jet dyeing.day1 contain entire detail terms on jet dyeing

will give knowledge about textile processing

1. Training on Jet dyeing Machine

2. Economics of manmade Fibre in surat Surat , located in the state of Gujarat, India, is one of the leading hubs for the production of man-made fibers, particularly synthetic fibers such as polyester and nylon. The economics of man-made fiber production in Surat is influenced by several factors: Industrial Cluster: Surat has developed into a prominent industrial cluster for synthetic fiber manufacturing due to factors such as availability of raw materials, skilled labor, infrastructure, and supportive government policies. The presence of a well-established ecosystem of suppliers, manufacturers, and service providers contributes to the economics of the sector. Raw Material Availability: Surat benefits from proximity to petrochemical refineries and polymer manufacturers, which supply the raw materials required for synthetic fiber production. Petrochemical feedstocks such as ethylene and propylene are used in the production of synthetic fibers like polyester

3. Economics of manmade Fibre in surat Technological Advancements: The synthetic fiber industry in Surat has witnessed significant technological advancements and modernization efforts, leading to improved production efficiency, product quality, and cost-effectiveness. Investments in machinery, equipment, and research and development contribute to the economics of the sector. Export Orientation: A significant portion of the synthetic fibers produced in Surat is exported to international markets. The city's strategic location, access to ports, and competitive pricing make it a preferred sourcing destination for global buyers of synthetic fibers. Domestic Market: In addition to exports, Surat's synthetic fiber industry caters to the domestic market, supplying fibers for a wide range of applications including textiles, apparel, home furnishings, industrial fabrics, and technical textiles. Growing domestic demand for synthetic fibers further enhances the economics of the sector.

4. Economics of manmade Fibre in surat Value Addition: The synthetic fiber industry in Surat encompasses various value-added activities such as spinning, texturizing, weaving, knitting, dyeing, and finishing. These value addition processes contribute to the overall economic output of the sector and create additional employment opportunities Government Support: The government of Gujarat and the central government of India have implemented various policies, incentives, and initiatives to support the growth and development of the synthetic fiber industry in Surat . These include infrastructure development, subsidies, tax incentives, and skill development programs. Overall, the economics of man-made fiber production in Surat is characterized by its significant contribution to industrial growth, export earnings, employment generation, and value addition. The sector's resilience, competitiveness, and adaptability to changing market dynamics contribute to its continued growth and sustainability

5. What is fibre ? A fibre is  a thin thread of a natural or artificial substance, especially one that is used to make cloth or rope . Fiber , in the context of textiles and materials, refers to a slender, thread-like structure that is either natural or synthetic and has a high ratio of length to thickness. Textile fiber can either be natural or synthetic which can be converted into yarns and then subsequently into fabric by weaving, knitting, and nonwoven. It is the smallest unit of textile production.

6. Properties of Textile Fibers

7. WHAT ARE PRIMARY PROPERTIES? Primary properties are essential properties which a particular fiber must possess in order to perform as a textile fiber . They are like the pre-requisites or mandatory properties that textile fibers should possess.

8. PRIMARY PROPERTIES LENGTH TO WIDTH RATIO TENACITY COHESIVENESS OR SPINNING QUALITY FLEXIBILITY UNIFORMITY

9. Length to width ratio Is the ratio between the length and breadth of a textile fiber. The textile fiber should be sufficiently long than its width. The minimum ratio is 1:100. This means that the measure of the length should be at least 100 times more than the measure of its width.

10. Length to width ratio of some textile fibers Fiber Length to width ratio Cotton 1400 Wool 8000 Flax 170 Silk 330000

11. Tenacity Tenacity refers to the strength of the fiber. A fiber should have adequate strength so as to undergo the stress and strain encountered during yarn manufacturing processes. Every textile fiber possesses varying levels of strength. Some possess higher strength and some possess lower. Also the strength of textile fibers varies in the dry state and wet state.

12. Tenacity of Some Common Fibers Fiber Grams Per Denier Cotton 3.0 - 4.9 Jute 3.0 - 5.8 Flax 2.6 - 7.7 Silk 2.4 - 5.1 Wool 1.1 - 1.7

13. Spinning quality or Cohesiveness Spinning quality or Cohesiveness is the ability of the fibers to stick together during yarn manufacturing processes. Spinning quality refers to Filament fibers. Cohesiveness refers to Staple fibers.

14. Staple fibers are shorter fibers and are measured in cms or inches. Cotton Fiber Jute Fiber Filament fibers are long fibers and are measured in kms or miles. Silk Fiber

15. Cohesiveness Staple fibers exemplify cohesiveness or stickiness in different ways . Example: Cotton fibers exhibits its cohesiveness by its cross sectional structure. Its cross sectional structure is kidney shaped because of its convolutions, which are the indentations in the structure of the cotton fiber.

16. Cohesiveness convolutions The kidney shaped structure of a cotton fiber enables it to adhere to or fit into another fiber, thus sticking together during yarn manufacturing.

17. Cohesiveness The longitudinal structure of wool fiber has serrated edges resembling a pine tree. With the help of these serrations one fiber entangles into the other, thus sticking together during yarn manufacturing serrations

18. Spinning quality In the case of filament fibers because of their long length they are spun into yarns by twisting or winding two or more filaments together. Example: Silk fibers are very long. The long length enables the twisting and spinning of these fibers.

19. Flexibility Flexibility is the ability of a fiber to bend without breaking during yarn manufacturing or during the regular wear and tear of the fabric in its end use. Textile fibers must be pliable, only then they can be spun with other fibers. Many substances in nature resemble fibrous forms, but cannot be practical textile fibers because they are stiff and brittle.

20. Uniformity To make a good quality yarn, every textile fiber must have uniformity in their properties. Synthetic fibers are far more uniform than natural fibers. Uniformity is inherently difficult to achieve in natural fibers. Thus natural fibers are blended to achieve uniformity.

21. What are Secondary properties? These are desired properties which a particular textile fiber might possess or not. Textile fibers might possess few of these properties and not necessarily all of them. Secondary properties increase the value of textile fibers in its intended use.

22. SECONDARY PROPERTIES Physical shape Lustre Specific gravity Elongation and Elastic recovery Moisture regain and Moisture content Resiliency Thermal behavior

23. Physical shape Physical shape comprises of the longitudinal and cross sectional structure of the textile fiber. Each textile fiber has its own physical shape. Natural fibers have surface irregularities while the shape of the synthetic fiber depends on the shape of the spinneret or mould through which it is extracted.

24. Physical shape Cross sectional and Longitudinal view of Cotton fiber

25. Physical shape Cross sectional and Longitudinal view of Silk fiber Longitudinal and cross sectional view of Viscose rayon Fiber

26. Physical shape Nylon Polyester

27. Lustre Lustre is the shine or sheen of a textile fiber. Textile fibers can be shiny, moderately shiny or even dull. Example: Amongst natural fibers, Silk is shiny and lustrous. In synthetic fibers, Viscose rayon is very lustrous. Sometimes when shine is not desired in these fibers, it can be controlled using a delustrant , like titanium dioxide

28. Lustre Lustre of a textile fiber very often depends on its physical shape. Silk has a smooth structure. When light falls on a smooth surface it reflects, hence silk looks shiny.

29. Lustre Whereas cotton has indentations or an irregular structure, hence when light falls on it breaks and does not reflect. Thus cotton looks dull.

30. Specific Gravity Specific gravity refers to the density of a fabric . Denser fabrics have more specific gravity than lighter fabrics . Cotton with a specific gravity of 1.54 is denser than silk with a specific gravity of 1.25.

31. Specific gravity of some common fibers Fiber Specific gravity Cotton 1.54 - 1.56 Flax 1.50 Jute 1.48 Silk 1.34 Wool 1.30 - 1.38 Viscose rayon 1.52 Nylon 1.14

32. Elongation The ability of a textile fiber to stretch when subjected to a force . This stretching is called as elongation or extension . Elongation is expressed as a percentage

33. Elastic recovery Elastic recovery is the ability of a textile fiber to return to its original length after being elongated . If a fiber returns to its original length from a specified amount of elongation it is said to have 100% elastic recovery.

34. Moisture regain and Moisture content Textile fibers generally have some amount of moisture or water content in them. Fibers with good moisture regain and moisture content will accept dyes and chemicals more readily than fibers with low moisture regain and moisture content. Moisture content has a relation with fiber strength.

35. Resiliency Resiliency of a textile fiber is the ability to return back to its original shape after being crushed, compressed or deformed . Resiliency plays an important role in the crease recovery of a fabric.

36. Resiliency Wool fiber has excellent resiliency. The inherent crimp in the wool fiber, acts like a coiled spring and bounces back to its original shape after the stress is released. Resilience of wool Crimp of wool

37. Thermal behavior Thermal behavior is the reaction of textile fibers to heat. Textile fibers should withstand temperatures used in processing . Flammability is an important aspect of thermal behavior of textile fibers. It is the ability of textile fibers to burn.

38. Types of fibres

39. Types of fibres Cotton Fibre Linen Fibre Jute Fibre Hemp Fibre Bamboo Fibre

40. Types of fibres Wool Fibre Silk Fibre Cashmere Fibre Mohair Fibre

41. Types of fibres Polyester Fibre Nylon Fibre Acrylic Fibre Polypropylene Fibre Spandex Fibre

42. Types of fibres Viscose Rayon Fibre Lyocell Fibre Asbestos Fibre Basalt Fibre Glass wool Fibre Mineral Fibres Regenerated Fibres

43. Polyester What Is Polyester? Polyester is a very durable plastic that is most commonly used in fiber form for clothing. It is the third most widely used commodity plastic.  Polyester is a long-chain polymer composed primarily of ester functional groups and terephthalic acid.

44. How Polyester is Made? Polyester plastic is made by combining two monomers, namely a dicarboxylic acid with a diol . More specifically, PET is a condensation polymer that is manufactured by combining terephthalic acid with ethane-1,2-diol. The product of this reaction is polyester and water.  The polyester is then either processed into fibers for fabrics or pellets for use in injection- or blow-molding applications.

45. Monomers used to produce polyester ethylene glycol and terephthalic acid is used to produce Polyester Condensation reaction is carried out to produce polyester. Melt spinning technique is used to produce polyester

46. Flow chart of polyester fibre manufacturing process: PTA + EG + Catalyst -> PET Polymer ↓ Solidification (cooling) -> PET Chips ↓ Melt Spinning -> Continuous Filaments ↓ Drawing -> Stretched Filaments ↓ Crimping -> Staple Fibres ↓ Finishing -> Texturizing, Coating, Dyeing, etc. ↓ Final Product -> Polyester Fibre

47. What are the Characteristics of Polyester? Property Value Density (g/cm3) 1.33 Hardness (Shore D) 81.2 Ultimate Tensile Strength ( MPa ) 49.2 Yield Strength ( MPa ) 61.8 Elongation @ Break (%) 82.9 Flexural Yield Strength ( MPa ) 82.1 Melting Point (°C) 246 Heat Deflection Temperature @ 0.46 MPa (°C) 90.8 Heat Deflection Temperature @ 0.8 MPa (°C) 72.3 Flammability (UL94) HB-V-0

48. Burning Test of polyester This shows a swatch of polyester. It ignited easily but burned briefly and immediately started to melt, and smelled like sweet chemicals. The residue was a shiny hard plastic-like bead.

49. Solubility Test Soluble In-soluble M-cresol 5% chlorine Bleach 100% Acetone 90% Formic Acid 20% HCl 60% & 70% Sulphuric Acid

50. Microscopic view of Polyester Longitudinal view Cross section

51. What is Viscose Rayon? Viscose Rayon is the oldest commercial man-made fiber. Viscose rayon is the naturally regenerated cellulosic fiber that can be made from naturally occurring cellulosic based material. (such as cotton linters, wood pulp etc ). It can be found in cotton-like end uses as well as silk-like end uses. Due to its fine silk-like properties, it is also known as“Artificial   Silk” .

52. Manufacturing of Viscose Rayon The process of manufacturing viscose rayon consists of the following steps mentioned, in the order that they are carried out: Steeping, Shredding, Aging, Xanthation , Dissolving, Ripening, Filtering, Degassing, Spinning, Drawing.

53. Manufacturing of Viscose Rayon Steeping: Cellulose pulp is immersed in 17-20% aqueous sodium hydroxide ( NaOH ) at a temperature in the range of 18 to 25°C in order to swell the cellulose fibers and to convert cellulose to alkali cellulose. (C6H10O5)n + nNaOH —> (C6H9O4ONa)n + nH2O Shredding: The pressed alkali cellulose is shredded mechanically to yield finely divided, fluffy particles called “crumbs”. This step provides increased surface area of the alkali cellulose, thereby increasing its ability to react in the steps that follow.

54. Manufacturing of Viscose Rayon Ageing:   The alkali cellulose is aged under controlled conditions of time and temperature (between 18 and 30° C) in order to depolymerize the cellulose to the desired degree of polymerization. In this step the average molecular weight of the original pulp is reduced by a factor of two to three. Reduction of the cellulose is done to get a viscose solution of right viscosity and cellulose concentration.

55. Manufacturing of Viscose Rayon Xanthation :  In this step the aged alkali cellulose crumbs are placed in vats and are allowed to react with carbon disulphide under controlled temperature (20 to 30°C) to form cellulose xanthate . (C6H9O4ONa)n + nCS2 —-> ( C6H9O4O-SC-SNa)n Dissolving:   The yellow crumbs of cellulose xanthate is dissolved in aqueous caustic solution. Because the cellulose xanthate solution (or more accurately, suspension) has a very high viscosity, it has been termed “viscose”.

56. Manufacturing of Viscose Rayon Ripening: The viscose is allowed to stand for a period of time to “ripen”. Two important process occur during ripening: Redistribution and loss of xanthate groups. The reversible xanthation reaction allows some of the xanthate groups to revert to cellulosic hydroxyls and free CS2. This free CS2 can then escape or react with other hydroxyl on other portions of the cellulose chain. In this way, the ordered, or crystalline, regions are gradually broken down and more complete solution is achieved. The CS2 that is lost reduces the solubility of the cellulose and facilitates regeneration of the cellulose after it is formed into a filament. (C6H9O4O-SC-SNa)n + nH2O —> (C6H10O5)n + nCS2 + nNaOH

57. Manufacturing of Viscose Rayon Filtering:   The viscose is filtered to remove undissolved materials that might disrupt the spinning process or cause defects in the rayon filament . 8 . Degassing:   Bubbles of air entrapped in the viscose must be removed prior to extrusion or they would cause voids, or weak spots, in the fine rayon filaments.

58. Spinning – (Wet Spinning) Production of Viscose Rayon Filament: The viscose solution is metered through a spinneret into a spin bath containing sulphuric acid (necessary to acidify the sodium cellulose xanthate ), sodium sulphate (necessary to impart a high salt content to the bath which is useful in rapid coagulation of viscose), and zinc sulphate (exchange with sodium xanthate to form zinc xanthate , to cross link the cellulose molecules). Once the cellulose xanthate is neutralized and acidified, rapid coagulation of the rayon filaments occurs which is followed by simultaneous stretching and decomposition of cellulose xanthate to regenerated cellulose. The dilute sulphuric acid decomposes the xanthate and regenerates cellulose by the process of wet spinning. The outer portion of the xanthate is decomposed in the acid bath, forming a cellulose skin on the fiber. Sodium and zinc sulphates control the rate of decomposition (of cellulose xanthate to cellulose) and fibre formation. (C6H9O4O-SC-SNa)n + (n/2)H2SO4 –> (C6H10O5)n + nCS2 + ( n/2)Na2SO4 In standard viscose of 30-50 poise viscosity made with 32% CS2 is spun into an aqueous acid salt spin bath of the following type at a temperature of 40-50 0c . H2SO4 = 8-10% Na2SO4 = 16-24% ZnSO4 = 1-2%

59. Physical Properties Shape Controllable Colour Controllable Luster Controllable Tenacity: Dry Wet 1.5 – 3.0 1.1 – 1.5 Elongation 20% Elastic recovery Good Density 1.5 g/c cm Moisture Content: 10 – 15 %

60. Physical Properties Dimensional Stability: Good Resistance against: Alkali Acid Sunlight Average Poor Average Thermal: Heat Flame Not above 150°C Burn

61. Burning Test of Viscose-Rayon It Ignite quickly & burns Smell like burning paper or wood Burns ; little after glow Grey Ash

62. Identification Microscopic View : Longitudinal: Uniform diameter with striation running parallel to the fiber. Cross-sectional: highly servated (nearly round for polynosic )

63. Solubility Test for Viscose-Rayon soluble In-soluble 60% Sulphuric Acid 5% Chlorine bleach 100% Acetone 90% Formic Acid 20% HCl

64. uses Blends: Regular rayon and high wet modulus usually blend with many fibers like polyester, acrylic, nylon, acetate, cotton, flax, wool and ramie. With polyester, nylon and acrylic: Rayon contributes absorbency, comfort, and softness when blended with them. With cotton: It alters appearance to create soft luster. With wool: It will decrease the cost. With flax and ramie: It can help produce appearance that are typically associated with linen like fabrics.

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