Bio processing of textiles - Rafsan

04/13/2023 Bio-processing of Textiles 1

Well come to my presentation


Md. Rafsan JanyId # 20072004000246th Batch

Supervisor: Dr. Shah Mohammad Fatah-ur-Rahman

Associate Professor


BIO-PROCESSING OF TEXTILEBio-polishing & Enzyme washing

Project Title


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


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.


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.

Limitation It is based on knit fabric. All the experiments had done by cellulase enzyme. Only Focused on bio-polishing & enzyme wash only.


Methodology

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


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


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.

Cont….


ETYMOLOGY & HISTORY

In 1876 German physiologist Wilhelm Kühne (1837–1900) 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.


ENZYME & INDUTRIAL APPLICATION

Industrial enzymes can be produced in an ecologically sound way where the waste sludge is recycled as fertilizer. 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 EnzymeEnzyme SourceCatalase LiverLipase Pancreas

Protease PancreasBacterial Enzyme

-amylase BacillusProtease Bacillus

Plant EnzymeProtease 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.


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 brightening2. Softening3. Soil removal


How does enzyme work????


Lock & key model

Induced model

http://en.wikipedia.org/wiki/Image:Induced_fit_diagram.svg


Stage-1: One bath Scouring and Peroxide bleachingRecipe:

Anti-foaming 0.07gm/lRucozen WBX (Detergent) 0.5gm/lStabilizer SOF 0.5gm/lPrimasol jet (Anti-creasing)

1.5gm/lSecuron 540 (Sequestering)

1gm/lCaustic 2gm/lH2O2 2.5gm/lpH 10-11Temperature 1050CTime 50min

Bio-polishing of knit fabric

Stage-2: Bio-polishingRecipe:

BP Nano 0.9gm/lAcetic acid 1gm/lT-100 (Peroxide killer) 0.08gm/lSecuron 540 0.25gm/lpH 4.5-5Temperature 550C-600CTime 40-60min


Fresh water and fabric Load at 450C

Temperature raise to 600C

Detergent & Peroxide Stabilizer (Inject)

Run for 5 min

Inject Caustic and run 5 min

Raise temperature to 700C

H2O2 inject and run 5 min


Process flw chart

Bio-polishing before dyeing

Bio-polishing after dyeing


Run for 30 min

Lower the temperature to 800C

Bath drain

BP Nano & Acetic acid

Securon 540 & Peroxide killer inject


Run for 60 min

Rinsing and unload the fabric.


Concentration Temperature pH TimeM : 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: 400C, 45 0C, 500C, 550C & 600C. 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.


Effects of Bio-polishing experimented

Effects of concentration of enzyme on bio-polishingEffects of Temperature of enzyme on bio-polishingEffects of pH of enzyme on bio-polishingEffects of M:L of enzyme on bio-polishingEffects of duration of enzyme on bio-polishingEffects of Enzyme treatment on dyeing property (3% shade)


Properties

ResultConcentration 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 2.07Abrasion (mm) 0.04 0.06 0.07 0.08 0.08 0.09 0.09Wash fastness 4-5 4-5 4-5 4-5 4-5 4-5 4-5Pilling rating 3 3 4 4 4 4 4

Effects of concentration

PropertiesResult

Temperature400C 450C 500C 550C

Weight loss (%) 0.75 1.03 1.45 2.56Abrasion (mm) 0.04 0.06 0.07 0.08Wash fastness 4-5 4-5 4-5 4-5Pilling rating 3 4 4 4

Effects of Temperature


PropertiesResult

pH3-4 4-5 5-6 6-7 7-8

Weight loss (%) 0.47 1.21 1.1 0.93 0.86Abrasion (mm) 0.03 0.08 0.06 0.05 0.04Wash fastness 3 3 4 3 3Pilling rating 3 4 4 4 4

Effects of pH

Effects of M:L

PropertiesResult

M: L Ratio1:5 1:10 1:15 1:20

Weight loss (%) 1.06 1.12 0.62 0.51Abrasion (mm) 0.03 0.04 0.06 0.06Wash fastness 4-5 4-5 4 4Pilling rating 4 4 3 3


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 4K/S Values 9.6 8.9 8.1 9.9 9.9 9.9


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 550C 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


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


Loss in weight Loss in strength

Disadvantages of bio-polishing

04/13/2023Bio-processing of Textiles 3

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Enzyme Wash (Denim)

Denim fabric composition: 100% cotton Indigo dye.

Weave: twill 3/1 weaveEnds/inch: 50-51Picks/inch: 41-42Surface density (gm/m2): 352-353Warp linear density (Ne): 6-7Weft 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:


Method of desizing

Table1: Recipe of desizing

Process parameter Amount

Soda ash 400gm

Caustic soda 400gm

Temperature 700C

Time 15min

Method of enzymatic wash

Table 2:Recipe of enzyme wash


SL enzyme 400gm

Acetic acid 200gm

Anti back staining agent 200gm

Temperature 400C

Time 12min


Method of softening

Table 3: Recipe of fabric softening


Softener(Cationic) 200gm

Wash 2 times

Temperature Room temp.

Time 5min

After softening the apparel was washed off for two times.


Changes of fabric specification after washing


Table : Effects of enzymatic wash on fabric specifications

Item No. of Observation Before wash After wash Difference % of

DifferenceAverage % of

Change

EPI

1 41 44 +3 +7.32

+6.88

2 40 43 +3 +7.503 39 42 +3 +7.694 42 44 +2 +4.765 42 45 +3 +7.14

PPI

1 38 42 +4 +10.53

+7.33

2 39 41 +2 +5.133 40 42 +2 +54 38 41 +3 +7.895 37 40 +3 +8.11

Warp count (Ne)

1 7 10 +3 +42.86

+34.52

2 8 10 +2 +253 7 9 +2 +28.574 7 10 +3 +42.865 6 8 +2 +33.34

Weft count (Ne)

1 9 10 +1 +11.12

+13.39

2 8 9 +1 +12.503 9 11 +2 +22.234 10 11 +1 +105 9 10 +1 +11.12

Surface density

(gm/m2)

1 337 335 -2 -0.59

-0.825

2 336 333 -3 -0.893 338 335 -3 -0.884 337 334 -3 -0.895 339 336 -3 -0.88


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


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 800C for 20 min. 2) By raising the pH to 11–12.


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.


Conclusion


References“Bio- Processing Of Textiles” by Abhishek Jadhav & Javed 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).“CIRCOT’s 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. Journal 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 ; January 2011.

http://www.ptj.com.pk/


THANK YOU ALL

Bio processing of textiles - Rafsan

Engineering

bioprocessing firms

effect of bio

generallymost enzyme

project titlebioprocessing

washing technique

effect of denim fabric

different types of enzymes

applications of enzymes