Sep 20, 2015

Nonwoven Fabrics: Raw Materials, Manufacture, Applications, Characteristics, Testing ProcessesWilhelm Albrecht (Editor), Hilmar Fuchs (Editor), Walter Kittelmann (Editor)




From the utilization of textile waste to the high-tech product - this is how modern nonwovens can best described.
Web formation and web bonding processes have recently being enhanced. Nowadays, fibres, granulates, binder and finishing agents are used. This development entails a wider range of applications in the fields of hygiene, medicine, the garment-producing and building industries, interior design as well as further technical uses. 

This book provides comprehensive information about nonwovens, from the raw material fibres via the manufacturing processes to finishing and to the ready-made product. Nonwoven characteristics and the fields of application are discussed in detail as well as the processes available to test the raw materials, the intermediate and the final products.

This book will be the standard reference on nonwovens in the years to come!


Recycling in Textiles, 1st Edition by Y Wang  




Youjiang Wang

Dr Youjiang Wang is a Professor of Polymer, Textile and Fiber Engineering at Georgia Institute of Technology. He is a fellow of the American Society of Mechanical Engineers (ASME) and of the Textile Institute.

Key Features

  • Provides extensive coverage of this hot topic
  • An invaluable guide for all in the textile industry
  • Learn how to increase the rate of recycling

Description

An increasing amount of waste is generated each year from textiles and their production. For economic and environmental reasons it is necessary that as much of this waste as possible is recycled instead of being disposed of in landfill sites. In reality the rate of textile recycling is still relatively low. On average, approximately ten million tonnes of textile waste is currently dumped in Europe and America each year. Considering the diversity of fibrous waste and structures, many technologies must work in concert in an integrated industry in order to increase the rate of recycling. Recycling in textiles shows how this can be achieved.

The first part of the book introduces the subject by looking at the general issues involved and the technologies concerned. Part Two explores the chemical aspects of textile recycling. Part Three focuses on recycled textile products, including nonwovens and alternative fibres. Finally, the last part of the book discusses possible applications of recycled textiles, including using recycled products in the operating theatre, for soil stabilisation and in concrete reinforcement.

Recycling in textiles presents several promising technologies and ideas for recycling systems. This is the first book of its kind to bring together textile recycling issues, technology, products, processes and applications. It will prove an invaluable guide to all those in the industry who are now looking for ways to recycle their textile waste.

Key words:
Bleaching, cotton knit fabric, light shade, shade matching, color fastness, energy saving, cost effective
1. Introduction:
Energy is one of the most important ingredients in any industrial activity [1]. However, its availability is not infinite. Global energy crisis, as well as high cost of fuels resulted in more initiatives to conserve energy to best possible extent. Knit dyeing process is one of the most crucial and dominating sector in Bangladesh, as Bangladesh earns around 40% of its foreign currency through this sector [2]. Undoubtedly this is the sector where we can dig attention for energy saving purpose and hence, steps should be taken to make this sector stronger by reducing processing time, production cost and by saving environment. Process time is a very important factor for a dyer, because a dyer delivers his product within lead time that is given by the buyers. To deliver product, dyer must reduce his dying time that also ensure more production means more money. In this competitive world reduction of processing cost is also a major factor. Moreover, it is of utmost necessity to keep our environment free from pollution of different chemicals used in dyeing factories. So to save environment a dyer should use least number of chemicals and preferably no hazardous chemicals for performing dyeing. In cotton knit dyeing process, reduction of process time and reduction of chemicals in the preparatory stage can play a significant role in the above aspect. However without using peroxide in the preparatory process, it could be possible to obtain desired shade after dyeing. But actually up to the scope of searching through internet or books, no relevant research works were found in a justified way.
To run with the processing heads, focusing on scouring, bleaching and so on can be initiated here. Natural fibers (cotton) are yellowish or off-white in color due to color bodies present in the fiber and cotton also contain oils, fats, waxes, minerals, leafy matter and motes as impurities that interfere with dyeing and finishing [3]. The process of destruction of yellowish or off-white color bodies is called Bleaching and the process of removing impurities and making good absorbency is called Scouring
2. Materials and Methods
2.1 Raw materials
Same fabric of Table 1 has been used in all trials done both in lab and bulk.
2.2 Methods:
The fabric was dyed in exhaust method in the laboratory and in bulk scale at Padma Poly Cotton and Knit Fabrics Ltd.
2.2.1 Processes followed in laboratory trial:
A. Pretreatment:


The samples were categorized as dyed samples with bleaching and dyed samples without bleaching at same dye bath and same recipe.
2.2.2 Processes followed in bulk trial: 
2.2.3 Process followed in testing
For colour fastness to wash ISO 105 C03 was method followed; for colour fastness to rubbing /crocking   EN ISO 105×12 was method followed and for color fastness to perspiration ISO 105 E02 method was followedIn respect to colour fastness properties, the unbleached samples revealed the same better results as it was in case of bleached samples.
3. Results and discussions
3.1 Color Measurement Committee (CMC) DE pass/fail values:
The above result shows that dyeing without bleaching is possible up to 0.5% red, 0.5% blue and 0.1% yellow shades and also for specific combination shades (0.5%)
4. Cost analysis
In the bulk trial bleaching process needed 9 chemicals and without bleaching process only 6 chemicals were used. So process without bleaching saves extra 3 chemicals.
4.1 Cost of chemicals (Source: Purchasing department of Padma Poly Cotton)

From the table it is clear that process without Bleaching saves 757Tk/1000kg (approx.) fabrics.
4.2 Time saved 
As per table 3, the process with bleaching needs 243 min and process without bleaching needs 185 min. So process without bleaching saves 58 min. As a result process without bleaching provides following benefits because of less time consumption:
1. Production will increase
2. Labor cost will decrease
3. Saves machine running cost. i.e. electricity, gas, and power cost.
4.3 Energy cost calculation for MCS dyeing machine [4]
1kw hour = 1 unit of electricity
1 unit cost  = 5.5Tk (approx)
Dyeing machine is of 60 KW capacity
o it consume 60×1 = 60 unit per hour
Cost =60×5.5 = 330Tk/hr
Since process without bleaching save 58 minutes, So it saves 58×5.5 = 319Tk (approx.) energy cost.
Source: Maintenance department of Padma Poly Cotton and Knit Fabrics Ltd.
4.4 Water saved due to elimination of per-oxide
The trial was done in Material: Liquor = 1:6. For conventional pretreatment process 30000lt water was required, whereas without bleaching pretreatment process required 24000lt. So proposed process saves extra 6000lt of water.
A. Cost of treated water after Water Treatment Plant (WTP) :

So for 6000 lt of water process without bleaching saves 6x5.11 = 30.66 Tk(approx.)
B. Cost in ETP :

So, for 6000Lt of water process without bleaching saves 6x11.97 = 71.82 Tk (approx.)
Total cost for 6000lt water = 30.66+71.82 = 102.48Tk = 103 Tk. (approx.)
4.6 Savings from cost of heating
Here:
Heat Needed= Specific Heat of Water(4.186 kj/kg/°C)*mass of water*change in temperature.
Heating Cost Savings=(Heat Needed/Specific Enthalpy of steam)*cost of steam
Cost of steam: Considering the steam cost of PPC

4.7 Total saving in cost

So proposed process saves 1466Tk/1000kg (approx.) and 58 minute duration.
5. Conclusion:
Detailed experimental data were manipulated through the research work. As the elimination of bleaching results the grayness retaining in cotton fabric, CMC DE pass/fail comparison with conventionally treated fabric were investigated.  Consequently color fastness to wash, rubbing and perspiration have been tested. During this experiment dyeing is performed for shade percentages of 2, 1.75, 1.5, 1.25, 1.00, 0,75, 0.50, 0.25, 0.10  with bleaching and without bleaching for Red, Yellow, Blue and combination shades. For Red, Blue and combination color up to 0.5% shade has been passed in data color result but below 0.5% the result in data color did not pass. It was passed up to 0.1% shade in case of yellow color. Besides, samples passed in data color results have been shown good color fastness (washing, rubbing and perspiration) values. Some bulk dyeing has been performed in factory after successful completion of laboratory trials. Experiments were done on two different combination shades % i.e. 2% and 1% and the results have been derived successfully. It can be concluded that dyeing with red (0.5%), blue (0.5%) and yellow (0.1%, 0.25%, 0.5%) colors, excluding bleaching process passed at data color 650 (CMC pass/fail) with conventional (including bleaching) dyeing process. In case of specific combination shade it was found that 0.5% shade is possible without bleaching operation. Cost analysis displays that 1220Tk (approx.) was saved per 1000 kg fabric dyeing through the proposed way.
References
1. http://www.fibre2fashion.com/industry-article/4/316/cost-effectiveness-in-textile-processing1.asp
2. Hasan, Md. Rakibul, "Scopes of Improvisation in Knit-Dyeing process of Cotton in Bangladesh to optimize the process-time", Bangladesh Textile Today, March-April 2010.
3. Tomasino, Dr. Charles, "Chemistry & Technology of Fabric Preparation & Finishing" North Carolina, USA.
4. Interview from Mr. Sehk Asadullah Tareq, Head of the department of Maintenance. Padma Poly Cotton & Knit Fabrics Ltd.
5.  Interview from Sahida Sultana, Manager of the department of ETP and WTP. Padma Poly Cotton & Knit Fabrics Ltd.

Smart Fibres, Fabrics and Clothing: Fundamentals and Applications (Woodhead Publishing Series in Textiles) by X M Tao



About the Author
Xiaoming Tao is Head and Chair Professor at Hong Kong Polytechnic University. Prof. Xiaoming Tao is Chair Professor and Head of the Institute of Textiles and Clothing. Graduating with a Beng in Textile Engineering and a first-class prize for undergraduate students from the East China Institute of Textile Science and Technology in 1982, She gained her PhD in Textile Physics from the University of New South Wales, Australia in 1987. Prof. Tao is an elected fellow of the Textile Institute International and the Hong Kong Institution of Textile and Apparel. She is a member of various professional societies including the Optical Society of America, the American Institute of Physics, the Institute of Electrical and Electronic Engineers, the Chinese Society of Textile Engineers as well as the Hong Kong Society of Materials Research and the Hong Kong Society of Theoretical and Applied Mechanics.

Product Details

  • Series: Woodhead Publishing Series in Textiles
  • Hardcover: 336 pages
  • Publisher: Woodhead Publishing; 1 edition (October 18, 2001)
  • Language: English
  • ISBN-10: 0824750608
  • ISBN-13: 978-1855735460
  • ASIN: 1855735466
  • Product Dimensions: 6.1 x 0.8 x 9.2 inches


This important book provides a guide to the fundamentals and latest developments in smart technology for textiles and clothing. The contributors represent a distinguished international panel of experts and the book covers many aspects of cutting edge research and development.

Smart fibres, fabrics and clothing starts with a review of the background to smart technology and goes on to cover a wide range of the material science and fibre science aspects of the technology including: Electrically active polymeric materials and the applications of nonionic polymer gel and elastomers for artificial muscles; Thermally sensitive fibres and fabrics; Cross-linked polyol fibrous substrates stimuli-responsive interpenetrating polymer network hydrogel; Permeation control through stimuli-responsive polymer membranes; optical fibre sensors, hollow fibre membranes for gas separation; integrating fibre-formed components into textile structures; Wearable electronic and photonic technologies; Adaptive and responsive textile structures (ARTS); Biomedical applications including the applications of scaffolds in tissue engineering

It is essential reading for academics in textile and materials science departments, researchers, designers and engineers in the textiles and clothing product design field. Product managers and senior executives within textile and clothing manufacturing will also find the latest insights into technological developments in the field valuable and fascinating.

Textile dyes is first of its kind ever published,reflects my past 18 years experience in textile chemical processing.







Mr. Mansoor Iqbal acquired his M.Sc in Textile and Polymer Technology, with erudite knowledge in textile wet processing. He has 17 years of research, education and industrial experience in various national and multinationals including Sumitomo dyestuffs application laboratory, ITTM textile institute, Siddiq sons industries, Al-Abid silk mills. Mansoor is currently working as a Senior Textile Research Associate at PCSIR.
He has published books on textile dyes, and textile fibres. He has also submitted various research papers elaborating on textile, dyeing, printing, light fastness, and tensile properties. Mansoor's hobby zone includes cricket, reading, and music.

Textile Printing Revised Second Edition By Leslie W. C. Miles
  Discover books, learn about writers, read author blogs, and more.




  • Hardcover: 320 pages
  • Publisher: Amer Assn of Textile; 2nd edition (June 1994)
  • Language: English
  • ISBN-10: 0901956570
  • ISBN-13: 978-0901956576
  • Product Dimensions: 0.8 x 6.5 x 9.5 inches


“Textile Printing is sometimes regarded as an industrial art, having a long history and an assured future. Although it will always be a multidisplinary activity, in the 21st century it is highly dependent on science and technology. The aim of this book is to introduce the reader to all technical considerations that are important in textile printing. At the same time the various authors, all with long experience in the industry, encourage the reader not to loose sight of the human factor in producing successful results, which require the coordination of many individuals’ skills. All the major printing techniques are covered, including screen printing, the dominant method at the present time. A brand new chapter on digital systems has been included.”

The Apparel Industry

by Richard Jones (Author)

About the Author

Richard Jones is a former Principal Lecturer in the Department of Clothing Design and Technology, Manchester Metropolitan University. He is also Editor of the Journal of Fashion Marketing and Management.




Product Details

  • Paperback: 328 pages
  • Publisher: Wiley-Blackwell; 2 edition (August 18, 2006)
  • Language: English
  • ISBN-10: 1405135999
  • ISBN-13: 978-1405135993
  • Product Dimensions: 6.8 x 0.6 x 9.6 inches

This textbook describes the structure of the industry in the UK and globally, and explains the current problems and strategic responses to global shifts in production. The new edition has been updated throughout to include the lastest available data, and takes account of the acceleration of the decline of manufacturing in the UK since 2002, the rapid expansion of production in China, and the final demise of the system of quota control. * Essential subject for students at undergraduate and postgraduate levels. * An expert guide to a bewilderingly complex industry. * No competition. * Addresses global issues, the opportunities and threats, with strategies for survival. * Author is Editor of International Journal of Fashion Marketing and Management.


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