 PH
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 Fabric speed
 Concentration.

BLEACHING OPERATIONS:

Object:
 Removal of coloured impurities.
 Removal of the seed coats.
 Minimum tendering of fibre.
 Technically reliable & simple mode of operation.
 Low chemical & energy consumption.
 Increasing the degree of whiteness.
 To increase dye affinity.
 To ensure level dyeing property.
 To make the fabric suitable for the next subsequent process.

Factors/Conditions Of Bleaching Process

Bleaching process depends on some important conditions. Some important conditions are
given below –

 Concentration of the chemical.

 M:L ratio.
 pH of the liquor.
 Temperature of the liquor.
 Time of treatment.
 Catalyst.

Machine:- Continuous Bleaching Range (Goller)

Machine specification: Goller Complexa – Scouring and bleaching range.

Widely use for compact, light to heavy weight quality fabric. Up to 120% even chemical pick up to
achieve high degree of whiteness fabric leading technology in low tension and crease free fabric
transportation . new version for high speed running of cotton elastane fabric. Indirect thermal plate
heating technology to prevent impurities from steam pipeline to the machine build in 100% saturated
steam generating system low utility consumption.
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Key Features

 Low tension fabric transport

 Fabric evenly heated by saturated steam
 Designed for dyeing in chromatic colours
 Creese mark-free bleaching process
 Smooth fabric surface (anti-pilling)
 Fine and soft handling
 High degree of permeability and hygroscopicity
 High degree of whiteness (80 Berger or above)
 Even bleaching effect (left, middle, and right

 MULTIDATA – high reproducibility

 Low energy consumption

Machine section:
1.Batch Section.
2.J-scray
3.Pre Washing Section
4.Steamer
5.Post Washing Section
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6.Vertical Dryer Range

7.J-scray
8.Batch Section.

LINE DIAGRAM OF CBR MACHINE.

 LOT
 INLET J SCREW
 BREAK ROLLER
 PRE WASHER
 APPLICATOR
 PRE ZENTAL
 STREAMER
 POST WASHER
 ACID TANK
 VDR
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 J SCREW
 BATCH

Inlet J-Scray:- It is to collect the fabric during batch changing to avoid machine
Stoppage by using tensioner roller, pressure roller and compensator.

Washer:
To Wash Of The Starch & Other Impurities From Desized Fabric By Using Hot Water.

Bleaching Steamer:
 Steamer is an important process in every Pretreatment process.
 Steam allows fast energy transfer directly into fibre.
 During the bleaching process it is necessary to expose the fabric to sensitive but effective
treatment.
 We satisfy the need of a successful process cycle by means of machine technology that offers a
safe guiding of material, which is adapted to the fabric and which is essential in the application
of chemical, the steam conditioning and the dosing technology.
 Our bleaching range perform the bleaching process in optimum conditions that guarantee a
fabric of corresponding degree of whiteness and high degree of absorbency.
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PROPERTIES:
 Inlet section with inclined cloth guiding.
 Middle section with vertical cloth guiding.
Drive via perforated pulling roll and pendulum compensator.
 Spray nozzle for cleaning and rapid cool down.
 Housing in self supporting segment construction mode.
 Temperature control through cloud control.
 Guiding roller in high quality execution with a high concentricity.
 Minimal cloth tension due to frequency controlled drives.
 Prevention of creases by small distances between the guide rollers. (1000mm)

CONCEPT
 Bleaching steamer consist of section with tight strand fabric guiding and roller bed.
 In tight strand section the fabric which has been impregnated with the bleaching liquor is
heated up as the requirements and on roller bed we maintain sufficient dwelling time for
reaction purpose.

Brief specifications
 Dwelling suction pulling device, plaiter, reversing drum for planting on roller bed.
 Roller bed with driven pulling rollers
 Exist section with sensible blade.
 By pass device for the roller bed.

Technical data

Working width 1600 to 3400 mm

Roll surface 1800 to 3600 mm
Fabric content (inclined section) 22 meter
Fabric content (Vertical section) 18 to 180 meter
Fabric feeding on roller bed Max 50 kg / meter sq.

Twin shaft Applicator:

Maximum Application Device

 Maximum liquor application according to the “aquaplaning “Principle, no liquor
exchange.
 Machine is stainless steel construction .
 minimum liquor content.
 Uniform feed at both fabric side over the entire width.
 Automatic cleaning
 Easy maintenance
 Minimum temperature reduction on fabric
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Field of application
 Bleaching liquor application in font of the Steamer in the pretreatment range.
 Dye liquor /Chemical application in front of steamer in dyeing range .
 Cold bleaching.

Technical Data

Working width : 1600 - 3400 mm

Roll surface : 1800- 3600 mm
Max. Liquor : 18L - at low 1800 mm

STEAMER LINE DIAGRAM

Neutralizing Compartment: This compartment neutralizes the fabric pH by dosing

Of mild Acetic acid and washes the excess acid. After this compartment there is a
Rinsing compartment to wash off the impurities from the fabric.
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Vertical Drying Range:

Self-supported and maintenance-free modular design of the structure makes it easy to install and
operate. With the option of 2-4 drying cylinders, utility piping and drive arrangement for each cylinder,
the drying range can be customized as per the requirement. Crease free fabric run with minimum fabric
tension and uniform temperatureacross the width. It has a user-friendly operation and control
mechanisms .Uniform heat output, standard components, less transportation cost.

Outlet unit: To collect the fabric during batch change to avoid machine stoppage
And provide perfect out batch of fabric without any crease.

Titration of Hydrogen Peroxide :

Object: a titration to standardize a solution and to determine the concentration of an unknown solution.

Hydrogen Peroxide H2O2

Mol. Wt – 34.02

About H2O2

Hydrogen peroxide is a clear colorless liquid miscible with water at available in various
strength,from 3 to 90℅ . The strength of commercial solution is generally express in term of
The Volume of oxygen which they are capable off yielding. 10 volume being equivalent to 3.04
℅ Hydrogen Peroxide.

Assay :
The sample is diluted with sufficient water to get a one volume solution. A solution of 2gm of
potassium iodide in 200 ml of water is mixed with 30 ml of sulphuric acid ( 1:2) and the mixture
cooled. After which 10 ml of the diluted peroxide solution is slowly run in and the flask allowed
to stand for about 5 minutes to complete the reaction. The iodine liberated is titrated with 0.1
N sodium thiosulphate using starch indicator.
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1ml 0.1 N Na2S2O3 = 0.001710 g H2O2

Reaction:

H2O2 + 2 KI + 2 HCl ----------- 2 KCl + 2 H2O + I2

I2 + 2 Na2S2O3 ------------ 2NaI + Na2S4O6

2nd method

The assays may also be carried out by titration with potassium permanganate. 10ml of the
diluted peroxide solution is added and the mixture titrated with 0.1 N KMnO4.

1 ml 0.1 N KMnO4 ------------- 0.001710 g H2SO4

Reaction:

5H2O2 + 2KMnO4 --------------- K2SO4 + 2MnSO4 + 8H2O + 5O2

Acidity:
25 ml of the diluted solution is titrated with 0 . 05 N sodium Hydroxide using
phenolphthalein indicatot.
The acidity of commercial sample should not exceed 1.5 ℅ expressed as sulphuric
acid.

Titration of Sodium Hydroxide.

Chemical potash (Caustic soda)

NaOH mol. Wt. – 40
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caustic soda is in the form of lumps,pellets stick chips etc. it rapidly abzorb water
and carbon dioxide from and Is very corrosive to animal and vegetable tissues.

Assays:
About 4g of the sample, accurately weighed, is dissolve in carbon dioxide free
distilled water, and made up to 1liter . A 50 ml aliquot is titrated with 0.1N
Hydrochloric acid first in the presence of phenolphthalein till the pink colour is
discharge and then in the presence of methyl orange till an orange tint is
produced.

Reaction :-
NaOH + HCl -----------NaCl + H2O

Description Of The Bleaching Of Cotton By Hydrogen Per-Oxide (H2O2)

Auxiliary used in bleaching operations:

Hydrogen Peroxide
Sodium Hydroxide
Wetting Agent
Sequestering agent
Stabilizers

Thenard produced H2O2 from BaO2 and dilute HCl in 1818. He named this as

oxygenated water.
BaO2 + 2HCl → BaCl2 + H2O2

H2O2 is an oxidizing agent which is used largely for cellulose fibre bleaching.
H2O2 is also used for protein fibre such as wool, silk-bleaching etc. In H2O2
bleaching, H2O2 releases hydrogen ion (H+) and per hydroxyl ion (HO2-). Here, PH
level is maintained 10.7 – 10.9.
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Per hydroxyl ion is released for alkalinity of hydrogen per-oxide solution. This per
ion bleached the textile materials. H+ ion has no bleaching action. It maintains PH
level.
(HO2-) + Colored materials = Bleached materials + H+
H2O2 is normally unstable, moreover Cu, Ni, Fe, etc. catalyst decomposes H2O2
and produces H2O and O2.
2H2O2 + Catalyst → 2H2O + O2
The produced O2 has no bleaching action. So, bleaching ability can be reduced if
water contain Cu, Ni, Fe, etc ion, then H2O2 catalytically decomposes and reduces
bleaching ability. So, all the above matters should be considered in H2O2
bleaching.

Other theoretical information:

List of Oxidizing Bleaching Agent Used in Textile Industry:

All the oxidizing bleaching agents have presented in the following:
 Oxygen (O2),
 Ozone (O3),
 Potassium Nitrate (KNO3),
 Potassium Phosphate (K2PO4),
 Potassium Permanganate (KMNO4),
 Potassium Chlorate (KCLO3),
 Sodium per Oxide (Na2O2),
 Sodium Hypochlorite (NaOCl),
 Calcium Hypochlorite {Ca(OCl)2},
 Bleaching Powder ({Ca(OCl)Cl},
 Hydrogen Peroxide (H2O2),
 Halogen (X2),
 Hypochlorous Acid (HClO2),
 Manganese Dioxide (MnO2),
 Per Acetic Acid,
 Led Dioxide (PbO2),
 Nitric Acid (HNO3),
 Sulphuric Acid (H2SO4),
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 Potassium Hypochlorite (KCLO),

 Potassium Sulphate (K2SO4),
 Aqua Resia (Con. HNO3+Con. 3hCL) etc.

List of Reducing Bleaching Agent Used in Wet Processing:

All the reducing bleaching agents have listed the below

 Hydrogen Sulphide (H2S),

 Carbon ©,
 Carbon Mono Oxide (CO),
 Sodium Sulphate (Na2SO4),
 Sodium Bi-Sulphate (NahSO4),
 Sodium Sulphite Formaldehyde,
 Zinc Dist (Zn),
 Zinc Oxide (ZnO),
 Sulfur Dioxide (SO2),
 Stannous Chloride (SnCl2),
 Ferrous Sulphate (FeSO4),
 Titanous Chlorite (TnCl2),
 Hydrogen Iodide (HI) etc.
 Hydrogen h2

Chemicals used in Textile Processing

 .Acetic Acid

Acetic acid is a colorless and corrosive liquid with pungent smell of its own. It is
miscible with water, alcohol and ether in all proportions. Acetic acid is used in
garment industry for dyeing purposes.
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 Citric Acid
Citric acid is in the form of colorless, translucent crystals or a white granular to
fine crystalline powder. It is used as sequestering agent, as mordanting agent in
dyeing and cleansing agent for boiler water.

 Formic Acid
Formic acid is a colorless and pungent smelling mobile liquid. It is miscible with
water, alcohol and ether in all proportions. It acts both as an acid and as reducing
agent due to presence of both carboxylic and aldehyde group. Formic acid is used
in dyeing wool and cotton fabrics.

 Hydrochloric Acid, HCl

Hydrochloric acid gas is a colorless, pungent smelling gas with acidic taste. It
fumes in moist air and is extremely soluble in water.

 Nitric Acid, HNO3

Nitric acid is a colorless fuming liquid when pure but may be colored yellow due
to its dissociation products mainly nitrogen dioxide. It is a strong acid and acts as
a powerful oxidizing agent. Nitric acid is used in the manufacture of dyes.

 Oxalic Acid, HOOC.COOH.2H2O

Oxalic is a colorless, crystalline solid with two molecules of water of
crystallization. Oxalic acid is used in garment and textile industry for the removal
of ink stains from cloths and bleaching of straw for hats. Its antimony salts are
used as mordant for dyeing and printing.

 Liquid Ammonia, NH4OH

Ammonia is a colorless gas with characteristic pungent odor and an alkaline taste.
It is used as a cleansing agent for removing grease in dry cleaning.

 Caustic Soda ( Sodium Hydroxide), NaOH

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Caustic soda is a deliquescent white crystalline solid, which readily absorbs

moisture and carbon dioxide from the atmosphere. It is used for mercerizing
cotton.

 Soda Ash ( Washing Soda), Na2CO3

Sodium carbonate is a white crystalline solid containing water of crystallization. It
is used in laundry as washing soda. It is also used for softening water.

 Sodium Bicarbonate ( Baking Soda), NaHCO3

Sodium bicarbonate is available in the form of white crystals, sparingly soluble in
water. It is alkaline in nature.

 Sodium Silicate
Liquid alkaline Sodium silicate is mostly used in garment industry as a fixing agent
and for rendering the garments fire proof.

 Trisodium Phosphate, Na3PO4

It is a white crystalline solid soluble in water. It is used as detergent in garment
processing.

 Common Salt
It is used as to exhaust dyeing with direct and reactive dyes.

 Diammonium Hydrogen Phosphate

It is used in printing paste as an acid liberating agent.

 14. Glauber Salt, Na2SO4.10H2O

It is used in dyestuff, textile and garment industry. In textile and garment industry,
it is added to the dye bath for cotton fabrics to promote dye exhaustion.

 Magnesium Chloride
It is a colorless, crystalline deliquescent substance soluble in water. It is used in
textile and garment industry for sizing, dressing and filling of cotton and woollen
fabrics, for thread lubrication or carbonization of wool.

 Tatar- Emetic
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Potassium Antimonyl Tartarateis known as Tartar-emetic. It is used as mordant in

large quantities in garment and textile industry.

 Zinc Chloride
It is a white deliquescent solid exceedingly soluble in water. The concentrated
aqueous solution of zinc chloride dissolves cellulose.

 Zinc Sulphate ZnSO4.7H2O

It is a crystalline solid very soluble in water. It is used as mordant in printing.

 Bleaching Powder
It is hypochlorite of calcium and sodium. Bleaching powder on treatment with
small quantities of dilute acid liberates hyopchlorous acid, which can easliy
furnish nascent oxygen and thus acts as an oxidizing and bleaching agent. It is
used for the following purposes:

1. As an oxidising agent in garment processing

2. For bleaching cotton, linen and wool.
3. In rendering wool unshrinkable.

 Hydrogen Peroxide, H2O2

Hydrogen peroxide is a colorless, odorless, syrupy liquid in the anhydrous state. It
is a powerful oxidizing agent. It destroys the color of some organic compounds
and is used in garment and textile industry for bleaching delicate fabrics like wool,
straw and silk.

 Potassium Chlorate KClO3

Potassium chlorate is a white crystalline solid, which is soluble in water. On
heating it decomposes to give oxygen. The ease with which it can lose oxygen, it
acts as a strong oxidizing agent. It is used for garment printing.

 Potassium Chromate
Potassium chromate is available in the form of lemon yellow crystals with no
water of crystallization. In garment industry it is used as a mordant.
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 Potassium Dichromate
It is available in the form of orange red crystals. It is soluble in water. In neutral or
acidic solution, potassium dichromate furnishes nascent oxygen and thus acts as
an excellent oxidizing agent. It is used in garment industry as an oxidizing agent
and as mordant in dyeing.

 Potassium Permanganate
It acts as a powerful oxidising agent in neutral, alkaline or acidic solution and
hence used in the garment industry as an oxidising agent.

 . Sodium Perborate
Sodium perborate is mainly used as a bleaching agent for a variety of fabrics
namely wool, cotton, rayon, linen etc. It is also used as an oxidising agent and dye
fixing agent.

 Sodium Hypochlorite
Sodium hypochlorite liberates hypochlorous acid and thus acts as a powerful
oxidizing and bleaching agent. It is used in textile and garment industry for
bleaching process.

 Sodium Bisulfite, NaHSO3

An aqueous solution of sodium bisulfite is obtained when an aqueous solution of
sodium carbonate is saturated with sulphurdioxide. It is an important reducing
agent and is used as an antichlor after bleaching garments with chlorine.

 Sodium Hydrosulfite
It is used as reducing and bleaching agent in garment and textile industry.

 Sodium Metabisulfite
On heating, it decomposes into sodium bisulfite and sulfur dioxide and hence it is
an important reducing agent. It is used as an antichlor after bleaching garments
with chlorine.

 Sodium Sulfite
It forms colorless crystals very soluble in water. It is decomposed by dilute
mineral acids with the evolution of sulfur dioxide. It is used as mild bleaching
agent for silk and woollen fabrics and as an antichlor after chlorine bleach.
28

 Sodium Sulfide
Its aqueous solution shows and alkaline reaction due to hydrolysis. It is used for
manufacture of sulfur dyes and as reducing agent in garment industry.

 Sodium Sulfoxylate Formaldehyde

It is also known as Rongalite C. It is a powerful reducing agent and exerts its full
reducing action only at high temperatures. It finds extensive application in
garment and textile industry for printing and stripping dyed fabric prior to re-
dyeing.

 . Sodium Thiosulfate
It is also know as hypo. It is a colorless, crystalline and efflorescent substance. It is
used as an antichlor after bleaching garments with chlorine.

 Stannous Chloride: It is used as mordant in garment dyeing and printing.

 Dextrin
It is a modified starch prepared by heat treatment of starch in the dry state, with
or without the addition of small quantities of chemicals. It is a white powder, and
finds extensive use as sizing and finishing agent.

 Glucose
It acts as a strong and cheap reducing agent in garment industry.
29

How to test scoured fabric :

As we understand cotton is scoured using alkali at boiling temperature. During or

after scouring, it is must to know whether the material scoured properly or not.
To ascetain that a simple drop test can be performed. In such type of test, if the
material is under scouring process, a small piece of fabric is cut from the lot of
fabric which is running in the machine say jigger (after stoping it). The piece is
washed properly under tap water (Soft water) and dried using iron or placing the
fabric piece on hot steam pipe line. After cooling the fabric, a drop of water is
allowed to fall on this piece of fabric. If the drop is absorb whithin few seconds
say 3 seconds, one can be assured that scouring is perfectly done. However, if the
drop is taking much time to absorb, there is a need to continue the scouring
process untill the fabric acquire optimum absorbency. If the fabric is being
scoured for printing process, it is required that the water drop should be
absorbed within 1 second. There are standard tests are also availabe for testing
absorbency of fabric in the laboratory e.g IS 2349 and AATCC 79.

Methylene Blue absorption Method:

Carboxyl groups present in the cellulose may be determined by methylene blue
absorption method. This method is based on the principle that when cellulose
containing carboxyl group is titrated with a standard solution of methylene blue,
under specified conditions, the dye (mehtylene blue) cation is quantitatively
absorbed and retained by the carboxylate anion in the cellulose.

The drop in concentration of the dye in the treating solution can then be found
out colorimetrically and the amount of carboxyl groups present in the cellulose
can be calculated in terms of milliequivalent/100 g of dry cellulose. For this
purpose pure methylene blue is required.
30

In this study first of all, a calibration curve is obtained with the known
concentration of methylene blue solutions ( 2-16 mg/litre with increment of 2
mg/litre). The curve will be between absorbance and known concentrations of
methylene blue solutions.

After plotting the curve, in the second step, the concentration of methylene blue
solution left after treatment of cellulose is determined using colorimeter. The
concentration of the dye in a solution to be estimated by finding out the
absorbance of a solution at 620 nm wavelength. Following reagents are used in
this study:

Reagent-1: Mehtylene blue solution: 0.2 moles/litre

Reagent-2: Potassium dihydrogen phosphate solution: 0.625 milli mole/litre
Reagent-3: Sodium hydroxide solution: 0.4 mole/litre

To start study a stoke solution of methylene blue dye should be prepared by

taking methylene blue, potassium di hydrogen phosphate and sodium hydroxide
in the above proportion.

Determination of copper number:

When cellulose is bleached i.e oxidised and hydrolysed by treatment with mineral
acid solution , reducing groups are formed. These reducing groups are capable of
reducing an alkaline solution of copper sulphate, when insoluble cuprous oxide is
formed is proportional to the amount of the reducing groups present in the
cellulose sample. This is expressed in terms of Copper Number, which is defined
as a gram of cupric copper reducing to cuprous oxide by 100g of the cellulose
sample under standard conditions of boiling in an alkaline medium.

To determine copper number following procedure is followed:

Solution A: 100 g/litre hydrated copper sulphate

Solution B: 50 g sodium bicarbonate + 150 g anhydrous sodium
Carbonate in 1 litre of distilled water
Solution C: 100 g/litre ferric alum and
Solution D: N/100 Ceric sulphate
31

 Take cellulose sample whose copper number to be determined and

conditioned it at 30oC at 65% RH for 48 hours
 Determine moisture content of the conditioned sample and note down the
value

 Take 0.25g of the dry sample in dry test tube in triplicate. For highly
degraded sample, 0.125g of sample may be taken
 Mix solution A and B in the ratio of 5:95 and boiled. Take 15 ml of this
solution and add to all the tree test tube. Now each test tube will have
cellulose sample and 15ml of mixture of solutions.
 Mouth of these tubes closed using glass stopper and placed in the boiling
water bath. Along with these three test tubes, also placed three blank test
tubes (only contain solution, No sample) in the boiling water bath. Boiling
continue for three hours.
 Cooled above test tubes and content of each test tube filter using Gooch
crucible (Sinterd glass, AG3) and washed with distilled water (now the
colour of solution become red).
 The residue in the crucible also treated with first 10 ml and then 5 ml
ferric alum solution (Solution C). The residue also washed with
successively with 10 ml and 5 ml 2N sulphuric acid. All these process are
carried out on each test tube.
 The solution so collected is titrated against N/100 ceric sulphate
(Solution-D) using a few drop of ortho-ferrus phenathroline indicator (the
initial red colour of the solution turns Green at the end point).
 The blank alkaline copper solution gives a reading of 0.02 ml of N/100
ceric sulphate solution. This blank reading is subtracted from the actual
reading in each case, where the cellulosic sample is treated.
 The copper number is calculated from the amount of ceric sulphate
solution consumed (after deducting blank reading) by ferrous sulphate
formed by the reduction of ferric sulphate sulphate by cuprous oxide
deposited on the cellulosic sample during the three hours of boiling.

Copper Number= (63.5 x V x N x 100)/ W x 1000 = (6.35 x V x N)/W

32

Where V is the titration reading (ceric sulphate solution) after deducting the blank
reading, N is the normality of ceric sulphate solution and W is the weight of the
bone dry cellulosic sample.
Some Parameters checking on CBR machine

Check Point Required Checking Duration

Temperatures:
Pre-Washer 95°C - 95°C - 65°C Daily
Steamer 99°C
Applicator RT 95°C – 95°C – 95°C -60°C
Post Washer
Vacccume Pressure 30mbar Every Lot

Apply Pressure mangle Intet (Bottom) Every Lot

2kg to 3kg
Left 1.3 kg to 1.5 kg
Intermediate mangle 2kg Every Lot
Pressure
Final Mangle Bottom 1kg to top 2kg Every lot
Washer counter Flow Pre – Washer Every Lot
2.5 l/kg to 3.5 l/kg
Post – Washer
2.5 l/kg to 3.5 l/kg
Guide Pressure 0.5 to 1 bar Every Lot
Steamer Pressure 2.5 kg Daily
Titration Caustic & Peroxide ------
NIP impression With carbon papers 15 days
Iron checking Using magnate Daily once
Tegwa on Fabric Above 6 location On every 500 mtr.
Whiteness Dyeing >70 On every 1500 mtr.
White >80
Absorbency < 3-4 sec On every stitch

Width -------------- On every stitch

33

MERCERIZATION

Mercerized cotton is produced by a special chemical process

that initially gives the cotton fibers a lustrous appearance while
simultaneously strengthening. Applying the mercerization
process to the cotton yarn or fabric during the stimulation
causes the fibers to swell, straighten and become round and
smooth, resulting in high luster fibers. Mercerization not only
helps the fiber to increase its potency with dyeing but also
improves resistance to disease and shrinkage. It is also worth
noting that mercerized cotton will absorb more water over time
but initially puts more pressure on the water than un-merged
cotton.

Types of Mercerization
There are different types of mercerization processes is used in
textile for cotton processing.

Mercerization without tension

Mercerized cotton fibers swell without tension which increases
in length and thickness. Swelling is caused by alkaline molecules
or radicals entering the amorphous region of the swollen
polymer system.

Mercerization under tension

Mercerization under tension that can only be run over a cotton
yarn or fabric causes slight swelling or fiber contraction. The
34

fiber is grown with increased significance and uniqueness,

albeit a repressive feat. This makes the fiber surface smoother
and more regular, enabling it to reflect incident light more
evenly.

Chainless mercerization
This method is called roller mercerization. The machine consists
of several stainless rollers and rubber rollers, relatively large in
diameter, tiered zigzags in close contact with each other inside
long holes, designed for immersion in alkaline solutions of
mercerization with low levels. Bound to a limited length of this
type of fabric. Alkaline penetration and fabric swelling in these
early stages, similar devices are used to remove most of the
alkali and to use an open-width soaping machine for further
removal and neutralization.

Chain mercerization
To compensate for the defects of the roller mercerizing
machine, a clip stenter is used for the post-mercerization
treatment after massaging the stenter, where the widthwise
tension is applied but most of the alkali is removed from the
fabric placed on top of the stenter, then the whole alkali is
removed and an open width washing machine is used for
neutralization.

Cold mercerization
The mercerization process takes place at 15 to 18°C with 31 to
35% caustic soda solution with a dwelling time of 50 seconds.
At this stage, cotton swells best but also swells. Fast swelling
35

increases the density of the outer edges of the fibers. Caustic

soda viscosity hardens penetration into gray fabrics, resulting in
poor disintegration of the core and lack of uniformity resulting
in the reaction being confined to the surface of the yarn or
fabric.

Hot mercerization
The mercerization process takes place at higher temperatures
with 30 to 38 % caustic soda solution, with a dwelling period of
20 to 30 sec. In this process alkali rapidly penetrates the fabric
and improves the core mercerization.
36

Specification of Mercerizing Machine:

 M/c name: Mercerize m/c
 Brand: Goller
 Origin :Germany
 Speed:60 m/min
 Capacity :1 lac m/day

Expander roller: Remove dirtness and keep the fabrics in level Padder Upperb
padder: made by rubber Check hardness : 80-90%, Lower padder: made by AUTO
Check hardness : 100%
Dancing roller: Tension keeps proper before going on dryer.
Caustic temperature : 35-55’C
Vacume pump(air): Remove water
Padder pressure: 3bar-washing, IMP-1 & IMP-2—3.5bar
IMP-1 :Strong lime with 30’ baume Solid caustic + 28’ baume mercerize oil.
IMP-2 :Here shrinkage is controlled by using caustic and mercerizing oil. Airing
zone: In airing zone = 11 air roller/8 air rollerIn airing zone, fabrics are dried by air
and chemical is added with fabrics.
Gear+chain : Maintain width, control shrinkage in weft And caustic is utilized in
every fibre equally.
Tanki : No. of tanki-5These keeps water hot and creates weak line (8baume)
Washing chamber (1-3): Hot wash 90’c
Washing chamber 4: Wash at room temperature
Cylinder dryer temperature : 110=-130’c
Cooling dryer temperature : 25-40’c
Exact roller : Maintain fabrics that, selvedge does not remain straight.Using acid
according to fabric GLM -1. 300+GLM thick- 100% acid, 2. 140-274 thickness-
50% acid + 50% water
Types of mercerizer : 1.cool mercerizer – 18’ baume . But for cool mercerizer
good chellers are needed. 2. Hot mercerizer- 28-30’ baume
Recipe: Sodium Hydroxide (NaOH) –  (28±2)º Be (Baume´) 267 gm/l (see note) Steam,
water  –    As required, Green acid / Nurta acid (32%) – 3-4 % of total water, Wetting
agent-  1-1.5 gm/l,
Compressed air -:  As required
Mercerizing Oil (Mercirol QW2F) : 3-4 gm/l
37

Tests : Barium activity test, 2.PH, 3.         Absorbency , 4.           Size chemical Suitable For
All cotton fabric, TC/CVC fabric, Twill Fabric
Flow chart of Mercerization
Fabric inlet

J-Box

Impregnation-1(IMP)

Airing Zone

Impregnation-2(IMP)

Gripping Chain

Stabilizing Compartment

Washing Chamber 1 2 3

Neutralizing chamber

Drying unit

J-Box
↓

Batching
38

Operational Procedure for Mercerized Cotton Yarn:

Fabric inlet for mercerized cotton: Batcher from scouring & bleaching unit is feed
into the inlet of mercerizing range. Where the fabric is passed over some free
roller, guider & expander. Here there is a compensator to control fabric open
width entry.

Chemical mixing tank for mercerized cotton: Caustic is mixed in a separate

mixing tank. Here 30 BAUME concentration is ensured. It is ensured by mixing 300
kg caustic in 1000 liter water. BAUME can be adjusted by adding water or
additional caustic. Then wetting agent & caustic is forced to main chemical mixing
tank from which it goes to chemical tank to maintain uniform chemical height in
the tank.

Impregnation-1(IMP) of Mercerizing Machine : Fabric comes to Impregnation-1

from inlet through guider & series of driven, free roller. In mercerizing process the
only wetting agent & caustic is used. Temperature is around 60’C.

Airing zone of Mercerizing Machine : Fabric is passed over the Airing zone after
chemical padding. Here there is no application of temperature & pressure. It
involves 4 rollers which are driven by motor. This application is only for drying in
contact of air which facilitates more chemical consumption from next bath
39

Impregnation-2(IMP): same as Impregnation-1(IMP). After that squeezing is

occurred.

Gripping chain for mercerized cotton: from Impregnation-2 fabric pass over the
free roller & comes in to chain for gripping. Here the fabric is stretched for control
width. If crease mark is found from previous process, that can also be controlled
by stretching. Here there is an additional option of showering by hot water.
Which ensure proper cleaning & removal of residual caustic.

Stabilizing compartment : Below chain where hot wash occurred there is

chamber for collecting caustic containing hot water. That is driven to caustic
recovery plant for making it ready to mercerize chemical once again.

Washing chamber(1 2 3) for mercerized cotton: From chain by squeezing fabric

comes directly to washing chamber. Here fabric passed over some driven roller to
make proper hot wash. There are 3 hot wash chambers that are linked with one
another & horizontally inclined. Here temperature is maintained is around 90’C.

Neutralizing chamber: after washing fabric goes through neutralizing chamber.

Caustic make the fabric highly alkaline so that is neutralized by the addition of
acetic acid. For controlling ph from control panel a command is given such as 7.
Then the fabric will takes this amount of acetic acid which makes the fabric
neutral by maintaining ph 7.

Dryer for mercerized cotton: After washing & neutralizing for drying process 2
stage vertical cylinder dryer is used. It is heated by steam. For course fabric the
cylinder dryer temperature is around 180-200’c. and for pocketing fabric the
cylinder dryer temperature is around 110-130’c.

Batching : Finally after drying the fabric is ready to dye. It is now rolled in the
batcher for next process.
40

How to know the fabric is properly mercerized or not

There are various methods to to test the quality of

mercerization. These are:
i) Lustre, %
ii) Microscopic examination
iii) Deconvolution count
iv) Barium activity number

i) Lustre, %: The mercerized sample is illuminated at

an angle of incidence of 45 degree with the help of
filament lamp. Light reflected at 45 degree and 90
degree is measured by photo electric cell. Lustre is
defind by the contrast ratio of specular to diffuse
reflectance. The specular reflectance measurement
method is considered as an accurate evaluation of
lustre.

Lustre = contrast ratio of specular to diffuse reflectance

Lustre= Light reflected at 45 degree/ light reflected at 90

degree.
41

ii) Microscopic examination:The test involves the

assessment of degree of mercerization by counting
the number of twisted and untwisted fibres
(deconvolution count) while viewing through the
microscope. If the sample under investigation is
immersed in a solution containing 20 g iodine in
100 ml potassium iodide for 3 seconds and then
wash off well, mercerized cotton will be stained
bluish black and unmercerised cotton will be white.

iii) Deconvolution count: Under this mercerised fibres

are cut down and examine under microscope and
fibre with and without convolution are counted.
The numbers of fibres without convolution per 100
fibres is called “Deconvolution Count” Generally
percent unconvoluted fibres are measured.
Generally the unconvoluted fibre(%) in the
unmercerized cotton is around 5 to 15 %, while in
fully mercerized it become upto 80%.
42

Iv) Barium Activity Number: The degree of mercerization can

be measured by this test. In increase in absorption properties
are shown by alkali’s, the ratio of soda absorbed by mercerized
to that by the unmercerized cotton may be used as a parameter
of the degree to which the cellulose has been swollen. From
the practical point of view, Barium hydroxide number is very
easy to estimate, and the ratio of uptakes for this reagent is
referred to as the barium activity number. In the test, the
mercerized and unmerserized samples weighing 1 g were
treated with 30 ml of 0.25 N Barium hydroxide solution for 2
hours. Then 10 ml of solution (with few drops of
phenolphthalein indicator) from that was titrated against 0.1 N
hydrochloric acid (pink colour to colourless). A blank was also
run without any fibre sample. The barium activity number is
measured by using following formula:

Barium activity number = {(B-M)X100}/ (B-U)

Where B is the titration reading for blank, M for mercerised and

U for unmercerized. While unmercerized cotton gives a barium
activity number of 100, it ranges between 115 to 130 for
mercerized fabric and 150-160 for mercerised yarns.
43

Operating of Mercerization machine:

 Understand and follow the instruction from lot card and

programme book.
 Switch On main power and then open compressed air,
water valve and Steam.
 Check the quality and lot number of the fabric before
putting on the machine By checking the label.
 Transport the fabric to be run, to the inlet J-scray of
mercerization machine Using hydraulic hand puller.
 Stitch the two ends without crease, (i.e.) one end of the
fabric is to be Mercerised and the other leader fabric in
the machine and ensure Straightness of fabric without
crease.
44

 Commence water spraying the impregnating unit

immediately without delay.
 Fill the water in all the washers and set the temperature of
all washing units.
 Set the concentration of the caustic soda and other
parameters like speed of The machine, width etc.,
 Observee for any defect in the fabric before and during the
process and Report to the supervisor if any irregularities
observed.
 Ensure that the Speed of the machine is same from
starting to end of the Process. ( For normal mercerization
operation requires 50-80 m/min (meters Per min), it varies
depends upon the quality. Light weight GSM fabric
requiresMore speed and vice versa.).
 Check actual flow rate of each chemical from flow meter
as well as the Operating monitor.
 Keep the chemicals ready for entire process.
 Switch ON the circulating pump while starting the
machine.
 Check the exit width of the fabric at every 500 meters.
 Check for any defects in the mercerised fabric like stains –
dust, chemicals, Rust, handling stains, crease, water
dropping, oil, grease, etc.
 If the machine stops for long time, put the leader fabric on
the machine and Commence water spraying the
impregnating unit immediately without delay.
45

Cleaning in mercerising machine:

 Remove regularly accumulated dust and dirt from the
machine.
 All the rollers to be cleaned with dry fabric at starting and
at the end of every programme.
 Clean the entire washer and its filter once in a day.
 Clean the Padding mangles properly and wash the trough
thoroughly.
 Collect all the waste and store them at designated place.

IMPORTANCE OF HEALTH AND SAFETY:

 Use and maintain personal protective equipment such as

Hand Gloves, Gum Boots, head cap etc., as specified.
 Never handle chemicals with bare hands
 Report to the supervisor any service malfunctions in the
machine that cannot Be rectified.
 Store materials and equipment at their designated places.
 Minimize health and safety risks to self and others due to
own actions .
 Monitor the workplace and work processes for potential
risks.
 Do not carry any metallic parts during machine running as
there are chances Of fire and damage to machine parts.
 Take action based on instructions in the event of fire,
emergencies or Accidents and participate in mock drills/
evacuation procedures organized at
 The workplace as per the organization procedures.
46

SOFT FLOW MACHINE

It was found that in using Winch machines, there were some inherent
problems. So the Jet dyeing machines when they came up in the 1970s
were specifically designed to overcome those shortcomings.

Soft flow dying machine:

In the soft flow dyeing machine water is used for keeping the fabric in
circulation. The conception difference of this equipment from a
conventional jets that operates with a hydraulic system is that the fabric
rope is kept circulating during the whole processing cycle (right from
loading to unloading). There is no stopping of liquor or fabric circulation for
usual drain and fill steps. The principle working behind the technique is very
unique. There is a system for fresh water to enter the vessel via a heat
exchanger to a special interchange zone. At the same time the
contaminated liquor is allowed channel out through a drain without any
sort of contact with the fabric or for that matter the new bath in the
machine.

Key Features of Soft flow Dyeing Machine:

o Significant savings in processing time.
o Savings in water that is around 50%.
o Excellent separation of different streams results in optimum heat
recovery and a distinct possibility of further use or a dedicated
treatment.
Principle of Soft Flow Dyeing Machine:
Textile material can be dyed using batch, continuous or semi continuous
process.
Batch processes are the most common method used to dye textile
materials. There are three general types of batch dyeing machines:

1. In which fabric is circulated

2. In which dye bath is circulated
3. In which both the bath and material is circulated.
47

Jet dyeing machine is the best example of a machine that circulated both
the fabric and the dye bath. Jet dyeing is used for knitted fabrics. For Terry-
towels soft flow dyeing is use. In jet dyeing machine the fabric is
transported by a high speed jet of dye liquid.As seen in the figure, this
pressure is created by venturi. A powerful pump circulates the dyed bath
through a heat exchanger and the cloth chamber. Cloth guide tube helps in
circulation of fabric.

TECHNICAL DATA:

Machine Used:- KEMPL

Made in : INDIA
Maximum Capacity:soft flow 4( sampling machine)-50kg
Work- sample dyeing (generally cream colour)
Soft flow 1-500kg,. Soft flow 2-500kg , Soft flow3-250kg
Soft flow5-1000kg
Work- • RFD for direct printed fabrics.
•washing of dyed fabrics.
•dyeing of fabrics (specially cream colour)

Chemicals :in case of redyeing

RGGR-levelling agent
Albatex AD-soaping and levelling agent
Soda ash-Fixing agent
Sodium sulphate-Exhausting agent
Acetic acid-neutralizer
Dosing time (batch wise)- for soft flow 4=10 minutes,for soft flow 1=20minutes
•M:Lratio :- 1:8 – 1:10
48

•Fabric run- viscose,cotton,pc blend etc.

In case of RFD for direct print- Imacol CG(lubricant)-1gpl, RGN(wetting
Agent)- 1.5gpl,

SED(Enzyme)- 1.5gpl, Defoamer-100gm,

Hydrogen peroxide-2.0gpl , Soda ash-2.0gpl, prostozone D -0.7gpl, Bixon Q-
0.5gpl, Acetic
Acid-1.0gpl, Invatex AC-1.0gpl, Invazyme CAT-0.5gpl

JET DYEING MACHINE

Machine Used: AKM

Made in: TAIWAN
Jet dyeing machine is mainly used for dyeing of polyester.
This is also used for washing of fabrics.
• Capacity:
J1:- 100kg , J2:-250kg & J3:-600kg(300kg+300kg)
• Temperature:
For polyester:135°C
For cotton:80-90°C
• M:L ratio:- for polyester-1:5-1:6
for cotton-1:8
• Nozzle pressure:- for cotton- 1kgf/cm2
for polyester-2kgf/cm2
•Tank pressure:- 3-4kgf/cm2(polyester)
49

HYDROEXTACTOR

Machine used: DMW(Deep Foundry & Mechanical works)

Made in: INDIA
Work-Removal of extra water present in the wet fabric by using Centrifugal force.
Specifications:
Motor HP/Kw=15HP
Max. Load = 200kg
RPM (Maximum) = 600

OPENER
Machine used: BIANCO
Made in: INDIA
Work- opening of hydroextracted fabric which is in rope form .
Sensor present-3

Continuous Washing Range ( CWR) Machine.

50

Menzel COMPACTFLOW, a new multifunctional and compact continuous washing line for
Washing after Digital printing and small batches The new machines performance compared to her
Big sister, the MENZEL OPTISPLASH drum washing line, is almost identical besides the
Production capacity. The substantially smaller COMPACTFLOW can be operated economically
Already from 5.000-6.000 production capacity per day. As a comparison; the conventional large
Scale continuous washer requires at least 40.000 Meters a day to be lucrative. MENZEL has
Succeeded to arrange four full washer modules on only four meters or two COMPACTFLOW
Modules, without reducing the machines efficiency. We have designed the COMPACTFLOW
Down to the detail in the aspects of modular concept, an outsourced and modular plug-and-play
Utility-rack and expandability with growing demands of the production. Menzel has also turned the
Aspect of drastically cut down time for erection and commissioning and for linking the machine to
The customers utility delivery points into reality. In sum and substance, considering all those cost
Aspects, the investment in a COMPACTFOW is a worthwhile investment with a comparably short
Return on investment. The goal of fulfilling the technical requirements of processing and the
Performance requirements on all practical relevant washing methods is not only reached but
Outperformed by the new COMPACTFLOW.
51

LIST OF PRETREATMENT PROCESSING MACHINE

( MI INDUSTRIES ALIGARH UTTAR PRADESH)

1. Singeing Machine OSTHOFF SENGE

2. Desizing Machine MENZEL
3. CBR MACHINE GOLLER
4. CWR MACHINE MENZEL
5. CHAIN MERCERISE GOLLER
6. SOFTFLOW MACHINE KEMPL INDIA
7. JET DYEING MACHINE AKM TAIWAN
8. Hydroextractor DMW INDIA
9. OPENER BIANCO INDIA.