PRODUCT DEVELOPMENT
Ultra Low Liquor
Dyeing of Acrylic Yarn
Treatability
Studies on Textile Effluent Using a Bio-reactor
(Sponsored by M/s. Pali Water Pollution Control, Treatment and Research Foundation
(PWPCTRF) Common Water Treatment Plant, Mandia Road, Pali)
Objectives :
- Characterization of Inlet and Outlet samples collected from common
effluent treatment plants (CETP) of Pali.
- Reduction in Chemical and Biological Oxygen Demands (COD/BOD load) by
biological treatment using a bio-reactor.
- Optimization of experimental conditions for the treatment of effluent
samples through the bio-reactor.
Findings :
The analysis showed that the inlet samples were having high initial COD/BOD loads. A
preliminary treatment was given to the effluent samples to reduce the load on bio-reactor.
A total reduction of ~ 85% in COD of inlet samples could be achieved. The
preliminary treatment could remove ~ 40% of COD and rest of the COD load was
reduced by biological treatment (anaerobic) using the bio-reactor within 24 hours. The BOD
level was simultaneously brought within the permissible limit for disposal of the
effluent. Similar treatment was given to CETP Outlet sample, which was having a moderate
initial COD load. A COD reduction of~ 44% (within 18 hours) was sufficient to bring the
COD value within the permissible limit for disposal of the effluent.
Development
of Combined Sizing and Sectional Warping for Fine Counts/Single Yarn for Producing High
Priced Cotton Fabric for Decentralized Power Loom Sector
(Sponsored by Deptt. of Science & Technology)
Objectives :
- To study the existing practices of sizing in decentralized sector
- To study the practices of sectional warping machine
- To develop a combined sizing and sectional warping system
- To test physico-chemical properties of sized yarn
- To study the performance of sized yarn on loom
- To study the economic feasibility of the developed machinery at the
shop floor
- Training at the shop floor
- Transfer of the technology to the machine manufacturer.
Findings :
Sizing machine has been developed and installed at Tanda, U.P.
“Development of Water Soluble Filament
Yarn” (Jointly with M/s. Zydex Industries, Vadodara)
Objectives :
To develop a quality towel having soft handle and good water absorbing properties.
Progress of work :
Earlier attempts have been made to develop soft handle towel by using Polyvinyl Alcohol
(PVA) filaments with cotton fibre for making pile yarn. During the wet processing, PVA
filaments are dissolved and 100% cotton towel is produed with a soft ahndle and good water
absorbency. PVA in the form of filaments has to be imported, which works out very
expensive. This makes its application in towels unviable. To reduce the cost, NITRA along
with M/s. Zydex Industries is trying to develop an alternate of PVA filaments which is
water soluble.
Development of Combined Sizing Sectional Warping
for Fine Counts/Single Yarn for Producing High Priced Cotton Fabric for Decentralized
Power Loom Sector (Sponsored by Deptt. of Science & Technology)
Objectives :
- To study the existing practices of sizing in decentralized sector
- To study the practices of sectional warping machine
- To develop a combined sizing and sectional warping system
- To test physico-chemical properties of sized yarn
- To study the performance of sized yarn on loom
- To study the economic feasibility of the developed machinery at the
shop floor.
- Training at the shop floor
- Transfer of the technology to the machine manufacturer.
Progress of work :
NITRA is having 7 powerloom centers scattered in various parts of northern region of
India. The main objective of these powerloom centers is to cater the need of decentralized
sector weavers by providing various services through various means including R&D, if
needed. Recently a survey was conducted in some of the powerloom service centers. The
output of this survey revealed that there is a tremendous need of such type of sizing
machine/attachment, which can be used in the existing system available at their work.
Since such type of machine is not available in India, especially for cotton yarn sizing,
it is suggested by the weavers of various powerloom owners to provide a sizing machine
which can be used along with existing sectional warping machine. By the development of
such machine, these weavers can improve their productivity as well as quality of the
product.
Fabrication of the machine is completed. Tests and trails are under progress.
Future Plan :
Installation in decentralized sector for tests and trails.
Development
& Standardization of Technology for Improving Aesthetic & Comfort
for Operation on Terry Towel (Sponsored by Ministry of Textiles, Govt. of
India)
Under this project various towel samples were
collected from decentralized and organized sector and evaluated for
physical & chemical properties. Reasons of poor quality of decentralized
towels were investigated and finally ways and means were suggested to improve upon various
properties. Under the same project, development of Terry towels having
zero twist yarn in pile, is under progress.
Development
of Process to Incorporate Elastane Yarn (Lycra) in a Fabric to get Body Fit Effect
To develop
a indigenous device to be attached on conventional Ring frame for manufacturing elastane
core yarn.
Application of above develop elastane core yarn in knitted fabrics.
Develop an attachment for existing testing instrument to test physical properties of elastane core yarn.To Develop know how of wet processing of above developed fabric and test different chemical properties.
Fabrication of a elastane core yarn attachment has been completed & various elastane core yarn sample have been prepared.
Testing of various elastane core yarn samples have been carried out and knitted fabric samples were also being prepared from these yarn.
The instrument/attachment for elastane yarn count measurement has been developed.
Chemical properties of fabric (Knitted) including dyeing behaviour & impact of processing parameters & dyeing technology has also been completed.
Development of Stop motion for Ring Frame which could stop the spinning process, in case the elastane filaments breaks is also to be done.
Progress
of work :
A
detailed survey of the literature on UV resistant fabric was completed. Relevant patents
and papers were arranged. Chemicals (dyes and UV absorbers) arranged for preparing UV
resistant fabrics, were tested for UV absorbance properties. Polyester cotton blended
fabrics were treated with suitable disperse and reactive dyes, UV absorbers and optical
brightness. Treated fabrics were found to have better sun protection property. Even after
ten washings, dyed fabrics and UV absorbers treated fabrics have retained sun protection
property. However, treatment of optical brightness has not retained the sun protection
property after washing. Mechanical properties like tensile strength, tear strength,
crease recovery, air permeability and bending length have not changed much after treatment
of UV absorbers. One paper on UV resistant fabrics has been prepared. One M.Sc. student
from Lady Irvin College completed training programme in this project on topic “
Development of UV resistant polyester cotton blended fabrics”
Future
Plan :
To optimize the treatment conditions.
Study of combined effect of dyes & UV absorbers.
Testing of treated fabrics Bulk trials.
Development
of X-Ray Opaque Fabric
Objectives
:
To develop
x-ray detectable fabric/material for surgical application (like surgical sponge, woven,
non-woven and knitted laparotomy pad).
Progress of
work :
X-ray
detectable material/fabric has been developed and sent to the sponsorer. Further
work, for development of x-ray detectable items for medical purpose is under progress.
Development of Antimicrobial and Blood Repellant Polyester Cotton Blended Dyed Fabrics
Use of reactive and disperse dyes along with antimicrobrial and blood repellant chemicals in one bathduring developing antimicrobrial and blood repellant polyester cotton blended fabrics.
Analysis of developed fabrics for antimicrobial, blood repellant and physical properties.
Findings :
Reactive dyes alongwith antimicrobial chemical treatment in one bath gives better colour value to fabrics.
Disperse dyes uptake is reduced in presence of antimicrobial chemical
Dyes cannot be used with blood repellant chemicals.
Fabrics have to be treated with antimicrobial and blood repellant treatments separately for getting better results.
Treated polyester cotton blended dyed fabrics show antimicrobial and blood repellant properties.
Wash fastness studies show that even after temp. washings, the antimicrobial and blood repellant properties of polyester cotton blended dyed fabrics are retained.
Tensile and tearing strength shows decrease after treatment. However,
wrinkle recovery angle and bending length show an increasing trend.
The dyed fabrics have good colour fastness to laundering, rubbing, perspiration and light
so it suitable for use.
One M.Sc student from Lady Irvin College completed training programme in this project on topic ‘Simultaneous dyeing and antimicrobial finishing of polyester cotton blended fabric.
Development of composite industrial yarn.
Development of Thermal Resistant fabric from above composite yarn suitable for extremely cold weather conditions.
Assessment of the above developed fabric
As per the objective of the
project, The yarn having three layered structure was spun on friction
spinning system in which the core was of fibre glass which had excellent thermal
insulation property while inner and outer sheath were
made from wool and acrylic fibre respectively. Both these fibres have proven thermal property.
From the above developed yarn, the
required fabric was woven and to increase the thermal resistivity. The fabric was raised on a raising machine. The GSM of the fabric was kept around 300. Various physical properties of the above fabric
was examined and found that strength and abrasion resistance of the fabric is excellent. Regarding thermal resistance property it is much
better than conventional fabric, however, it is still lower than International Standards. Now we are planning to develop some more yarns
with different combinations of fibres and weave them with different fabric structure. So that the thermal resistivity of the fabric can
be increased upto desired level.
Development of Special Melton Cloth for Different
Types of Balls
Development of special cost effective melton cloth for balls.
Development
of balls from developed melton cloth.
Progress of
work :
Elton cloth is used as covering around the rubber core for making tennis ball as well as practice balls for cricket and it required properties like good strength, good wear resistance, good adhesion to rubber core, good shine etc.
Literature search was carried out on melton cloth & Indian and imported melton cloth was arranged.
Reverse engineering was carried out to know the materials and weaving/raising used in the melton clothes. Materials and details of wearing and raising have been identified.
Suitable processing techniques to develop desired melton cloth have been identified.
Various parameters like ends/picks, thickness, bending length, tensile strength, tuft thickness, tuft density, pilling, yarn count etc. have been evaluated for indigenous and imported melton clothes.
Suitable fibres for making melton clothes are being arranged
Future Plan
:
Arrangement of fibres
Preparation and testing of melton
cloth
Development of balls and their testing.
Cotton yarn developed using water soluble PVA fibre. Terry towel manufactured with this yarn and finished. Performance of terry towel showed in terms of physical and chemical properties better water absorbing capacity and lights in weight.
Terry towel fabric is a speciality product which shows its superiority in quality in terms of high softness, good moisture absorption capability and feel of the fabric etc. To get further improvement in the above specific quality of the product, the project was designed in which a speciality bicomponent yarn was developed having a better and softer feel. The yarn is produced by using two different fibres, one of these two components which is water soluble, is dissolved after producing fabric and produces porous, soft fabric which has shown better performances in the above fabric quality.
Under this project a cost effective denim yarn dyeing machine was developed for decentralised sector.
In this project, main type of sewing threads were collected & evaluated viz-a-viz leading international brands. A survey of garment manufacturers was carried out to understand the problems they are facing with various sewing threads presently available in the market. Project led to the development of blended sewing threads.
Since last couple of years, diversified textile products specially for industrial use have been tried for due to their higher value addition. This project was also aimed for same objective and some of the industrial uses have been identified such as filter fabric, tarpauline fabric in addition to some, specially product such as fire and flame retardant, fabric etc. Inspite of using conventional technology, latest DREF spinning technology has been procured to produce core yarn. Two/three products have already been developed and evaluation of the same is under progress
Achievements :
- Literature search was completed
- Antimicrobial fabrics from multinational companies are being arranged.
- Relevant chemicals are being procured
Under this project dyed yarn for
Denim Fabric and other heavy fabric will be developed yarn. different finishing process
will be applied and compared with the conventional fabric in terms of quality cost and
ecofriendly behaviour. |
There are large number of users of HVI & other cotton fibre testing equipments in India. At present, mills have to import calibration cotton which takes quite a lot of time & money. NITRA has decided to develop entire range of calibration cotton for its users. The work is under progress & is expected to complete in near future.
Detail Rheological behaviour of synthetic & natural thickner has been studied. A synthetic thickner has been developed and initial trials show that about 50% replacement of sod-alginate is possible to get best results and performance of developed thickener in pigment, reactive, disperse printing were found satisfactory.
Protective finish formulation using eco-friendly chemicals for cotton and P/c suiting was optimised. The performance study using two different pesticides was carried out using various chemicals and GC method.
In this project around 6 type of spindle oils developed with different additives and undertook the trials first in pilot plant level then after selected best oil \s (three types) for detail industrial trials. The other conventional oils, which are already existing in the market, are also tried. On the basis of their superior properties i.e. lower power consumption, low degradation, low acid numbers, lower sludge formation, better operational life as well as economical in comparison of other market oils. Finally one oil was developed named servo-super EE-10, which is now commercially available in the market, and industries are using it satisfactorily.
The major highlight of the project is development of adsorbent based on natural polymer through suitable chemical modification, which can selectively remove anionic class of unused dyes i.e. reactive, direct etc. from textile effluents generated by cotton process houses. The adsorbent can be regenerated to an extent and reused. The adsorbent being a bio material can be either used as a fuel or in handicrafts after getting exhausted. A provisional patent on the above is under process.
Under this project a sizing lubricant was developed for polyester filament yarn. In this process lubricant is applied on the yarn with a kier roller device. There is no need of any heat energy for drying than yarn. Antistatic property of the lubricant is inbuilt.
Generation of static charges is the inherrent limitation during spinning synthetics and blends. Addition to spin-finish oil prior to spinning reduces the severity of the above deficiency. In view of the potential scope of improvement in spinning performance through use of suitable spin-finish oil. NITRA jointly with Indian Oil Corporation has developed a similar type of lubricant having superior properties.
Pilot plant studies & mill trials indicate the better performance of NITRA – IOC oil both in terms of static charge generation as well as yarn quality. In additon to this NITRA – IOC oil have better controls to combat the static problem during synthetic fibre spinning.
A suitable non-cellulosic polymeric membrane has been developed using indigenous material and simple technique. The membrane has been characterised and evaluated for its performance terms of productivity and rejection. A design and fabrication for polymerisation reaction vessel to prepare membrane casting solution has been done. Efforts are on to produce the membranes in bulk for subsequent industrial trials in textile unit.
An In-house project on development of knitted fabric for comfort is being completed. During the project work three thread fabric were produced of different fibre samples on face & back such as polyester-Cotton, Polyester-Viscose, Acrylic-Cotton & Acrylic-Viscose. The samples were tested for different characteristics and the findings are as below :
- The moisture in knitted fabric is influenced by the fabric characteristics at the face & back of the fabric.
- The rate of moisture transfer from face to back is effected the moisture regain of the fibres at face & back.
- The fibres having a low moisture regain percentage have a tendency to transfer the moisture to a high moisture regain percentage fibre quickly.
- The moisture transfer from face to back is much slower in case of same fibres used at face & back.
- The rate of moisture transfer is higher in the case of fibres used at face & back having the maximum difference in their moisture regain percentage.
- The rate of moisture transfer is highest in the case of Polyester-Viscose sample, facilitating drying of the upper layer in a knitted fabric.
An In-house project on development of knitted fabric for comfort is being completed. During the project work three thread fabric were produced of different fibre samples on face & back such as polyester-Cotton, Polyester-Viscose, Acrylic-Cotton & Acrylic-Viscose. The samples were tested for different characteristics and the findings are as below :
- The moisture in knitted fabric is influenced by the fabric characteristics at the face & back of the fabric.
- The rate of moisture transfer from face to back is effected the moisture regain of the fibres at face & back.
- The fibres having a low moisture regain percentage have a tendency to transfer the moisture to a high moisture regain percentage fibre quickly.
- The moisture transfer from face to back is much slower in case of same fibres used at face & back.
- The rate of moisture transfer is higher in the case of fibres used at face & back having the maximum difference in their moisture regain percentage.
- The rate of moisture transfer is highest in the case of Polyester-Viscose sample, facilitating drying of the upper layer in a knitted fabric.
Under this project new rotor groove geometry for open end rotor machine is proposed. Groove angle, slide wall angle and grooove depth has been optimised to achieve better quality at higher rotor speed. The work on selection of metallergy to reduce power cost and life of rotor is in progress.
The Indian cotton suffers from numerols deficiencies like high trash level, alongwith high incidence of seed coats, foreign matter, contamination fibre length irregularity & matted fibres obtained from unfertilised ovules etc. Due to this short coming most of our mills are not being able to spun yarn of international standard. It is also felt that the improved ginning practices can make a major break through in this direction. Hence it was decided to study the existing ginning technology & practices with a view to develop a suitable ginning m/c for high quality ginned lint.
In this project a new ginning concept has been established. A pilot model of the machine has been designed and optimisation of the process is in progress.
