Md. Rafsan Jany Id # 2007200400024 6 th Batch Supervisor: Dr. Shah Mohammad Fatah-ur- Rahman Associate Professor BIO-PROCESSING OF TEXTILE Bio-polishing & Enzyme washing Project Title 9/25/2014 Bio-processing of Textiles 3 The department of Textile Engineering of Southeast University has given me the field to perform the project with the Bio-processing of Textiles.
I am deeply indebted to our honorable supervising teacher Dr. Shah Mohammad Fatah-ur-Rahman, Associate Professor and my entire course teacher of textile department as their rendered them hand for all kind of help to me.
I would also like to thank Engr. Md. Faridul Hasan, Executive, Dyeing, Viyellatex Group Ltd. for helping by giving me information about the project.
The encouragement as a continued source of inspiration provided by my parents is fully appreciated.
Finally I would like to acknowledge that I remain responsible for the inadequacies and errors, which doubtlessly remain. Acknowledgement 9/25/2014 Bio-processing of Textiles 4 Abstract
Now a days the whole universe is concern about the hygiene and they are looking for eco-friendly processes everywhere. Textile processing is responsible for polluting the environment at a large degree. Use of Cellulase enzyme for denim washing is a standard eco-friendly technique to achieve desired appearance and washing of denim and also the desired appearance of the knit fabric. Applications of enzymes to replace harsh chemicals and other difficulties for the processing industries have been practiced for decades.
I have studied the bio-polishing effect of knit fabric & washing effect of denim fabric with Cellulase enzyme under different condition. 9/25/2014 Bio-processing of Textiles 5 Objectives of the project To know the effect of bio-polishing on knit fabric/garment. To know the effect of enzyme washing on denim fabric/garment. To find out the washing technique by which faded/old look effect is created in the garments. 9/25/2014 Bio-processing of Textiles 6 Limitation It is based on knit fabric. All the experiments had done by cellulase enzyme. Only Focused on bio-polishing & enzyme wash only. Methodology 9/25/2014 Bio-processing of Textiles 7 Visited to different washing Industries and knit dyeing industries Observed Different processes of bio-polishing &enzyme washing (cellulase enzyme) Observed the effect of enzyme on fabric and garments. Group discussion done Selected the suitable Process and Recipe for Enzyme application on Textile Processing Bio-processing can simply be defined as the application of living organisms and their components to industrial products and processes. It is not an industry in itself, but an important technology that will have a large impact on many industrial sectors in the future. Bio-processing is the application of biological organisms, systems or processes to manufacturing industries. Bio-processing firms will rely mainly on inexpensive substrates for biosynthesis, processes that will function at low temperatures, and will consume little energy. Introduction 9/25/2014 Bio-processing of Textiles 8
Enzymes are proteins that catalyze chemical reactions. Mainly they are consist of long chains of amino acids held together by peptide bonds Like all catalysts, enzymes work by lowering the activation energy for a reaction and thus dramatically accelerating the rate of the reaction. However, enzymes do differ from most other catalysts by being much more specific. Enzymes are known to catalyze about 4,000 biochemical reactions.
Enzyme are proteins produced by living organisms. Some enzyme replicated in the lab or engineered to perform in a particular task.
Practically most catalyst have a limited stability & after certain time they lose their activity & are not usable again. Generally most enzyme are used only once & discard after they have done their job. Enzyme 9/25/2014 Bio-processing of Textiles 9 Different types of enzymes are suitable for different stains. Enzyme washing process breaks the stain down into smaller molecules which can be removed by conventional soap or with water.
I worked only with cellulase enzyme . I tried to know the effect of bio-polishing & enzyme washing.
Enzyme works at low temperature & also environment friendly. Many detergent products mix enzyme into their formulas , to ensure that they are effective at all temperature & on all stains. 9/25/2014 Bio-processing of Textiles 10 Cont. ETYMOLOGY & HISTORY In 1876 German physiologist Wilhelm Khne (18371900) proposed that the name 'enzyme' be used as the new term to denote phenomena previously known as 'unorganised ferments', that is, ferments isolated from the viable organisms in which they were formed. The word itself means 'in yeast' and is derived from the Greek 'en' meaning 'in', and 'zyme' meaning 'yeast' or 'leaven'.
Enzymes are usually named according to the reaction they carry out. Typically the suffix -ase is reaction or the type of added to the name of the substrate. 9/25/2014 Bio-processing of Textiles 11 ENZYME & INDUTRIAL APPLICATION Industrial enzymes can be produced in an ecologically sound way where the waste sludge is recycled as fertilizer. 9/25/2014 Bio-processing of Textiles 12 Amylase Desizing (1952). Protease Wool (1984). Cellulase Bio-stoning (1987). Catalase Bleach cleanup (1993). Laccase Denim Bleaching (1996). Peroxidase Enzymatic Rinse (1999). Pectate Lyase Bio-scouring (2003). Industrial application of enzymes started: Enzymes for Textile There are lot of enzymes like amylases, cellulases, catalase, pectinase and protease for various textile wet-processing applications like desizing, bio-polishing, denim finishing, bleach clean-up, bio- scouring and de-wooling. Sources of Enzymes
Successful enzymes for textile bio- processing has yet to be synthesized . Animal Enzyme Enzyme Source Catalase Liver Lipase Pancreas Protease Pancreas Bacterial Enzyme -amylase Bacillus Protease Bacillus Plant Enzyme Protease Carica papaya DIFFERENT TYPES OF ENZYME: Proteases: Proteases are the most widely used enzymes in the detergent industry. Proteases hydrolyze proteins and break them down into more soluble polypeptides or free amino acids. As a result of the combined effect of surfactants and enzymes, stubborn stains can be removed from fibres. Lipases: oily and fatty stains have always been troublesome to remove. The trend towards lower washing temperatures has made the removal of grease spots an even bigger problem .The lipase is capable of removing fatty stains such as fats, butter, salad oil, sauces and the tough stains on collars and cuffs.
9/25/2014 Bio-processing of Textiles 15 Amylases: Amylases are used to remove residues of starch-based foods like potatoes, spaghetti, custards, gravies and chocolate. This type of enzyme can be used in laundry detergents as well as in dishwashing detergents.
Cellulases: Cellulase enzyme has properties enabling it to modify the structure of cellulose fibre on cotton and cotton blends. When it is added to a detergent, it results into the following effects: 1. Color brightening 2. Softening 3. Soil removal 9/25/2014 Bio-processing of Textiles 16 9/25/2014 Bio-processing of Textiles 17 How does enzyme work???? 9/25/2014 Bio-processing of Textiles 18 Lock & key model Induced model 9/25/2014 Bio-processing of Textiles 19 Stage-1: One bath Scouring and Peroxide bleaching Recipe: Anti-foaming 0.07gm/l Rucozen WBX (Detergent) 0.5gm/l Stabilizer SOF 0.5gm/l Primasol jet (Anti-creasing) 1.5gm/l Securon 540 (Sequestering) 1gm/l Caustic 2gm/l H 2 O 2 2.5gm/l pH 10-11 Temperature 105 0 C Time 50min Bio-polishing of knit fabric Stage-2: Bio-polishing Recipe: BP Nano 0.9gm/l Acetic acid 1gm/l T-100 (Peroxide killer) 0.08gm/l Securon 540 0.25gm/l pH 4.5-5 Temperature 55 0 C-60 0 C Time 40-60min 9/25/2014 Bio-processing of Textiles 20 Fresh water and fabric Load at 45 0 C Temperature raise to 60 0 C Detergent & Peroxide Stabilizer (Inject) Run for 5 min Inject Caustic and run 5 min Raise temperature to 70 0 C
H 2 O 2 inject and run 5 min Temperature raise to 105 0 C Process flw chart Bio-polishing before dyeing Bio-polishing after dyeing 9/25/2014 Bio-processing of Textiles 21 Run for 30 min Lower the temperature to 80 0 C Bath drain BP Nano & Acetic acid Securon 540 & Peroxide killer inject Temperature raise to 55 0 C Run for 60 min Rinsing and unload the fabric. 9/25/2014 Bio-processing of Textiles 22 Concentration Temperature pH Time M : L Rnatio Mechanical Agitation Process variables To achieve optimum bio-polishing, the process variables have been varied as mentioned below Concentration of enzyme: 0.5%, 1%, 2%, 2.5%, 3% & 4%. Temperature: 40 0 C, 45 0 C, 50 0 C, 55 0 C & 60 0 C. pH: 3-4, 4-5 & 5-6. M: L: 1:5, 1:10, 1:15 & 1:20. Mechanical Agitation: Vigorous Stirring, Medium Stirring & Without Stirring. 9/25/2014 Bio-processing of Textiles 23 Effects of Bio-polishing experimented Effects of concentration of enzyme on bio-polishing Effects of Temperature of enzyme on bio-polishing Effects of pH of enzyme on bio-polishing Effects of M:L of enzyme on bio-polishing Effects of duration of enzyme on bio-polishing Effects of Enzyme treatment on dyeing property (3% shade) 9/25/2014 Bio-processing of Textiles 24 Properties Result Concentration of Enzyme 0.5% 1% 1.5% 2% 2.5 % 3% 3.5 % Weight loss (%) 0.36 0.77 0.88 1.46 2.09 2.12 2.07 Abrasion (mm) 0.04 0.06 0.07 0.08 0.08 0.09 0.09 Wash fastness 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Pilling rating 3 3 4 4 4 4 4 Effects of concentration Properties Result Temperature 40 0 C 45 0 C 50 0 C 55 0 C Weight loss (%) 0.75 1.03 1.45 2.56 Abrasion (mm) 0.04 0.06 0.07 0.08 Wash fastness 4-5 4-5 4-5 4-5 Pilling rating 3 4 4 4 Effects of Temperature 9/25/2014 Bio-processing of Textiles 25 Properties Result pH 3-4 4-5 5-6 6-7 7-8 Weight loss (%) 0.47 1.21 1.1 0.93 0.86 Abrasion (mm) 0.03 0.08 0.06 0.05 0.04 Wash fastness 3 3 4 3 3 Pilling rating 3 4 4 4 4 Effects of pH Effects of M:L Properties Result M: L Ratio 1:5 1:10 1:15 1:20 Weight loss (%) 1.06 1.12 0.62 0.51 Abrasion (mm) 0.03 0.04 0.06 0.06 Wash fastness 4-5 4-5 4 4 Pilling rating 4 4 3 3 9/25/2014 Bio-processing of Textiles 26 Effects of duration Effects of Enzyme treatment on dyeing property Properties Result Time(min) 30 40 50 60 Weight loss (%) 0.72 1.01 1.42 2.48 Abrasion (mm) 0.04 0.06 0.07 0.07 Wash fastness 4-5 4-5 4-5 4-5 Pilling rating 3 4 4 4
Properties Results Enzymes treatment after dyeing Enzyme treatment before dyeing Concentration of Enzyme 1% 2% 3% 1% 2% 3% Weight loss (%) 0.77 1.23 1.89 0.79 1.25 1.93 Abrasion (mm) 0.04 0.07 0.08 0.05 0.06 0.09 Wash fastness 4 4-5 4-5 2-3 3 3-4 Pilling rating 3 4 4 3 4 4 K/S Values 9.6 8.9 8.1 9.9 9.9 9.9 9/25/2014 Bio-processing of Textiles 27 The best result is obtained at 3% concentration of enzyme. 1:10 M: L ratio gives the best result. At pH range of 4-5, enzyme shows maximum activity. At 55 0 C temperature, enzyme activity is maximum. Mechanical agitation supports enzyme activity. Depth of shade increases when enzyme treatment is given before dyeing and the depth decreases when enzyme treatment is given after dyeing. Pilling tendency decreases with application of enzyme. One bath application saves energy, time & cost. But the bio- polishing effect is not as good as the two bath method. Wash fastness of the enzyme treated sample before dyeing is very poor. Wash fastness of the enzyme treated sample after dyeing is good. Wash fastness of one bath enzyme treated sample is moderate. Discussions 9/25/2014 Bio-processing of Textiles 28 Hairiness fluffs and pills are removed. Material sticking (the burr effect) is prevented. Improved handle Achievement of surface smoothness and a clear structural appearance. Improved luster. Material texture relaxation Increased flexibility and therefore a soft handle even with over end products and mercerized fabric. Improved sew ability. Fast to washing, low pilling tendency, no napping in use, or during care operation. Stone wash effect without pumice stone and dyestuff destroying chemicals. Poor quality, uneven, napped, knoppy material surface (i.e.) typical second quality goods are converted into elegant, lustrous, soft, top quality with a fine, high quality surface appearance. Advantages of bio-polishing 9/25/2014 Bio-processing of Textiles 29 Loss in weight Loss in strength Disadvantages of bio-polishing 9/25/2014 Bio-processing of Textiles 3 0 Enzyme Wash (Denim) Denim fabric composition: 100% cotton Indigo dye.
Weave: twill 3/1 weave Ends/inch: 50-51 Picks/inch: 41-42 Surface density (gm/m2): 352-353 Warp linear density (Ne): 6-7 Weft linear density (Ne): 1 1-12
The denim garments have been processed by various types of enzyme washing and finally softening method as mentioned below. Material selection: 9/25/2014 Bio-processing of Textiles 31 Method of desizing Table1: Recipe of desizing Process parameter Amount Soda ash 400gm Caustic soda 400gm Temperature 70 0 C Time 15min Method of enzymatic wash Table 2:Recipe of enzyme wash Process parameter Amount SL enzyme 400gm Acetic acid 200gm Anti back staining agent 200gm Temperature 40 0 C Time 12min 9/25/2014 Bio-processing of Textiles 32 Method of softening Table 3: Recipe of fabric softening Process parameter Amount Softener(Cationic) 200gm Wash 2 times Temperature Room temp. Time 5min After softening the apparel was washed off for two times. 9/25/2014 Bio-processing of Textiles 33 Changes of fabric specification after washing 9/25/2014 Bio-processing of Textiles 34 Table : Effects of enzymatic wash on fabric specifications Item No. of Observation Before wash After wash Difference % of Difference Average % of Change
-0.825 2 336 333 -3 -0.89 3 338 335 -3 -0.88 4 337 334 -3 -0.89 5 339 336 -3 -0.88 9/25/2014 Bio-processing of Textiles 35 Denim trousers were chosen as apparel and after washing, changes on characteristics of denim trousers has been observed. It is concluded that after enzyme wash the denim fabric changed from harsh to softer. Due to abrasion damage ends/inch and picks/inch of denim fabric has been increased and as a result surface density of fabric increased. Again tensile strength of fabric and seam strength of trousers has been decreased due to enzyme washing. Stiffness of denim fabric has been decreased after washing which results in the increase of denim fabric softness. To hold the qualities of sewn apparel it is very necessary to observe the effects of enzyme wash on denim apparels. Discussion 9/25/2014 Bio-processing of Textiles 36 Enzyme Inactivation To prevent any damage of the fabric after the finishing operation it is very essential that the reaction be terminated at the end of treatment by enzyme inactivation. If the enzyme is not inactivated entirely then at the end of the reaction fibres get damaged and even extreme cases total destruction of the material may result. The enzyme inactivation is therefore of great importance from the technical point of view.
There are two distinct process of termination of enzyme:
1) Hot treatment at 80 0 C for 20 min. 2) By raising the pH to 1112. 9/25/2014 Bio-processing of Textiles 37 Why the industry owner should use Bio- technology in textile processing????? It is very useful during waste managing. Bio-technology helps the quality control. Used instead of harmful dyestuffs and chemical treatments. Prevents the adulteration. Enhance the low energy type detergents. Using enzymes in finishing department. Low temperature operation. Cost saving. Eco friendly. 9/25/2014 Bio-processing of Textiles 38 Conclusion
9/25/2014 Bio-processing of Textiles 39 References Bio- Processing Of Textiles by Abhishek J adhav & J aved Sheikh. Chemistry & Technology of Fabric Preparation & Finishing by Dr. Charles Tomasino. Applying Enzyme Technology for Sustainable Growth by Guifang Wu, Han Kuilderd & Sonja Salmon (Novozymes). Bio Polishing of Knit Goods by Prof. S.K. Laga, Prof. Dr. A.I. Wasif & Mr. Karan Shah (Textile & Engineering Institute, Ichalkaranji). CIRCOTs Eco-friendly Process for Scouring of Cotton Textile: Bio- scouring Annual article of Central Institute for Research on Cotton Technology, Mumbai. Bio-vision in Textile Wet Processing Industry- Technological Challenges by C. Vigneswaran, N. Anbumani and M. Ananthasubramanian. J ournal of Textile & Apperal, Technology & Management; Volume 7, Issue 1, spring 2011. Effects of industrial enzyme wash on denim apparel characteristics by M. M. Rahman, Daffodil International University. www.ptj.com.pk ; J anuary 2011. 9/25/2014 Bio-processing of Textiles 40 THANK YOU ALL
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