Enzymes for Textile

At Maps, we continuously develop our product line in order to have innovative enzymes with unique performance features for existing and new applications within the textile industry. Our R&D aims to provide innovative products for fabric treatment reducing process time, chemical consumption and energy costs in compliance with sustainable development.

We provide a range 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.

Desizing

For fabrics made from cotton or blends, the warp threads are coated with an adhesive substance know as 'size‘; to prevent the threads breaking during weaving. Although many different compounds have been used to size fabrics, starch and its derivatives have been the most common sizing agent. After weaving, the size must be removed again in order to prepare the fabric for dyeing and finishing.

This process (desizing) must be carried out by treating the fabric with chemicals such as acids, alkali or oxidising agents. However starchbreaking enzymes (amylases) are preferred for desizing due to their high efficiency and specific action. Amylases bring about complete removal of the size without any harmful effects on the fabric. Another benefit of enzymes compared to strong chemicals mentioned above is that enzymes are environment friendly.

Maps offers a range of amylases for desizing which work at different temperatures and for different equipments.

Palkozyme Alpha amylase for low-medium temperature conventional desizing.Palkozyme Ultra Alpha amylase for low-medium temperature desizingPalkozyme Plus Alpha amylase for high temperature desizingPalkozyme HT Heat-stable alpha amylase for high temperature desizingPalkozyme CLX Alpha amylase for low temperature desizing

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Bio-Polishing

Cotton and other natural fibres based on cellulose can be improved by an enzymatic treatment known as BioPolishing. This treatment gives the fabric a smoother and glossier appearance. The treatment is used to remove 'fuzz' - the tiny strands of fibre that protrude from the surface of yarn. A ball of fuzz is called a 'pill' in the textile trade. After BioPolishing, the fuzz and pilling are reduced. The other benefits of removing fuzz are a softer and smoother handle, and superior colour brightness.

Maps offers a range of cellulases for bio-polishing which work on depending on fibre, fabric type and equipments.

Palkofeel Cellulase for bio-polishing cotton and blended fabric and garmentPalkofeel C Cellulase for bio-polishing cotton fabric and garmentsPalkosoft Cellulase for bio-polishing cotton and blended fabric and garment

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Denim Finishing

Many garments are subjected to a wash treatment to give them a slightly worn look; example is the stonewashing of denim jeans. In the traditional stonewashing process, the blue denim was faded by the abrasive action of pumice stones on the garment surface. Nowadays, denim finishers are using a special cellulase.

Cellulase works by loosening the indigo dye on the denim in a process know as 'Bio-Stonewashing'. A small dose of enzyme can replace several kilograms of pumice stones. The use of less pumice stones results in less damage to garment, machine and less pumice dust in the laundry environment.

BioStonewashing has opened up new possibilities in denim finishing by increasing the variety of finishes available. For example, it is now possible to fade denim to a greater degree without running the risk of damaging the garment. Productivity can also be increased because laundry machines contain fewer stones or no stones and more garments.

Maps offers a range of cellulases for denim finishing, each with its own special properties. These can be used either alone or in combination with pumice stones in order to obtain a specific look.

Palkowash Cellulase for bio-stonewashing denims used in garment wet-processingPalkostone Cellulase for bio-stonewashing denims used in garment wet-processingPalkocel Cellulase for bio-stonewashing denims used in garment wet-processing

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Bleach Clean-up

Natural fabrics such as cotton are normally bleached with hydrogen peroxide before dyeing. Bleaches are highly reactive chemicals and any peroxide left on the fabric can interfere with the dyeing process. A thorough 'Bleach Cleanup' is necessary. The traditional method is to neutralize the bleach with a reducing agent, but the dose has to be controlled precisely. Enzymes present a more convenient alternative because they are easier and quicker to use. A small dose of catalase is capable of breaking down hydrogen peroxide into water and oxygen. Compared with the traditional cleanup methods, the enzymatic process results in cleaner waste water or reduced water consumption.

Maps offer catalase for removing residual hydrogen peroxide after the bleaching of cotton. It reduces the rinsing necessary to remove bleach or it can be used to replace chemical treatments.

PalkoperoxCatalase for bleach clean-up i.e. removal residual hydrogen peroxide after the bleaching of cotton.

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Bio-Scouring

Cotton yarn or fabric, prior to dyeing or printing, goes through a number of processes in a textile processing unit. A very important process is scouring. In this process, non-cellulosic components from native cotton are completely or partially removed.

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Scouring gives a fabric with a high and even wet ability so that it can be bleached and dyed successfully. Today, highly alkaline chemicals caustic soda are used for scouring. These chemicals not only remove the non-cellulosic impurities from the cotton, but also attack the cellulose leading to heavy strength loss and weight loss in the fabric. Furthermore, using these hazardous chemicals result in high COD (chemical oxygen demand), BOD (biological oxygen demand) and TDS, in the waste water

Recently a new enzymatic scouring process know as 'Bio-Scouring' is used in textile wet-processing with which all non-cellulosic components from native cotton are completely or partially removed. After this Bio-Scouring process, the cotton has an intact cellulose structure, with lower weight loss and strength loss. The fabric gives better wetting and penetration properties, making subsequent bleach process easy and resultantly giving much better dye uptake.

Maps offers multi-component enzyme for bio-scouring

PalkoscourMulti-component enzyme for bio-scouring i.e. complete or partial removal of non-cellulosic components from native cotton

Enzymes

At Maps, we produce are a versatile range of enzymes like amylases, proteases, cellulases, xylanase, beta glucanase, glucoamylase and Catalase; using the most sophisticated fermentation technologies. We are India’s largest producer and exporter of industrial enzymes. We sells a complex portfolio of nearly 60+ enzyme products for industries like Textile, Leather, Baking, Alcohol, Brewing, Detergent, Starch and Animal feed. Every year, about 5 new products are launched on the market; either completely new type of enzyme or existing enzymes adapted for new applications.

To know more about industrial applications of our enzymes you can review below links which give a comprehensive presentation of industries, applications and products. To learn more about enzymes, there history and the way they are made, you can review the Know Enzymes section

Textile

We provides a range 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.

We continuously develop our product line in order to have innovative enzymes with unique performance features for existing and new applications within the textile industry. Our R&D aims to provide innovative products for fabric treatment reducing process time, chemical consumption and energy costs in compliance with sustainable development.

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Leather

The leather industry is another major market for Maps’ enzymes. Maps offers a total enzyme solution for bating, un-haring, degreasing and soaking in the beam-house processes. With the introduction of our new range of products based on Microorganisms, we assure to provide clean and green leather tanneries.

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Baking / Alcohol / Brewing

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Over the recent years, Maps has built up considerable expertise in enzymes for the baking, alcohol and brewing industries. Some notable successes are the launching of xylanase enzyme for baking industry and beta glucanase enzyme for brewing industry.

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Detergent

The main application of enzymes is in heavy-duty detergents for household laundry. The majority of enzymes used in laundry detergents are proteases for removing protein stains. They are often used in combination with amylases for removing starch. Maps has successful launched protease and lipase for detergents.

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Starch

Starch processing is one of the oldest areas for the application of enzymes. For instance, dextrose, high fructose corn syrups are made using enzymes. They act as a substitute for ordinary sugar in food and beverage processing. Maps’ future work in starch processing will focus on optimising processes by developing improved enzymes.

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Animal feed

This is a large industry characterised by rapid growth in the use of enzymes, which are now accepted as a standard ingredient in many parts of the world. Maps has a range enzymes specially designed for degrading different feed components in order to improve the digestibility of nutrients.

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New developments

There are a number of other industries with significant potential of enzymes. This year, Maps is in the process to develop some unique new enzymes for the pulp and paper industry where enzymes can be used in the bleaching of pulp or in the de-inking of waste paper for recycling. We shall also launching new enzymes for the textile and leather industry for applications shall be de-gumming in textile and anti-wrinkle in leather. Apart from these, emphasis is put to develop enzymes for application in food and beverage industries.

Know Enzymes

Enzymes are miracles of nature

Enzymes are large protein molecules, and like other proteins, they are made up of long chains of amino acids. Enzymes are present in all living things, where they perform the essential functions of converting food to energy and new cell material.

Enzymes are bio-catalyst and can be used to speed up chemical processes or to make reactions take place that otherwise would not. Enzymes do this by binding to the starting material (substrate), catalysing the reactions, and then releasing themselves from the products so that they can react again. Although the enzyme is not consumed in the reaction, it does lose its activity over time and so eventually needs to be replenished.

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Compared with other ways of controlling chemical reactions enzymes are more specific, more efficient and work under milder conditions. When enzymes are used in an industrial process, these characteristics can often be used to achieve higher purity and better yields while saving on energy.

Enzymes can be classified by the types of substrates they work on. Proteases works on proteins, carbohydrases (amylases) work on carbohydrates, cellulases work on cellulose and lipases work on lipids. They can also be classified by the types of reactions they catalyse. Hydrolases split molecules, synthetases join them and tranferases move groups of atoms from one molecule to another.

Over two thousand different enzymes have been identified, and several hundreds are available commercially, but so far only 25 are produced on an industrial scale. Some enzymes are still derived from plants and animals, including papain from papayas and rennet from calf stomachs. But the last 100 years, and especially since mid 1960s, microorganisms have become the most important source of enzymes. Microorganisms can be selected to produce almost any kind of enzyme in almost any quantity.

What are Enzymes?History of EnzymesHow are Enzymes made?

What are Enzymes?

Enzymes are proteins and biocatalyst

Enzymes, like other proteins, consist of long chains of amino acids held together by peptide bonds. They are present in all living cells, where they perform a vital function by controlling the metabolic processes, whereby nutrients are converted into energy and new cells. Moreover, enzymes take part in the breakdown of food materials into simpler compounds. As commonly known, enzymes are found in the digestive tract where pepsin, trypsin and peptidases break down proteins into amino acids, lipases split fats into glycerol and fatty acids, and amylases break down starch into simple sugars.

Enzymes are biocatalyst, and by their mere presence, and without being consumed in the process, enzymes can speed up chemical processes that would otherwise run very slowly. After the reaction is complete, the enzyme is released again, ready to start another reaction. In principle, this could go on forever, but in practically most catalysts have a limited stability, and over a period of time they lose, their activity and are not usable again. Generally, most enzymes are used only once and discarded after; they have done their job.

Enzymes are specific and work in mild conditions

Enzymes are very specific in comparison to inorganic catalysts such as acids, bases, metals and metal oxides. Enzyme can break down particular compounds. In some cases, their action is limited to specific bonds in the compounds with which, they react. The molecule(s) that an enzyme acts on is known as its substrate(s), which is converted into a product or products. A part of large enzyme molecule will reversibly bind to the substrate(s) and then a specialised part(s) of the enzyme will catalyse the specific change necessary to change the substrate into a product. For each type of reaction in a cell there is a different enzyme and they are classified into six broad categories namely hydrolytic, oxidising and reducing, synthesising, transferring, lytic and isomerising. During industrial process, the specific action of enzymes allows high yields to be obtained with a minimum of unwanted by-products.

Enzymes can work at atmospheric pressure and in mild conditions with respect to temperature and acidity (pH). Most enzymes function optimally at a temperature of 30?C-70?C and at pH values, which are near the neutral point (pH 7). Now-a-days, special enzymes have been developed that work at higher temperatures for specific applications.

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Enzyme processes are potentially energy saving and save investing in special equipment resistant to heat, pressure or corrosion. Enzymes, due to their efficiency, specific action, the mild conditions in which they work and their high biodegradability, they are very well suited for a wide range of industrial applications.

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Enzymes are part of a sustainable environment

As mentioned earlier, enzymes are present in all biological systems. They come from natural systems, and when they are degraded the amino acids of which they are made can be readily absorbed back into nature.

Enzymes work only on renewable raw materials. Fruit, cereals, milk, fats, meat, cotton, leather and wood are some typical candidates for enzymatic conversion in industry. Both the usable products and the waste of most enzymatic reactions are non-toxic and readily broken down. Finally, industrial enzymes can be produced in an ecologically sound way where the waste sludge is recycled as fertiliser.

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Enzymes and industrial applications

Maps produces industrial enzymes originating from microorganisms in the soil. Microorganisms are usually bacteria, fungi or yeast. One microorganism contains over 1,000 different enzymes. A long period of trial and error in the laboratory is needed to isolate the best microorganism for producing a particular type of enzyme. When the right microorganism has been found, it has to be modified so that it is capable of producing the desired enzyme at high yields. Then the microorganism is 'grown' in trays or huge fermentation tanks where it produces the desired enzyme. With the latest technological advancements of fermenting microorganisms, it possible to produce enzymes economically and in virtually unlimited quantities.

The end product of fermentation is a broth from which the enzymes are extracted. After this, the remaining fermentation broth is centrifuged or filtered to remove all solid particles. The resulting biomass, or sludge in everyday language, contains the residues of microorganisms and raw materials, which can be a very good natural fertiliser. The enzymes are then, used for various industrial applications.

History of Enzymes

The history of modern enzyme technology really began in 1874 when the Danish chemist Christian Hansen produced the first specimen of rennet by extracting dried calves' stomachs with saline solution. Apparently this was the first enzyme preparation of relatively high purity used for industrial purposes.

This significant event had been preceded by a lengthy evolution. Enzymes have been used by man throughout the ages, either in the form of vegetables rich in enzymes, or in the form of microorganisms used for a variety of purposes, for instance in brewing processes, in baking, and in the production of alcohol. It is generally known that enzymes were already used in the production of cheese since old times.

Even though the action of enzymes has been recognised and enzymes have been used throughout history, it was quite recently that their importance were realised. Enzymatic processes, particularly fermentation, were the focus of numerous studies in the 19th century and many valuable discoveries in this field were made. A particularly important experiment was the isolation of the enzyme complex from malt by Payen and Persoz in 1833. This extract, like malt itself, converts gelatinised starch into sugars, primarily into maltose, and was termed 'diastase'.

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Development progressed during the following decades, particularly in the field of fermentation where the achievements by Schwann, Liebig, Pasteur and Kuhne were of the greatest importance. The dispute between Liebig and Pasteur concerning the fermentation process caused much heated debate. Liebig claimed that fermentation resulted from chemical process and that yeast was a non-viable substance continuously in the process of breaking down. Pasteur, on the other hand, argued that fermentation did not occur unless viable organisms were present.

The dispute was finally settled in 1897, after the death of both adversaries, when the Buchner brothers demonstrated that cell free yeast extract could convert glucose into ethanol and carbon dioxide just like viable yeast cells. In other words, the conversion was not ascribable to yeast cells as such, but to their nonviable enzymes.

In 1876, William Kuhne 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'.

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Early developments in Japan

During the early part of this century, enzyme technology was also developing slowly but surely outside Europe. In the Far East, an age-old tradition prevailed where mould fungi, the so-called koji, were (and still are) used in the production of certain foodstuffs and flavour additives based on soya protein (shoyu, miso, tempeh) and fermented beverages (sake, alcohol). Koji is prepared from steamed rice into which a mixture of mould fungi is inoculated, the composition of the mixture being passed down from generation to generation. This formed the basis which the Japanese scientist Takamine developed a fermentation process for the industrial production of fungal amylase; the process included the culture of Aspergillus oryzae on moist rice or wheat bran. The product was called 'Takadiastase' and it is still used as a digestive aid. The method of fermentation suggested by Takamine, the 'surface culture' or 'semisolid culture’ is still actively used in the production of various enzymes.

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Textile Desizing

At about the same time as Takamine was developing his novel fermentation technique, another field was being opened up for the use of enzymes - the desizing of textiles. Previously, textiles were treated with acid, alkali or oxidising agents, or soaked in water for several days so that naturally occurring microorganisms could break down the starch. However, both of these methods were difficult to control and sometimes damaged or discoloured the material. It represented great progress, therefore, when crude enzyme extracts in the form of malt extract, or later, in the form of pancreas extract, were first used to carry out desizing.

Bacterial amylase derived from Bacillus subtilis was used for desizing, the first time by Boidin and Effront as early as 1917.

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Leather Bating

Investigations carried out by the German chemist and industrial magnate Otto Rohm before World War I were of great importance for the further development of the industrial use of enzymes. Among other things, he studied the so called 'bating' process, a step in the preparation of hides and skins prior to tanning.

According to tradition, bating required the excrement of dogs and pigeons, a fact that did not improve the image of tanning which was considered a stinking and unpleasant activity. Rohm's

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theory was that these excrements exerted their effect because they contained residual amounts of the animals' digestive enzymes. If this was so, it might be possible to use extracts of the pancreas directly for bating. Such extracts were tried and produced the expected positive results. Naturally, Rohm accepted this as confirmation of the correctness of his theory, but later experiments showed that it was not the animals' enzymes that were active, but rather enzymes of bacteria growing in the intestinal tract.

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The first detergent enzyme

Parallel to his studies of the problems involved in tanning, Rohm investigated other processes where enzymes would prove even more valuable. Nevertheless, his efforts were not to score a success until 50 years later. Rohm actually developed the first method for washing protein stained cloth in detergents containing enzymes and manufactured the first detergent preparation containing enzymes.

The enzyme preparation used was pancreatin (extracted from pancreatic glands), which contains the protein degrading enzyme trypsin.

Breakthrough in detergents was made in 1959, when a Swiss chemist Dr. Jaag, developed a new product called Bio 40 containing a bacterial protease instead of trypsin.

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Sugars from starch

A very important field in which enzymes have proved to be of great value over the last 15-20 years is the starch industry. In 1950s, fungal amylase was used in the manufacture of specific types of syrup, i.e., those containing a range of sugars, which could not be produced by conventional acid hydrolysis. The real turning point was reached early in the 1960s when an enzyme glucoamylase, was launched for the first time, which could completely break down starch into glucose. Within a few years, almost all glucose production was reorganised and enzyme hydrolysis was used instead of acid hydrolysis because of the more benefits such as greater yield, higher degree of purity and easier crystallisation.

The process was further improved by the introduction of a new technique used for the enzymatic pre-treatment (liquefaction) of starch by using a heat-stable alpha amylase.

Years of research in biochemistry and biotechnology have boosted knowledge of enzymes for industries as well as research. Many new techniques have been established to modify enzymes or increase their yields. New techniques for purification of enzymes are constantly developing and so are being discovered new application of enzymes in medicine, research and industries.

The success and importance of using enzymes in a variety of modern industrial processes is illustrated by the applications described under Enzymes section

How are Enzymes made?

The starting point for enzyme production is a vial of a selected strain of microorganisms. They will be nurtured and fed until they multiply many thousand times. Then the desired end-product is recovered from the fermentation broth and sold as a standardised product.

A single bacteria or fungus is able to produce only a very small portion of the enzyme, but billions microorganisms, however, can produce large amounts of enzyme. The process of multiplying microorganisms by millions is called fermentation. Fermentation to produce industrial enzymes starts with a vial of dried or frozen microorganisms called a production strain.

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One very important aspect of fermentation is sterilisation. In order to cultivate a particular production strain, it is first necessary to eliminate all the native microorganisms present in the raw materials and equipment. If proper sterilisation is not done, other wild organisms will quickly outnumber the production strain and no production will occur.

The production strain is first cultivated in a small flask containing nutrients. The flask is placed in an incubator, which provides the optimal temperature for the microorganism cells to germinate. Once the flask is ready, the cells are transferred to a seed fermenter, which is a large tank containing previously sterilised raw materials and water known as the medium. Seed fermentation allows the cells to reproduce and adapt to the environment and nutrients that will be encountered later on.

After the seed fermentation, the cells are transferred to a larger tank, the main fermenter, where fermentation time, temperature, pH and air are controlled to optimise growth. When this fermentation is complete, the mixture of cells, nutrients and enzymes, called the broth, is ready for filtration and purification.

Filtration and purification termed as downstream processing is done after enzyme fermentation. The enzymes are extracted from the fermentation broth by various chemical treatments to ensure efficient extraction, followed by removal of the broth using either centrifugation or filtration. Followed by a series of other filtration processes, the enzymes are finally separated from the water using an evaporation process.

After this the enzymes are formulated and standardised in form of powder, liquid or granules.

At Maps, we believe that our enzyme products should have a stable activity, storage comfort and most importantly be safe to use.

BIO POLISHING ENZYME

(BIO POLISHING ENZYME)

is a technically advanced Enzyme system for the cotton fabric / garment finishing industry . The active ingredients of TLP SOFT are cellulolytic enzymes obtained by the fermentation of non – pathogenic moulds of the Trichoderma species.

is used in the finishing of Cotton , Viscose , Jute , Flax , Polynosics , Ramje , Tencel to produce a range of Bio – finished

The product is suitable for Bio polishing of Cotton twills , Chinos , Knits etc fabrics / garments and also in low mechanical friction wet machinary's.

ADVANTAGES OF USING ENZYMES:

High Dose Response TLP SOFT has a high dose response which provides the flexibility of varying dose , pH temperature and time to achieve a wide range of abrasion from light to heavy.

Compatibility With Auxillary Chemicals  TLP SOFT is compatible with most other processing aids , including Non-ionic surfactants ,

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Dispersing agents , Pumice stones , Abrasive powder , Diatomaceous earth etc.

In Fabric Finishing Applications , the enzyme creates an improved hand increases softness , eliminates dead and immature Cotton , removes surface fibers , and prevents pill formation on cellulosic fabric.

In Garment Finishing Applications , the enzyme treatment can be used for general bio polishing to remove surface hairyness and impart a clean and highly polished surface. Bio polishing treatment can be given prior to dyeing or after dyeing treatment  after dyeing results in partial removal of dye and softens the fabric . While treatment before dyeing improves the colour yield along with the hand feel.

Enzymatic “Bio Polishing” comprises of three main steps :

DESIZING/PRE WETTING

Proper and complete desizing is required for consistent performance in case of Denims. In case of other cotton fabrics proper stripping of finishing chemicals should be done with suitable wetting agent or 0.1 % HCL . M.L's   DEL DESIZING is recommended for the removal of starch sizing materials.

In case of Non-Denims , Prewetting is recommended before Bio finishing.          

On completion of Desizing the Liquor is drained and rinsed once with plain water. The fabric / garment is then steeped in water at a ratio of approximately 10 : 1 and the temperature of the water is then raised to 55 Deg C ( 131 Deg F ) and the pH of the water is adjusted to 4.5 with Acetic

is then dosed at a recommended level of 0.5 to 1 %  based on fabric / garment weight. Biowashing is then carried out for a period of 45 to 90 minutes depending on the effect desired ensuring that the temperature is maintained between 50 to 55 Deg C. It is imperative to ensure that the temperature does not exceed 55 Deg C ( 131 Deg F ) in order to prevent destabilization of the Enzyme system.Non – Ionic wetting Agents may be added in conjunction with Enzymes in order to enhance the performance of Enzymes

OPERATIONAL RANGE

50 - 55  Deg C

4.5 - 5.5

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0.5 - 1% 

45 - 60 minutes

1:8 to 1:15

At the end of Biopolishing which is evaluated by the required appearance, removal of surface protruding fibre , the liquor is drained and the fabric / garment is rinsed atleast twice with plain water to remove the surplus dye .The fabric / garment is then washed with a  mild detergent for approximately 5 minutes. At the end of this wash , the liquor is drained and the material is rinsed with plain water followed with a 5 minutes wash with an optical brightener and a suitable softener .

is available as off white coloured powder in standard 25 Kgs HDPE Drum.

STORAGE AND HANDLING :

should be stored in preferably cool and dry place. Care must be taken to ensure that the containers are kept closed after use to prevent moisture entry into the product. Other handling instructions are available on request.

is stable under recommended storage conditions for a period of 6 months with less than 10% drop in activity. M.L.’s standard assay method for cellulase activity is available on request.

M.L.CHEMICALS (INDIA) PVT.LTD provides technical assistance related to application of enzymes in the textile industry.

Bio Polishing Enzymes

Cotton and other natural and man-made cellulosic fibres can be improved by an enzymatic treatment called Bio-Polishing. The main advantage of Bio-Polishing is the prevention of pilling. Cellulases hydrolyse the microfibrils (hairs or fuzz) protruding from the surface of yarn because they are most susceptible to enzymatic attack. This weakens the microfibrils, which tend to break off from the main body of the fibre and leave a smoother yarn surface. A ball of fuzz is called a 'pill' in the textile trade. These pills can present a serious quality problem since they result in an unattractive, knotty fabric appearance. After Bio-Polishing, the fabric shows a much lower pilling tendency. Other benefits of removing fuzz are a softer, smoother feel and superior colour brightness. Unlike conventional softeners, which tend to be washed out and often result in a greasy feel, the softness-enhancing effects of Bio-Polishing are washproof and non-greasy. AETL’s Sebrite series is much effective to impart pill proof biopolishing on woven and knit cotton fabric and garments. Sebrite also gives high color retention.

Bio-Polishing is optional for upgrading the fabric. However, Bio-Polishing is almost essential for the new polynosic fibre lyocell (the leading make is known by the trade name Tencel®). Lyocell is made from wood pulp and is characterised by a tendency to fibrillate easily when wet. In simple terms, fibrils on the surface of the fibre peel up. If they are not removed, finished garments made with lyocell will end up covered in pills. This is the reason why lyocell fabric is treated with cellulases during finishing. Cellulases also enhance the attractive, silky appearance of lyocell. Lyocell was invented in 1991 by Courtaulds Fibres (now Acordis, part of Akzo Nobel) and at the time was the first new man-made fibre for 30 years. Addcool series is best suitable for biopolishing of lyocell as it works at pH 5.5 – 6.0 and

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temperature 30 – 45 0C, causing less damage to fabric and high quality finish.

The Bio-Polishing of cotton and other fibres based on cellulose came first, but in 1995 enzymes were also introduced for the Bio-Polishing of wool. Wool is made of protein and so this treatment features a protease that modifies the woolfibres. 'Facing up' is the trade term for the ruffling up of the surface of wool garments by abrasive action during dyeing. Enzymatic treatment reduces facing up, which significantly improves the pilling performance of garments and increases softness. Proteases or

are also used to treat silk. Threads of raw silk must be degummed to remove sericin, a proteinaceous substance that covers the silk fibre. Traditionally, degumming is performed in an alkaline solution containing soap. This is a harsh treatment because the fibre itself, the fibrin, is also attacked. However, the use of proteolytic enzymes is a better method because they remove the sericin without attacking the fibrin. Tests with high concentrations of enzymes show that there is no fibre damage and the silk threads are stronger than with traditional treatments.

Bio Washing Enzymes

Abrasion Yarn the abrasive action of lightweight pumice stones on the garment surface, which removes some of the dye. However, too much abrasion can damage the fabric, particularly hems and waistbands. This is why denim finishers today use acid, hybrid or neutral cellulases to accelerate the abrasion by loosening the indigo dye on the denim. Since a small dose of enzyme can replace several kilograms of stones, the use of fewer stones results in less damage to garments, less wear on machines, and less pumice dust in the working environment. Productivity can also be increased through laundry machines containing fewer stones but more garments. With a stone-free process, the need for the removal of dust and small stones from the finished garment is reduced. There is also no sediment in the wastewater, which can otherwise block drains. Denim garments are dyed with indigo, which adheres to the surface of the yarn. The cellulase molecule binds to an exposed fibril (bundles of fibrils make up a fibre) on the surface of the yarn and hydrolyses it, but leaving the interior part of the cotton fibre intact. When the cellulases partly hydrolyse the surface of the fibre, the indigo is partly removed and light areas are created.

Neutral cellulases or Neutrastone Series designed by AETL acting at pH 6-8, acid cellulases (Denicell Series) acting at pH 4-6  and hybrid cellulases (Addcool acting at pH 5 – 6.5 are used for the abrasion of denim. There are a number of cellulases available, each with its own special properties. These can be used

either alone or in combination in order to obtain a specific look. Application research in this area is focused on preventing or enhancing backstaining depending on the style required. Backstaining is defined as the redeposition of released indigo onto the garments. This effect is very important in denim finishing. Backstaining at low pH values (pH 4-6) is relatively high, whereas it is significantly lower in the towards neutral pH range. Neutral cellulases are therefore often used when the objective is minimal backstaining. Hybrid cellulases are effective tool to save energy cost as processing can be done at ambient or room temperature conditions.

Backstaining is not the cause of worry now a days due to availability of effective anti backstaining agents based on chemicals. AETL is one of the first companies to introduce backstaining removing enzyme (Stain Clear Series), unlike chemical agents which are used to prevent backstaining. Products are based on blends of different proteases, lipase and endolase.

Enzymes have opened up new possibilities in denim finishing by increasing the variety of finishes available. For example, it is now possible to fade denim to a greater degree without running the risk of damaging the garment. This can be effectively done by using enzymes like Laccase or peroxidase replacing bleaching chemicals like hydrogen peroxide or hypochlorite. Peroxidases introduced by AETL as Ecowash BB are further advantageous over Laccase as it has to be used in neutral pH 6 – 7 and temperature 50 – 55 0C. The denim industry is driven by fashion trends. The various cellulases available for modifying the surface of denim give   fashion designers a pallet of possibilities for creating new shades and finishes. The combination of new looks, lower costs, shorter treatment times and less solid waste has made abrasion with enzymes the most widely used fading process today. Incidentally, since the denim fabric is always sized, the complete process also includes desizing of the denim

Anti-pilling finish:

Home >>Textile Finishes

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Biopolishing:

Cotton and other natural and man-made cellulosic fibers develop pills or protruding fibers during spinning, weaving and wet processing operations, due

to abrasions. These pills make the appearance of the yarn or fabric to be dull and hazy.  In order to improve the appearance it is necessary to either

remove the protruding fibers or to cement it to the surface properly by the application of some over coating.

What is Biopolishing (bio-polishing)?

Cotton and other natural and man-made cellulosic fibers can be improved by an enzymatic treatment called Bio-Polishing. The main advantage of Bio-

Polishing is the prevention of pilling.

Enzyme cellulases hydrolyze the micro fibrils (hairs or fuzz or pills) protruding from the surface of yarn because they are most susceptible to enzymatic

attack. This weakens the micro fibrils, which tend to break off from the main body of the fiber and leave a smoother yarn surface. 

After Bio-Polishing, the fabric shows a much lower pilling tendency. Other benefits of removing fuzz are a softer, smoother feel and superior brightness

of the dyed shade or white. Unlike conventional softeners, which tend to be washed out and often result in a greasy feel, the softness-enhancing effects

of Bio-Polishing are wash proof and non-greasy. 

For cotton fabrics, the use of Bio-Polishing is optional for upgrading the fabric. However, Bio-Polishing is almost essential for the new polynosic fiber

Lyocell is made from wood pulp and is characterized by a tendency to fibrillate easily when wet. In simple terms, fibrils on the surface of the

fiber peel up. If they are not removed, finished garments made with lyocell will end up covered in pills. This is the reason why lyocell fabric is treated with

cellulases during finishing. Cellulases also enhance the attractive, silky appearance of lyocell.

Bio-Polishing of wool: 

Wool is made of protein and so this treatment features a protease that modifies the wool fibers. 'Facing up' is the trade term for the ruffling up of the

surface of wool garments by abrasive action during dyeing. Enzymatic treatment reduces facing up, which significantly improves the pilling performance

of garments and increases softness.

are also used to treat silk. Threads of raw silk must be degummed to remove sericin, a proteinaceous substance that covers the silk fiber.

Traditionally, degumming is performed in an alkaline solution containing soap. This is a harsh treatment because the fiber itself, the fibrin, is also

attacked. However, the use of proteolytic enzymes is a better method because they remove the sericin without attacking the fibrin. Tests with high

concentrations of enzymes show that there is no fiber damage and the silk threads are stronger than with traditional treatments. 

Anti-pilling finish (Synthetics and blends):

Pilling is an unpleasant phenomenon usually associated with spun yarn fabrics, especially when they contain polyester. Fibers are released from the

yam by bending and abrasion, and they combine together at the surface of the material to form knots known as pills.

Resin finishing reduces the Pilling tendency. However, following treatment also can impart anti-pilling to the fabric.

Anionic polyacrylate - 20-50 g/l

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Canvas - Dyed and Water Proof finish

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Proces s Sequence for Dyed Water Proof finish:

Dyeing           --- in Jumbo Jiggers

fabric                    --- Cylinder Drying Machine

proof mixture      --- 3 bowl padding mangle - 2 dips and 2 nips

fabric                --- Cylinder Drying Machine

Proofed fabric   --- in Jumbo Jiggers

fabric                --- in Cylinder Drying Machine

This is the general sequence of operations that is being carried out in Canvas Processing Units.

Scouring, Bleaching and Dyeing of Canvas Fabric:

Scouring and Bleaching:

It is obvious that a water proofing by it name itself is making the fabric leak proof when some water quantity is store over the fabric surface. So the process is filling the

total fabric surface with some flexible coating and make it leak proof.

A simple wetting out treatment with an anionic wetting agent followed by a peroxide bleach for a short duration is the over all scouring and bleaching operation put

together. This would be carried out in open jiggers for a maximum period of 45 to 60 minutes.

of alkali and wetting agents is the next process. A hot wash - 2 ends and a cold wash 2 ends, will do.

Neutralization of pH alkalinity is the next step. An usual practice is use of 1 to 1.5%  w/w of Acetic acid at room temperature is employed.

Vat dyeing is the best choice as for as a quality manufacturing of weather proof canvas is concerned. Vat dyeing takes place for around 60 minutes. (oxidation and 

neutralization - all would take further 1 hour time).

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preferred by you, then you can choose a padding operation rather than exhaust

compatibility is checked against the proofing mixture, you can very well do bother

pigment padding and proofing in single step. However a thorough scouring and bleaching operation are

essential for uniform application of pigment.

The conventional and safe method of water proofing is a two stage process.  (1) Application of water proofing emulsion over the fabric using a 2 dips / 2 nips padding

mangle - followed by cylinder drying at 110 to 130°C. (2) Fixing treatment of the proof content on the jigger, usually with  a concentrated solution of Aluminium or

Zirconium Acetate or Formate. After the fixing treatment a thorough rinse on running cold water is essential to remove all the Aluminium salts. 

A final drying to completely remove the moisture content of the fabric on a Cylinder Drying Machine essential. 

Before packing, allowing the fabric to cool  is also essential.

A properly water proofed fabric can easily pass a Cone Test of 24 hours.

Canvas Bleached Water Proof fabric:

Machineries Required: 

Since we are considering heavy to very heavy fabrics for bleaching, a continuous processing may not yield expected quality results. The best

suitable machineries are as below:

(1) Jumbo Jiggers, (2) Cylinder Drying Machine, (3) 3 bowl - Padding Mangle 

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Scouring and Bleaching in Jigger followed by cylinder drying, water proof emulsion padding and drying - are the main process route for this

In general an anionic wetting/scouring agent would be employed in combination with caustic soda, hydrogen peroxide and stabilizer. The

bleaching process timing and recipe are adjusted as per the requirement and would be carried out for a minimum period of 90 to 120 minutes. A

thorough neutralization of alkali and washing off are essential steps for good water proofing finish.

In bleached water proof finishing, a cationic wax emulsion is employed along with necessary quantity of paraffin wax and French chalk filler

powder. All these components would form a homogeneous thick padding solution. Guar gum or CMC is used as a thickening and binding agent

for holding all the ingredients in a uniform suspension.

In general a pure only water proof material would not be manufactured. The customer would prefer  multiple specialty finishes, such as fire-

resistance, rot proofing, etc. Necessary chemicals would be included in the padding bath to impart the required qualities.

Water Proofing Recipe:

Waxol PA (ICI) = 100 gpl

Paraffin wax = 20 gpl

CMC (Cellpro MVB) = 10 gpl

An emulsion is made using all the above chemicals at a temperature of say 80°C and applied on the fabric

through a 2 dip 2 nip padding mangle at 70% expression. The padded fabric is dried either in cylinder or

hotflue at a temperature of 100 to 110°C. Then the dried fabric is again padded with a solution of

Aluminium Formate 75 gpl in a 2 dip 2 nip padding mangle and washed throghly in washers or jiggers

Canvas Bleached Collar Lining Fabric

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Process Sequence:

lining canvas fabrics are normally not so heavy enough like the tent manufacturing material. These are called canvas fabric because it

backs and support the collar in to  a specified shape and form. Usually collar lining fabrics are of two types.  Fusible and non-fusible collar

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Collar Lining (Non-fusible): Singe - Desize - Bleach - Mercerise are the regular process route for obtaining a suitable

white material ready for finishing. The stiff finish recipe for collar lining is as below:

Poly vinyl acetate emulsion (Appretan EM) =250 gpl

Poly vinyl alcohol (PVA) = 25 gpl

Poly Ethylene Emulsion (PE) = 5 gpl

Anticreasing Agent (Finish MA (VLF)) = 100 gpl

Leucophor BFBI = 5 gpl

Leucophor TBLF

Magnesium Chloride = 1 gpl

Citric Acid = 0.3 gpl

Pad - Dry @ 110°C - Cure @ 150°C for 4 minutes.

 

Collar lining (Fusible) . 

Nowadays only fusible type of collar lining materials have good market potential due to their versatility in application.

Singe - Desize - Bleach - Mercerise - Bleach or Singe - Desize - Bleach are the two simple sequences selected by the manufacturers of A prior

stiff finishing with a mixture of Poly Vinyl Alcohol and Poly Vinyl Acetate would help giving a body to the fabric to be coated. After proper drying,

collar lining proof, would be wound on spools of  A - frames.

(Fusible Collar Lining).

There are two kinds of polyethylene fine granular powders are available in the market. One is called LDPE ( Low Density Poly Ethylene) and the

other one is called HDPE (High Density Poly Ethylene) powder. These are free-flowing powders. The key characteristic of this powder is its low

Low melting temperature helps to increase line speeds and lower energy costs.

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Some of the salient feature of a powder coating machine would be like the one mentioned below.

12 - 25m/min

90kW, 380V, 50Hz 

- 160cm

electronic components, intelligent temperature 

instrument, and motor speed converter 

unique fabric feeding device with selvedge calibrator and fabric

finished product rate

use a boiler keeping temperature difference of less than ±2oC

and stable powder point transfer 

chamber results in finished fabric having soft 

winding device allows for easy machine operation.

Flame Retardant Finishing

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The field of flame retardancy has witnessed a vigorous development of new technologies and new products and

materials to meet the challenge of the needs of new industries-such as computer, electronics and

telecommunication industries. Flame retardants are also used in health care settings, Intravenous pumps,

hospital beds Hospital curtains.. An additional challenge is the growing awareness of environmental issues

and the stiffening demands of consumer safety, which has been put forward by governments and public agencies. New

flame-retardant systems are needed to meet the new product and market demands.

New regulations, standards and testing methods, as well as instruments, are essential for assessing and defining these

needs. These new regulations present new challenges to the flame-retardancy industry. With new fibers /blends rapidly

changing the economic situation, today manufacturer needs to be fully aware of new regulations and the products and

processes that will meet them. Companies that adopt the latest technology will have the edge in providing superior

products with the best balance of properties at the lowest possible price Synthetic polymers have largely replaced the

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use of wood, Glass and other metallic materials in our homes, offices, automobiles and other public areas. These

synthetic materials are often petroleum based plastics that easily ignite, spread flames quickly and release toxicants

Fire safety is a significant cause of property damage and of death. Standards are therefore set for electrical appliances,

textiles upholstery and many other materials to minimize these losses. To meet fire safety standards, products made of

synthetic materials are modified with flame retardant chemicals that inhibit the ignition and spread of flames. Recently,

there has been a great deal of interest in providing effective flame retardants for normally flammable substrates. For

example, there is great interest in the development of flame retardant finish on synthetic fibers like polyester, nylon,

polypropylene etc, without disturbing the desirable physical characteristics of the fibers. Textiles consist of highly

ignitable materials and are the primary source of ignition. They contribute to rapid fire spread; however, reduction of

ignitability can be obtained by

1: Use of Inorganic materials {Asbestos, Glass etc}

2: Through chemical treatment with FR {Flame Retardant chemicals}

3: Through modification of the polymer.      

Types of Flame Retardants:

Brominated flame retardants

Chlorinated flame retardants

Phosphorous-containing flame retardants {Phosphate ester such as Tri phenyl

phosphate

Nitrogen-containing flame retardants (i.e. Melamines)

Inorganic flame retardants.

These can be further classified as:

Inorganic, Organo Phosphorous, Halogenated organic and Nitrogen based

compounds.

2: Halogenated organic flame retardants are further classified as containing

either Chlorine or Bromine {Brominates Flame Retardants – BFR}

There are three types BFRs currently produced. These are Poly Brominated

DiPhenyl Ethers {PBDE}, Tetra Bromo Bisphenol A {TBBPA} and Hexa Bromo

Cyclodecane {HBCD} The PBDEs that are commonly used in products are Deca,

Octa, and Penta BDE .The concentration of BFRs in products ranges from 5 to

30 % .Compounds containing Iodine are known, but of limited utility as flame

retardants, due to their poor thermal stability and dark colour of iodine.

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Compounds containing Fluorine generally exist as functional polymers rather

than materials to be added to other polymeric systems to provide flame

retardancy. These polymers are oxidatively stable and only decompose at very

high temperature.

Antimony oxide is another important component flame retardant composition,

containing halogen, particularly Chlorine and Bromine. It is totally ineffective if

used with out halogen. The Tri oxide is the common material used although the

Pentoxide can also use. The pentoxide has a much finer particle size and is more

effective per unit weight added than the trioxide. Polyesters are very sensitive to

residual acidity in all forms of antimony oxide. Alkaline salts of antimony oxides

are used in these critical cases. Antimony oxide acts as synergists with chlorine

and bromine.

Antimony tri bromide is a dense white product and is one of the main

components of the typical white smoke that is seen from burning polymers

containing halogen and antimony oxide. High levels of water from normal

combustion cause reversion of SbBr3 to HBR and Sb203.The remaining

antimony oxide is then available to react with fresh HBR from decomposing

brominated compound. Typically compounds used in flame retardant application

contain either 40 to 70 % Chlorine or 45 to 80% Bromine, depending on the

flame retardant requirements from 20 to 40 parts of Brominated compound would

be used per 100 parts of polymer. Antimony oxide used is typically 1/4th to ½

that of the halogenated material.

Many of the flame retardants do not remain on the fabric, instead they slowly leak

from the products in the atmosphere. Brominated flame retardants are a subject

of scrutiny. Evidence shows that they are likely to persist in the environment, bio

accumulate in the food chain and finally in to our bodies. A survey of the newer

flame retardants suggests a simple theory for their constitution. The molecule

should be water-insoluble to achieve durability in laundering. 

A solvent-soluble organic molecule will give better results. The ortho-phosphate

group should be present in the molecule to dehydrate catalytically the cellulose

substrate. The molecule should contain polymerizable groups to effect a

permanency of finish. The molecule should contain halogen or other groupings to

reduce the flammability of the gases of decomposition.

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When chemical free alternative materials or designs are not feasible, non

halogenated flame retardants can be used to meet fire safety standards.

Numerous alternatives are available. It is also confirmed that flame retardants

based on Aluminum Trioxide, Ammonium Polyphosphates and Red phosphorous

are less problemasimple recipe on water repellaet finish (DWR):

Water repellency or durable shower proofing is an important finishing process. It is usually

applied to fabrics for

outerwear where an excellent wash fastness is expected. Also, often internal resin treatment is

required to be given

to the same fabric. Both finishes can be combined.

Recipe

Dimethyl Dihydroxy Ethylene Urea - 40-60 g/l

Ziroconium salt-containing wax emulsion - 60 g/l

Reactive Softener - 60 g/l

Magnesium chloride. - l0 g/l

Pad, dry and cure at 150oC for 5 min.

For further reading on water repellent finish

tic in the environmentWhat is Soil Release Finish?

Durable press fabrics containing polyester fibres are known to show tendency to retain stains and

also attract soil from the wash liquor during washing. This is due to hydrophobic nature of these

fabrics. Various soil-release agents have been developed. These are described as durable film

forming polymers containing polymer groups which are capable of hydrogen bonding with water.

These finishes are applied by a pad-cure process along with the resin.

Treatment of synthetic fibers with hydrophilic polymers is in general called soil

release finishing, which makes the soil adhereing the hydrophobic fibers more

accessible to water and easily removable.

The fluorocarbons use dfor this purpose are dual action fluro polymers containing

hydrophilic hydrocarbons as well as perfluroalkyl groups. These finishes are

generally applied to synthetic fibers which are generally prone to soiling.

When a finished fabric is immersed in a liquid, hydrophilic hydrocarbon groups

orient towards polar aqueous environement and flurocarbon groups collapse

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below the surface promoting the release of stains. Thus easy removal of stains

takes place when the fabric is subjected to laundering.

This finish can be applied by pad-dry-cure method along with durable press

finish. Although these finishes are the most expensive ones, they are the most

widely used because of ther performance, comfortability with durable press finish

and not side effects.

Antistatic Finishing:

During spinning, weaving and finishing, textile fibres, yarns and fabrics are subjected to friction.

Static electricity is

thus generated on the fibre. Polyester fibre has low conduction hence it accumulates static

electricity. Static electricity gives rise to a number of problems. For instance, the operator at the

delivery end of a stenter may get electric shocks because of static electricity. Garments made of

polyester fibres attract soil during normal wear and also have a tendency to cling to the body of

the wearer.

Non-durable antistatic agents are usually hygroscopic surface-active materials, closely allied in

composi6on to softeners and wetting agents. A permanent antistatic finish can be given by using

a combination of a cationic and an anionic compound.

Cationic quaternary ammonium compound - 3-4%

Acetic acid (30%) - 0.5-1 cc/l

Treat the fabric with the above composition for 10-20 min at 70'C (in a jigger). Then add (anionic

alkyl sulphate) - 1.6-2.2%

Continue treatment for another 10-20 min. Dry and cure if required.

.

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Bio-polishing Agent  

 

Product Name Properties/Uses

Finozyme AX

A specially designed enzyme for application in superior BioFinishing Process and Denimwashing of all cellulosic fabrics both woven and knits

     FINOZYME AX

FINOZYME AX is a specially designed eco-friendly liquid Acid Cellulase Enzyme (Carbohydrase Enzyme) of Trichoderma sp. produced in a state-of-the-art fermentation facility

FINOZYME AX is specially designed for application in superior BioFinishing Process and Denim washing of all cellulosic fabrics both woven and knits.

CHARACTERISTICS:

     

SPECIAL FEATURES:

     

Clean Finish : More effectively removes fuzz and cotton pill balls from fabric/ garment compared to most other acid cellulases. The cutting effect is very obvious.

     Low Colour Bleeding

: Exhibits low colour bleeding properties when compared to regular acid cellulases.

     

Softness : Significantly softens cellulosic fabric/ garment with reduced strength loss.

     Flexibility in finish

: Versatile looks and finish can be achieved by varying the dosage and process parameters.

     

Natural Look : Yields permanent softness and luster to the fabric / garment and improves the general look

   

FINOZYME AX is active at a broad range of pH (3.5 to 6.5) and temperature (45 to

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Appearance : Amber coloured clear and viscous liquid.      Odour : Mild fermentation odour     pH   4.5 – 4.9      

65 deg.C).

 

1. BioFinishing Process:

FINOZYME AX hydrolyses the microfibrils of fabric/ garment thereby effectively removing fuzz/ pill ball and imparts a smoother and polished appearance to surface of fabric/ garment. PARAMETERS OPERATIONAL RANGES Temperature 50 – 60 deg.C PH 4.5 – 5.0; best at 4.8

Liquid to goods ratio

Fabric 8:1 to 15:1 Garment 6:1 to 10:1

FINOZYME AX 0.5% - 3% on weight of garment Time 30 to 60 minutes

   

For drum washers try to maintain a low garment liquor ratio for best results. In fabric processing follow the minimum F/L ratio recommended by equipment manufacturer. Unlike many BioFinishing Process Cellulases FINOZYME AX can run at 60 deg.C, thereby offering an approximate of 25% saving in dosage or time.

     

2Softening :

     

FINOZYME AX effectively softens fabrics/ garments made up of cellulose and its blends imparting a silky soft permanent finish. FINOZYME AX can be applied on any wet processing step in the garment Finishing Process process.

     

Optional: FINOZYME AX can be applied after preparation/ bleaching, either as a separate process or in conjuction with garment Dyeing Process (more suitable with bifunctional reactive dyes). However, with FINOZYME AX bio-Finishing Process , fabrics/ garments may also be processed after Dyeing Process.

     

3Fuzz/ Pill Ball Removal :

     Using the above process parameters 0.5% -2% owg FINOZYME AX has been found effective in the removal of fuzz balls and fuzziness when run for 15 to 20 minutes.

     

4Denim Washing :

Effective desizing is required for efficient denim washing.

TopPARAMETERS OPERATIONAL RANGES

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Temperature 50 – 55°C; best at 52°C PH 4.5 – 5.0; best at 4.8 FINOZYME AX 6.5 : 1 to 10:1 Time 30 to 60 minutes

   

FINOZYME AX can also be used with pumice stones.

     

Removal of loose stains:

     

Follow-up enzyme process with a hot (60 – 70 deg.C) detergent wash. Can be optional if followed up by bleaching.

     NOTE : The above information is in good faith but without warranty.

     

Check the ‘weight loss’, ‘strength loss’ and the ‘look’ you achieve before committing to volume production.

   

The liquid ratio should allow free movement of the goods, but should be low enough to create the required mechanical action.

   

Regulate liquor ratio with respect to enzyme activity/ backstaining/ patchiness-streaks

   

Caution:

     

Avoid direct steam injection into the enzyme bath, ionic charged chemicals and exposure to heavy metals.

     

Inactivation

     

FINOZYME AX can be inactivated by raising the temperature above 70 deg.C or pH above 8.0 or combination of the two. However if the very next step is detergent washing inactivation is not necessary.

     

Storage Condition

     

FINOZYME AX has less than 10% activity loss after four months when stored at 30 deg.C out of direct sunlight and in the original, closed container.

     NOTE :

The above information is in good faith but without warranty.

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Application of Chitosan in textile Wet Processing

Chitin and chitosan have higher affinity for dyes and metals and certain

surfactants, which

contribute to water pollution. Using the shellfish waste thus has two-fold

advantage: -

a) First to find a viable method to purify dye wastewaters.

b)To use natural resources, which could otherwise had been wasted.

After use for color removal the spent sorbent further finds use as a fibrous

raw material for papermaking.

The use of chitosan as a combined thickener and binder in pigment

printing has been studied in comparison with the commercial printing

system. Printing pastes made from chitosan, acetic acid and pigments at

appropriate viscosity give stable pastes and satisfactory results on

polyester and polyester –cotton blends.

Chitosan can also be used in the dyebath, because due to the

unimolecular structure it has an extremely high affinity for many classes

of dyes, including disperse, direct, reactive, acid, vat, sulphur etc. Rate of

diffusion of dyes in cellulose is similar to that in cellulose. Sorption of

chitosan is exothermic: hence an increase in temperature leads to an

increase in dye sorption. At lower pH chitosan free amines are protonated

causing to attract anionic dyes.

Chitosan is used as a shrink-proofing agent and also is used to increase

the dye uptake of wool. In its protonated form, it exhibits the behavior of a

cationic polyelectrolyte, forming viscous solutions and interacting with the

oppositely charged molecules. Thus it is suitable for processing of wool

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near its isoelectric point, offering minimum fiber damage and providing

good quality. However the main limitation is the uneven distribution on

the fabric surface.A new ecological method for shrink proofing of the

wollen fabric is based on the enzymatic pretreatment and chitosan

deposition on the wollen fabric. This

method shows the enzymatic pretreatment has an essential influence on

the shrink proofing qualities and chitosan stabilizes the shrink proofing

property. It also increases the kinetics of dyeing and causes a decrease in

hydrophobicity.

Antimicrobial finishing is very important because cotton fabrics have poor

resistance to microorganisms and thus the possibility of harming the

human body. Due to the Antimicrobial action of the amino group at the C-

2 position of the

glucosamine residue, chitosan is also known to be an antimicrobial

polysaccharide. The ability of chitosan to immobilize microorganisms

derives from its polycationic character. Its protonised amino groups block

the protein sequences of microorganisms, thus inhibiting further

proliferation. Chitosan binds to the negatively charged bacterial surface

disrupting the cell membrane and altering its permeability. This allows

materials to leak out of the bacterial cells resulting in cell death. Chitosan

can also bind to DNA inside the cell inhibiting mRNA and hence protein

synthesis. Recent studies have revealed that chitosan is more effective in

inhibiting the growth of bacteria than chitosan oligomers. Also the

antibacterial effect of chitosan oligomers are reported to be dependent on

its molecular weight.

1,2,3,4-Butanetetracarboxylic acid (BTCA) and citric acid are

representative of polycarboxylic acids that crosslink with cotton through

an esterification reaction. BTCA is the most effective of these

plycarboxylic acids, but its cost is very high; citric acid is a less effective

crosslinking agent but is not as costly. However, cotton fabrics treated

with citric acid alone exhibit appreciable yellowing, although there have

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been some investigations undertaken to reduce this yellowing.

Generally, cellulose is treated with chitoan by dissolving the chitosan in

dilute acetic acid solution, but this method does not create any firm

chemical bonds between chitosan and cellulose and thus is not durable to

repeated laundering. The esterification reaction not only occurs between

citric acid and cellulose but also between citric acid and the hydroxy

groups of

chitosan, and free carboxylate groups can also react with the amino

groups of chitosan resulting in a salt linkage. It is widely known that the

Antimicrobial properties of cotton treated with chitosan is attributed to

amino groups of chitosan, which convert to ammonium salts in dilute acid

solution; the salt then binds to the negatively charged surface of the

microorganism..

As a durable press and an Antimicrobial finishing agent for cotton fabric,

citric acid and chitosan show satisfactory results. The WRA and DP rating

of treated cotton fabrics increase, and there are slight improvements in

tensile and tear strength using chitosan as abn extender of the

crosslinking chain. A high Antimicrobial property level is obtained by

treatment with CA as

well as chitosan, and despite repeated launderings, the Antimicrobial

property remains at over 80%.

Chitosan is expected to be one of the safest and most effective

Antimicrobial agents for hospital applications where many antibiotic

substances are used. Chitosan is especially important in depressing the

growth of methicilin resistant taphylococcus aureus, which is resistant to

most antibiotic substances. Hygienic yarns can also be made through the

addition of chitosan fibres. Chitosan fibers are blended with cotton fibers

and a yarn is spun out of this blend; 10% chitosan component is sufficient

to achieve a hygienic effect. This effect should endure 20 washes.

(1)currently, there is also a hightened interest in protecting health care

workers from diseases that might be carried by patients. Especially for

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surgical gowns, there is an increasing need to protect medical staff from

infection by bloodborne pathogens such as HIV and HBV> gowns should

be able to prevent “ strike through” or “wetting out” of the fabric, and so

surgical gown materials should have not only

Antimicrobial properties but also blood barrier properties. Chitosan and

fluoropolymers seem to be the most suitable finishing agents for providing

surgical gown materials with barriers against microorganisms and blood.

Because many medical products including surgical gowns are used in

close proximity to human skin, the hand and air permeability of these

materials are also very important. Recently, single-use gowns made from

non-woven have gained in popularity because non-woven fabrics block

fluids so well and single-use gowns are so reliable.

One of the most important characteristics of chitosan is its Antimicrobial

activity at specific molecular weights. Protonated amine groups in

chitosan inhibit the growth of microorganisms by holding negatively

charged microorganism ions. Many studies have examined chitosan as an

Antimicrobial finish for textile materials, either for production of low

molecular weight

chitosan followed by its application on textile fibers or for co-spinning or

co-casting of low molecular weight chitosan with cellulose molecules to

make Antimicrobial fibers and films. However, these methods had to

produce chitosan with specific molecular weights, which could

considerably increase production costs. In addition, insolubility of chitosan

in neutral or alkaline conditions further limited its application.

A quarternery ammonium derivative of chitosan, N-2-hydroxy propyl-3-

trimethylammonium chitosan chloride (HTCC), is synthesized as an

Antimicrobial finish for cotton using a reaction of

glycidyltrimethylammonium chloride (GTMAC) and chitosan. The use of

crosslinking agents or binders increase laundering durability of cotton

treated with HTCC. A 5% nonionic binder applied along with 0.1% or

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higher concentration of HTCC on cotton is quite effective in increasing the

laundering durability of the HTCC-treated cotton.

There are some reports about the utility of chitosan polymer to impart

Antimicrobial activity in textile finishing. For example, chitosan salt

produced by an organic acid was bound to the surface of textiles by a

tremendous amount of resin, which formed cross-links. When fully

deacetylated chitosan is depolymerised into chito-oligosaccharide with

sodium nitrite, its DP can be

controlled by adjusting the amount of sodium nitrite added to the acetic

acid solution containing the fully deacetylated chitosan.Chitosan when

applied along with DMDHEU results in a substantial improvement in soil

removal when oily soil is applied to cotton fabrics. The highest levels of

soil removal are exhibited by fabric samples treated with DMDHEU with

chitosan of average molecular weight below 21,000. the improvement in

soil removal attributes to the prevention of deep soiling due to blocking of

pore structure abd the increase in hydrophilicity by chitosan

treatment.Chitosan treated samples of cotton with resin treatment show

higher moisture regain values, this is because amine and hydroxyl groups

provide reactive sites for

water.Various methods such as physical, chemical, and biological

treatments are used for deodorizing. In the field of cosmetics,

antibacterial agents, antiperspirants, and fragrances are used to

effectively reduce or mask malodors. The antibacterial agents

control the bacteria that decompose human fats found in sweat to

produce low molecular weight fatty acids. Using the same technology, the

textile industry applies antibacterial agents for odor control. However,

because antibacterial agents can attack human skin as well, there are

only a limited number of such chemicals allowed for use in textile

treatment.Over the past

few years, a considerable number of studies have been done on the

performance of chemical deodorizers that swiftly couple with targeted

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odor substances. Their neutralizing ability makes such of low molecular

weight substances less volatile. For example, these chemical deodorizers

can target sweat, which generally shifts from human skin to fabric and

then is concentrated to generate unfavorable odors after bacterial

decomposition.

However, existing chemical deodorizes are highly surface active and can

cause unpleasant results such as discoloration, aggregation, and skin

irritation. Notably, most of the highly active substances are hydrophilic,

and their activities become

weak under hydrophobic conditions. Chitosan was selected because while

its primary amino group possibly deodorizes, its high molecular weight

offers safety. The polymerization reactions of methacrylic acid with

chitosan were done in water, and the emulsions were free of monomeric

acid. The polymer particles showed high deodorizing performance, even in

hydrophobic and hydrophilic circumstances, and fabric treated with the

emulsion was also found useful for deodorizing.

In the manufacturing and coloration of cotton fabrics, the textile industry

experiences dyeing problems with some lots of cotton. The cotton does

not absorb dye uniformly and creates tiny white or light-colored spots.

This results from small

clusters of immature cotton called neps. Immature cotton results from a

variety of reasons e.g. plant disease, insect attack, premature harvesting

after using harvest-aid chemicals, or adverse weather conditions.

Previous research has shown that pretreatment of cotton fabrics with

chitosan significantly improves the dye coverage of neps. After dyeing

with reactive dye using standard procedure dyed fabrics are treated with

chitosan by exhaust or pad-batch method. The chitosan treatment alone

did not cover the neps in the dyed fabrics. However, after redyeing with

0.1-0.2 dye, the neps were more or less completely covered. The

coverage ratings increased from 1-2 to 4-5. The chitosan aftertreatment

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and redyeing with a small amount of dye caused very little change in total

color difference value. There is a significant increase

in k/s value of dyed fabric. Nep coverage improved the quality of the dyed

fabrics.

Among synthetic fibers, polyester (PET) exhibits excellent properties such as

elastic recovery, dimensional stability. However, it does not absorbwater or moisture

well. As a result, friction can cause static electricity to occur. Electric resistivity of

natural fibers is 109 to 1010 Ω.cm; polyester fiber is less than 1015 Ω.cm; water is 103

Ω.cm. This static electricity causes electric shock, fiber contamination during textile

finishing.Many endeavors to endow an antistatic property to polyester include research to

change the characteristics of fiber surface. Chitosan shows high moisture regain even in

low relative humidity and does not swell much in water; thus it can resist the decrease the

durability that water causes. A permanent antistatic finish can be achieved by

crosslinking hydrophilic materials that form an insoluble conductive sheath on the

surface of the fiber. So chitosan seemingly has the potential to improve the water-

absorbency and antistatic properties of polyester fiber.

Polyester fibers can be grafted with AA or NVF by preirradiation with γ rays. By acid

hydrolysis, amide groups on the fiber surface can be converted into amino groups.

Chitosan can then be grafted to modified polyester surfaces by either esterification or

imine formation. The highest surface density of amino groups can be achieved by imine

formation between chitosan and glutaraldehyde- treated PET-g-NH2.

Chitosan grafted polyesters show antibacterial activity for MRSA, S. aureus-2, and E.

coli. The antibacterial activity increases with the surface density of amino groups.

Furthermore, the antibacterial activity for E. coli is higher than that for the other bacteria,

whereas the antibacterial activity for MRSA is the lowest.

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