Mercerizing:
Mercerization is one of the most important
finishing processes of cotton with caustic
alkaline ( NaoH) solution in order to improve the
lustre, hand and other properties.
It imparts gloss to the fiber, increases its
hygroscopicity, strength and improves its dye
affinity.
It improves the reactions with a variety of
chemicals and elongation of the fibres and also
improves the stability of form.
Mercerizing process consists in treatment of cellulosic
materials with concentrated solutions of caustic soda
at a temperature of 15 to 18C.
Purpose of mercerizing:
[Link] improve the lusture.
[Link] improve the strength.
3. To improve the dye uptake and
moisture regain.
Effect of Mercerization:
Improve Luster.
Increase ability to absorb dye.
Improve reaction with a verity of chemicals.
Improve stability of form.
Improve strength/elongation.
Improve smoothness.
The molecular cross-sectional reshaped.
Recipe and parameters
Caustic Soda- 35% strength
Wetting agent: 0.5 to 1%
Temperature: 18 degree centigrade
Dwell time : 55 second
Principles:
Pad-- squeeze stretch hot or cold wash---dry
Machine Working: Chain type and chain less
type.
In both case padding mangle is for pad
For stretch either stenter and roller to be used. For
chainless curved roller to be used for width tension.
Types of Mercerization
Mercerization are Two Types:
1) Tension Mercerization
The purpose of mercerization is to increase luster of Cotton
fibers
The fiber untwists and swells, lumen becomes rounder in crosssection and it gains luster. Dye affinity and chemical reactivity
increase. Fabric becomes stronger and smoother.
2)
Slack Mercerization
Not as lustrous as tension method
Elongation and recovery properties improve and thus have
been used to produce comfort stretch garments and fabric
bandages, which need to conform to body shapes.
THE ADVANTAGES OF Mercerization: :
1. Larger dyeing affinity
2. Larger dimensional stability of the articles
3. Increasing of the lustre
4. Increasing of the tensile strength
5. Better covering of dead and/or mossy cotton
6. Improving to the touch
ffects of the chain mercerization of cotton fabric
Mercerization
Note: Fabric Mercerization is Cheaper than double Mercerization which provides a softer hand
THEORY:
Native cellulose (Cellulose I) forms alkali cellulose I with concentrated
sodium hydroxide. On washing and neutralization cellulose II is
formed.
As a result of the penetration of the alkali into the lattice, internal
hydrogen bonds are
broken and in Cellulose II the number of available hydroxyl groups (OH) is increased by 25%. The process is commercially known as
mercerisation. The treatment with alkali and subsequent washing
may be performed so that the fabric or yarn may either freely
contract or they may be held under tension. In both cases the
mercerised cotton has an increased affinity for both reactive and
direct cotton dyes, water and an increased strength. Cotton yarn or
fabric mercerised without tension contracts, but if held under tension
it retains its original dimensions and the lustre is increased.
What is the mercerizing process
The mercerizing involves these three subsequent steps,
1. Impregnation of the material in in relaxed state,cold caustic
solution of required strength and wettability..
2. Stretching while the material is still impregnated in the caustic
solution.
3. Washing off the caustic soda from the material while keeping
the material still in the stretch state.
(1) Twaddle (Concentration of NaOH):
If the concentration of NaOH is increased above 56oTw improvement
inluster will be attained but if it is decrease below 48o Tw. The
quality of luster willbegin to be adversely affected.
(2) Temperature:
High degree of luster is attained at temperature 18-20oC. As
thetemperature is increased the quality of luster is adversely
affected but onlowering the temperature no improvement in the
luster is obtained.
(3) Tension:
For acquiring better luster the material must be stretch to its
originaldimension
mercerization).
(both
If
the
in
warp
and
materialis
weft
direction
allowed
to
during
shrink
duringmercerizingthen quality of luster will be impaired onthe
other hand if the material is stretched more no improvement in
luster isachieved.
(4) Time:
The optimum time for mercerizing is 30-60 seconds by increasing
theduration of time no applicable improvement in the quality of
mercerization can beachieved but if the time limit is less than 30
seconds in the quality ofmercerization will be improved.
Different mercerizing
machinery/technology:
Automatic hank yarn mercerizing
m/c.
Chainlesss mercerizing Machine.
Clip or chain type mercerizing m/c.
Open width fabric mercerizing m/c
with caustic recovery unit.
Factors of Mercerizing:
In mercerizing followings are important:
Concentration of NaoH
Temperature
Tension
Time
luster of yarn after mercerization:
Before and after shade with
same parameters
Image of Mercerizing M/C:
CHAINLESS MERCERISING RANGE
CHAINLESS MERCERISING RANGE
Chainless Mercerizing
Chainless mercerizing is practiced on a range where the cloth is maintained in contact with
rotating drums virtually throughout the entire process. The tension on the fabric depends on
the friction between the cloth and the surface of the drum. This results in good control of
length but limited control of width. Bowed rollers are sometimes used to stretch the width
but they are much less effective when compared with the clips of the chain Mercerizer.
Chainless Mercerizing is used on fabrics that cannot be handled on a clip frame such as
knits.
Specialized equipment has been developed for Mercerizing tubular knit goods.
CHAIN MERCERISING RANGE