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Scouring

To remove pectic substances and cotton wax contained in cotton


woven fabrics, the use of caustic soda (NaOH), strong alkali, is the most effective. The
caustic soda has the effects of not only converting water-insoluble pectose contained in
pectic substances into water-soluble pectic acid soda, but also of hydrolyzing
(saponifying) cotton wax. However, a single use of the caustic soda does not provide
enough penetration, emulsion, washing, and scouring powers, and so a surfactant is
generally used together. A chelating agent may also be used together to prevent
insolubilization caused by calcium and magnesium. Also, a method of scouring with an
enzyme instead of with the caustic soda is being considered in recent years. In this
case, protopectinase is used for degrading pectin, and lipase and the like are used for
degrading oil.

Objects of scouring:

To make the fabric highly hydrophilic.


To remove impurities such as oils, waxes, gum, husks,as nearly as posible.
To produce a clean material by adding alkali.
To make the fabric ready for next process.
To remove non-cellulosic substance in case of cotton.

Scouring process depends on:

The type of cotton.


The color of cotton.
The claanlliness of cotton.
The twist and count of cotton.
The construction of fabric.
The shade % and type of shade of finished product.

Process of scouring:
1) Kier Lining: Prior to filling the fabric in kier.
i) STANDARD: No cheeping of interior wall of kier.
ii) ACTION: Ensure proper cementing of interior wall of kier.
iii) FILLING DENSITY: 7-8Kg/Cubic feet during filling of kier.
2) Removal of Air:
i) ACTION: Air removal before raising pressure
ii) STANDARD: No air, ensure complete removal of air.
3) Circulation:
i) During scouring, circulation is tested by flow rate method.
ii) STANDARD: Smooth circulation.
iii) ACTION: Cleaning of circulation pump.
4) Recipe:

i) Concentration of scouring liquor: Check by titration before and during process.


ii) ACTION: Adjust the concentration.
iii) PRESSURE: 15psi or as per quality and regulate steam supply.
iv) TIME: Previous time record or as per quality.
v) CONCENTRATION OF BLEND LIQUOR: Standard 90% must be consumed

Bleaching
Bleaching of textile material is a commercial, chemical process can be defined asDestruction of natural coloring matters to impart a pure permanent and basic white
effects suitable for the production of white finishes, level dyeing and desired printed
shade with the minimum or number tendering or without diminishing the tensile
strength.

Bleaching agent:
Hydrogen peroxide.
Calcium hypochlorite.
Bleaching agent.
Sodium hypochlorite.
Sodium chlorite.
per acetic acid.
Ozone.
Zinc dust.
Staneaous chloride.
Ferrous sulphate.
Sulphur di-oxide.

Hydrogen Peroxide (H2O2) Bleaching:


The H2O2 bleaching is the most common bleaching method,
and is environmentally friendly (degradable into water and oxygen). The best
bleaching whiteness can be obtained at pH 11 adjusted using caustic soda.
However, if metal ions, such as iron ions and copper ions are present in fabrics
or in water, catalytic action of these metal ions causes abnormal degradation of
H2O2, which may sometimes cause embrittlement of fabrics until holes (pinholes) are generated due to the excessive degradation.
Usually, the abnormal degradation of H2O2 and the resulting generation of pinholes are prevented by adding a chelating agent. Also, as a stabilizer for H2O2,
sodium silicate has been conventionally employed. The obtained bleaching
whiteness is favorable. However, the use of sodium silicate has the following
disadvantages. Silica scales are generated due to calcium ions and magnesium
ions reacted with silica ions. The generated silica scales are adhered to
machinery, damaging fabrics, or undermining hand of the fabrics.
This case, however, suffers from a contradiction that complete removal of

calcium ions and magnesium ions will undermine the stability of H2O2.
To solve the disadvantages and contradiction, a non-silicate type stabilizer
containing no sodium silicate has been developed, although the cost is higher
than sodium silicate.
Furthermore, when dyeing is performed without a drying process after the H2O2
bleaching, the problem of residual H2O2 arises. 10ppm of residual H2O2 or more
causes dyeing problems, although it depends on a type of dye. To degrade the
residual H2O2, a reducing agent or the like, or an enzyme (catalase) can be
used. The enzyme appears as a current mainstream.

Sodium Chlorite (NaClO2) Bleaching:


The NaClO2 bleaching is performed after pH
adjustment to 3.5 with an acid such as a formic acid. It provides soft hand with
less embrittlement of cotton. Compared with the H2O2 bleaching, some insist
that even bluish (?) whiteness can be achieved with the NaClO2 bleaching.
Also, the NaClO2 bleaching is free from worries about pin-hole generation, as
often occurs in the H2O2 bleaching. However, a harmful chlorine dioxide gas is
generated during the bleaching process, and therefore, suitable measures
including the equipments need to be taken for metallic corrosion problems and
dechlorination purposes. After bleaching, a dechlorination process needs to be
provided. A trace chlorine which exists in fabrics reacts with nitrogen compound
to form chloroamine, or cause yellowing of the fabrics when exposed to light and
heat.
Note here that a special reducing agent, sodium thiosulfate (hypo), or hydrogen
peroxide (so-called, `cosmetic bleaching`) is used for the dechlorination
purposes.
Sodium chlorite low-temperature activator

BRITE FB CONC

One-bath desizing and bleaching


Desizing agent
Bleaching auxiliary

BIOGEN 300
BIOGEN NN

Dechlorination agent

BRITE CL-B

Sodium Hypochlorite (NaClO) bleaching:


The NaClO bleaching is characterized in that the
bleaching is performed at room temperatures without requiring a heating
apparatus such as a steamer, and that the chemical cost is low. However, the
disadvantages of the NaClO bleaching include relatively low bleaching whiteness
and embrittlement of fabrics.
No particular pH adjustment is required in the NaClO bleaching. The NaClO
bleaching is usually employed for bleaching fabrics after Kier-scouring, or for
bleaching towels. For towels, the two-step bleaching comprising the NaClO
bleaching and the H2O2 bleaching is preformed to obtain full whiteness. The
NaClO bleaching is also employed for jeans fade adjustment, etc.
Note here that a dechlorination process needs to be provided as in the NaClO2

bleaching. Since `chlorine free` is a recent trend, like PRTR, a method without
using chlorine is being examined. The same applies to NaClO.

Process of bleaching:
By Kinetic study of bleaching, take 3 titration at 5 minutes. If
decomposition in 2nd and 3rd titration is fast then metallic impurity is present.
Remedy: Hexametaphosphate (7-8gpl to 15-20gpl is taken. It does not chelate Fe ion. If Fe ion
is present
then EDTA is used. If hardness of water is around 250-300 PPM, then 3gpl EDTA is sufficient,
but in
presence of Fe Ion 6-8gpl is needed at 250-300 PPM Hardness. EDTA chelate is stable at higher
temperature).

Concentration of Chemical:
Concentration is selected from uniformity and reproducible
results of previous processing. Adjust the
feeding concentration of chemical as required.
PROCESS CONTROL AND SAFETY IN CHEMICAL PROCESSING Prof.Y.M.Indi

Stock Solution Quantity:


Take study of MLR of process or nature of fabric quality.
STANDARD: Full consumption of Stock solution should be there, nothing should remain back
as wastage.

Temperature:
Check temperature during process. Temperature depends on bleaching process and bleaching
chemical.
Regulate steam supply as needed.

Time:
METHOD: Dwell time record, concentration of bleaching method and process selected.
Give adequate
treatment time.
pH: Adjust the pH during the process by pH indicator or pH paper.

STANDARD: For Hypochlorite 9.5-10.5 and for Hydrogen peroxide 10.5-11.5.


Concentration of Drain: After bleaching, with the help of titration ensure
optimum utilization.

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