Sustainable and Eco Friendly

Alternatives in Textile Wet Processing

area - ATIRA Developments

Sarika Singh, Dr. Md.S Rahman, B S Parikh

Ahmedabad Textile Industry’s Research Association

P O Ambawadi Vistar, Ahmedabad

Date: 01/03/2013

Fibre

1. Spinning Waxes/Oils

2. Sizing Starch, Binder,

Lubricants, PVA etc

3.Weaving

Fabric

4. Fabric Preparatory Process

5. Dyeing /Printing Dyes, Soda Ash, Caustic

Soda, Sodium chloride/Glauber Salt,

Soap etc

* In Knits Manufacturing, sizing is not done.

Textile Manufacturing process

Textile Wet Processing

• Singeing

Removal of hairiness

• Desizing

Removal of sizing ingredients

• Scouring

Removal of Oils, Lipids, Waxes and Pectin from substrate.

• Hypo Bleaching (optional)

Decolorizes coloring matter

• Peroxide Bleaching

Decolorizes coloring matter

• Mercerization

Dimensional stability, Absorbent

• Dyeing / Printing Coloration

Chemicals used in conventional

Preparatory processes • Singeing

• Desizing

In oxidative – Hydrogen peroxide, Caustic soda, Wetting

agent, Sequestering agent, Peroxide Stabilizers etc.

In Enzymatic - Enzymes, Wetting agents, Acetic Acid.

• Scouring–Caustic soda, Wetting agent, Sequestering

agent,

• Hypo Bleaching -Sodium Hypochlorite

• Peroxide Bleaching- Hydrogen peroxide, Caustic soda,

Wetting agent, Sequestering agent, Peroxide Stabilizers

etc

• Mercerization- Caustic Soda, Acids

Environment Scenario

Conventional wet-processing requires use of salts & alkalis, which results in increase in pollution load in terms of T.D.S, color, C.O.D. and heavy metals.

Most important environmental issue facing manufacturing business in India is development of “Green or Environment Friendly” technologies/products.

ATIRA’s developed processes

• Singeing : Can be opted.

• Desizing

In oxidative – Hydrogen peroxide, Caustic soda,

Wetting agent, Sequestering agent, Peroxide

Stabilisers etc.

In Enzymatic - Enzymes, Wetting agents, Acetic

Acid.

• Scouring–Caustic soda, wetting agent,

Sequestering agent.

• Hypo Bleaching-Sodium Hypochlorite

• Peroxide Bleaching- Hydrogen peroxide, Caustic

soda, Wetting agent, Sequestering agent, Peroxide

Stabilizers etc

• Mercerization- Caustic Soda, Acids

Chemicals used in ATIRA’s Developed

process •Desizing cum scouring

Enzymes, Wetting agents, Acetic acid

•Peroxide Bleaching-

Hydrogen peroxide ( 60 % reduction in qty)

Wetting agent, Sequestering agent, Peroxide

Stabilizers (60 % reduction in qty) , Caustic

Soda (90% reduction in qty) etc

(All chemicals are used in significantly less

quantity)

•Mercerization- Caustic Soda, Acetic Acid.

Benefits to ETP

Quality of fabric produced is similar to conventional one.

Contribution to Total Suspended Solids: In conventional process, 7-8 % fibre loss In enzymatic process-2-3 % fibre loss Fibres ( going to ETP) which is

considered as Total Suspended Solids (TSS) will be reduced up to 5% considering Fiber loss only.

Benefits to ETP

Less times of neutralization, less TDS

Almost neutral process, Less Wash

Off water.

Enzymes are Bio-degradable , less

load to ETP Reduced waste-water volume and

pollutant load, reduces cost of Waste-water treatment

Reactive Dyeing

Conventional

Dyes

Sodium

chloride /

Glauber salt

Soda ash

Sodium

Hydroxide

Soap

ATIRA Process

Dyes

Sodium

chloride /

Glauber salt

Soda Ash (70%

less qty)

Sodium

Hydroxide

Soap

Water used in exhaust pretreatment

Dyed fabrics

ATIRA’s Process Conventional

Process

13 baths of each 500 ltrs

and 6 of each 500 ltrs

rinses

Total water : 10,500 lts

for lots of 400-500 kgs

fabric

10 baths of each 500 ltrs

and 4 of each 500 ltrs

rinses

Total water : 7000 lts for

lots of 400-500 kgs fabric

water saving

by 20-25 %

The waste dye liquor & 1st wash off collected are tested :

Sample

Description

Results

pH TDS

(mg/L)

COD

(mg /L)

BOD

(mg/L)

Waste Dye

liquor

Control 10.09 25946 1248 541

Trial 10.20 5686 392 127

1st Post wash

Control 8.61 1438 344 110

Trial 8.39 1348 40 <10

Standard Methods for the Examination of Water & Waste Water, 21st edition, prepared & published by APHA-AWWA-WPCF, USA & BIS method

Results

High productivity: Due to no reaction time

for salts & less neutralization due to very

low alkali in dyeing process, less times is

required for dyeing

Benefits to ETP are more in terms of Total

suspended solids, total dissolved solids,

COD, BOD etc

Developed process are economical due to

less use of chemicals & auxiliaries.

Thank You…..

Contact:

ctd@atira.in / atiralabs@atira.in