What are the benefits of Hot Mercerization?

Short and hot

During hot impregnation the lye penetrates faster and more evenly into the yarn core. Swelling
therefore does not take place only on the fabric surface. As Compared with cold impregnation
the swelling behavior is considerably better and has a positive influence on the dimensional
stability. The more uniform swelling gives, with dyed goods, a more equal appearance. With the
wet-on-wet method the exchange factor is increased thus permitting a shorter impregnation zone
than with conventional processes. In addition, the lye volume is kept very low. The lye
concentration is simple to control. The lye bath has been kept purposely small and under it there
is one single lye tank integrated into the machine.

The process lye is continually circulated and the temperature and concentration monitored. The
automatic lye control permits the addition of fresh lye, water or recovered lye of 20 to 40 B
from recycling. Reaction heat is emitted when mixing the process lye. In hot mercerizing this is
utilized, while in cold mercerizing it causes an energy consuming lye cooling process.
Squeezing to lower lye content is possible with hot mercerizing. The lower lye consumption
provides savings in water and steam at lye extraction.
This is achieved by objective selection of the process parameters such as:

Lye temperature

Lye concentration

Lye reaction time

Fabric lengthwise and crosswise tension

The thus optimized process provides the best mercerizing effect with savings in lye, water and
steam. In comparison with other mercerizing ranges the small lye volume permits very fast
changes in concentration and, therefore, short roduction interruptions. No lye losses occur at
changes. Therefore change over to a lower lye concentration is profitable in addition to the
covering of immature cotton.

Savings of lye, washing water and steam are money for your account.

Instead of 4550 seconds as with cold mercerizing, the same effect can be obtained in only 25
30 seconds with hot mercerizing. In order to keep width contraction as low as possible, the fabric
is kept under constant tension during the reaction phase. No selvedge to middle differences
occurs with the DIMENSA. In the retention compartment of the DIMENSA the proven chainless
principle with lifting top rolls is employed. The retention compartment is not flooded. On the
DIMENSA MS the cloth is pinned onto the integrated stenter at the end of the retention
compartment. On the DIMENSA ML the retention zone consists of a chainless reaction
compartment only.

To summarize the benefits of Hot mercerization:

Faster caustic soda penetration speedier swelling

 High swelling uniformity no ring mercerizing

Better dye penetration

Smoother cloth appearance

softer handle

Shorter impregnation times

No cooling needed for mercerizing

Maximum squeezing action at in feed squeeze

Lower investment cost through shorter impregnation sections

Further positive features of tensioned mercerizing are:

Orderly orientation in the crystal areas

Removal of fiber unevenness

increasing the number of micropores

Unification of the pore size

And from this result:

Better residual moisture

Better luster

[Comparison of Hot & Cold Mercerization]

Better dyeing behavior with an increased dyestuff yield

Better handle

Coverage of immature cotton

Courtesy: Benninger AG
How to improve the tear and tensile strength of the fabric?

1. i. There are many reasons for the loss of tensile and tear strength. Right from
singeing, if the intensity and height of the flame is higher than the required; the
fabric is likely to be scorched. To avert this, various speeds ranging from 70, 80,
90 meter/minute are to be tried in singeing and the efficiency can be ascertained
by pilling test over specified measurements (10 x 10 sq.in).
2. ii. Excessive emerizing may lead to strength loss.
3. iii. Resin finishing (for DP value) : A loss of 20 per cent fabric strength is
unavoidable if the chemicals after application and curing are not properly washed
by suitable alkali treatment (2 gpl soda ash in cold water and then washing etc.).
We also suggested a suitable recipe for obtaining a better DP value onn their
fabric.
1. DMDHEU Resin = 60 gpl
2. Magnesium Chloride = 15 gpl
3. Poly-ethylene emulsion = 24 gpl
4. Silicone emulsion = 15 to 20 gpl
5. Acetic Acid = 2 gpl
6. 100% Non-ionic wetting agent = 2 to 3 gpl
1. PAD DRY @ 120 to 130C CURE @ 140 to 150 C for 4 to 5
minutes
2. Fabric is washed in an open soaper with 2 gpl soda ash at cold in
the 1st compartment and then cold wash in all other compartments.