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Project on:
Effect of Reducing Agents on DischargePrintingFor Different Types of Textiles
SUPERVISOR Prof.Dr.Engr.Md.ZulhashUddin
Dean Faculty of Textile Chemical Processing Engineering and applied science. Bangladesh University of Textiles
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
Declaration
This Report Presented as the Partial Fulfillment of the Requirements for the Degree of Bachelor of Science in TEXTILE ENGINEERING under the supervision of Prof.Dr.Engr.Md.ZulhashUddin .Dean Faculty of Textile Chemical Processing Engineering and applied science. Bangladesh University of Textiles We also declare this project has not been submitted elsewhere for award of any degree or diploma.
PREPARED BY NAME AHMAD SAQUIB SINA ASHEQUR RAHMAN KHAN RAYHAN AHMED MD. MORSHEDUR RAHMAN IMTIAZ HOSSAIN MD.MAJED PARVEZ ID NO 2008-1-030 2008-1-040 2008-1-043 2008-1-130 2008-1-152 2008-1-106
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
ACKNOWLEDGEMENT
Bangladesh University of Textiles gave us the opportunity to perform the project work.Wewish to express our deepest appreciation & sincerest gratitude to Prof. Dr. Engr. Md. ZulhashUddin. Dean, Faculty of Textile chemical Processing Engineering and Applied Science and supervising teacher from the University for giving us the opportunity to accomplish of the project work and for his kind cooperation. Heartfelt thanks goes to senior textile engineers & understanding the information about different printing operation. Above all, we would like to acknowledge our deep dept to all teachers of our university and especially of wet processing department for their kind inspiration and help, which remain us the back drop of all our efforts. Finally, we would like to convey our acknowledgement that we remain responsible for the inadequate and errors, which may unintentionally remain in the following report.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
After printing the printed sample were subjected to several tests a. b. c. d. Color fastness to perspiration. Color fastness to rubbing. Color fastness to washing Tensile strength.
Finally from the overall comparison for different reducing agents, we found that Rongolite is the most suitable reducing agents used in industrial production.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
Table of Content
Content
Abstract Chapter 1 Chapter 2 General Introduction Literature Review
Description
Page No
5 7-8 9-20
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
Objectives: 1. To determine the best reducing agent used for discharge style of printing. 2. To assess the quality by using different testing procedure. 3. To find out the overall comparison.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
Printing is a process for reproducing text and images, typically with ink on paper using a printing press. It is often carried out as a large-scale industrial process, and is an essential part of publishing and transaction printing. By the term Textile Printing we mean the localized application of dyes or pigments and chemicals by any method which can produce particular effect of color on the fabric according to the design. 2.2Discharge ability of direct dyeing:
[6]
More than 75% of all direct dyes are unmetallisedazo structures and without after treatment may show good discharge ability. They are suitable for dyeing fabrics that are to be printed with a white or colored discharge, the lack of wet fastness is a disadvantage for many end uses but this can be overcome by subjecting the discharge print to a resin finishing process. Diazotized and developed direct dyeing, generally exhibit very good discharge ability, providing excess developer is removed. With fabrics intended for discharge printing, residual sodium nitrate and acid must be removed after diazotization or undesirable by products may be found during coupling. Because, during discharge printing the reducing agent reduces the azo groups in a correctly developed direct dyes but not in the byproducts, resulting in an unsatisfactory discharge. Pre-metalized direct dyeing and those after treated with copper salt are generally less readily dischargeable than those dyeing that do not contain copper. The maximum discharge effect is obtained by dyeing, discharging and then after treating and then after coppering, but difficulties due to inadequate wet fastness arise when washing off the uncoppered discharge print. Printer generally prefers to after copper the dyeing before discharge printing.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Discharge style of printing means the process which can produce a white or color effect or a previously dyed ground. Steps of discharge style: 1ststep: Dyeing dye. Fabric is dyed firstly with an easily reduce able
Reduction (reducing agent) Dye (-N=N-) Steaming 2ndstep: printing - The fabric is printed with a thicked solution of discharging agent - This discharging agent destroys the color at the printed areas and leaves the dye of unprinted areas unaffected. - If any dye is present in the solution of discharging agent which is not affected by its discharging action, can also be deposited and fixed on the ground. - Reducing agent must be stronger than dye. 3rdstep: Steaming 4thstep: Washing ~NH2 + NH2~
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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2.4White discharge : After dyeing and printing, the discharge agents discharge the dye of printed areas and leave the dye present on the unprinted area unaffected. A white design is produced on dyed ground. g
GREEN GREEN
GREEN
DYED FABRIC
2.5 print past preparation of discharge printing: 1. Dye selection: The correct choice of dye is of fundamental importance in successful discharge printing. - Dyes which are suitable for the dischargeable ground usually contain azo groups that can be split by reduction. - The suitability for dyes for the production of discharge grounds is however, dependent on the substituents in the ortho position to the azogroups. A dye with a chlorine atom in the ortho position is more readily discharged than one with a bromine atom in the same position. Cl O2N N= N Cl CI. Disperse orange 5 Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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CH3 -N CH2CH2OH
- Dyes having the structure (shown below) are difficult to discharge and in such structure the formation of internal hydrogen bonds would seem to produce a stabilizing effect towards the discharge agent.
N =N OH
COOH
In addition to discharge ability, the color of the amines produced by reductive cleavage is important. The ease with which the cleavage products can be removed from the discharge print during subsequent washing should be taken into consideration, if they are not completely removed these residues will slowly darken, due to oxidation, and a white discharge that was initially satisfactory will become unacceptable.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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ArN=N Ar + 4H
ArNH2 + Ar NH2
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Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
- Tin (II) chloride has been used since the earliest times. It is readily soluble compound which reactswithazo dyes as shown below. Ar N=N-Ar + 2 SnCl2+ 4 H2O ArNH2 +Ar NH2 + 2 SnO2 + 4 HCl It is important that SnCl2solnare used quickly since hydrolysis, which give a turbid soln, occur on standing. The hydrochloric acid produced will attack unprotected metal. The steaming equipment is particularly vulnerable in this respect, and even the squeegee holders on printing m/cs may have to be protected with resistant lacquer. The choice of reducing agent is determined largely by the fibre to be printed and to some extent, by the dyes used. Printing pastes containing a high proportion of insoluble matter can , however, give rise to the difficulties of sticking in , scratching of copper rollers and backing of screens unless finely ground powders with soft particles are used. - The actual amount of reducing agent required for optimum discharge will depend on- The dye to be discharged -The depth of the ground -The fabric being printed - The use of insufficient reducing agent will of course , give an incomplete discharge, whereas too much results in flushing or haloing during steaming as well as being wasteful and uneconomic . Flushing of fine details. That is not to say that flushing must be avoided at all costs. 3. Other chemicals and auxiliaries: a. Anthraquinone: It is often used to improve the discharge effect of a reducing agent, and is therefore used on fabric dyed with the azo dyes which are more difficult to discharge.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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structure: CH2OH H H OH OH H O OH H O H
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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CO2Na O H HHH HO H H OH O
-
Source: Brown seaweeds. Feature: - Readily soluble - pH stability is good (pH 4-10) Special attention: - An essential criterion for successful discharge printing is the correct balance between penetration of the fabric and control of flushing and haloing. Factors affecting the balance are 1. The viscosity of the discharge print paste 2. The amount of print paste applied (controlled by factors such as mesh size, squeegee setting,and engraving depth and so on.) 3. Steaming condition
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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1. One of the most difficult is the location of the design on the fabric. This is because the print pastes are often almost colorless and when applied to a dark grounds are virtually invisible, especially in r/r printing with the m/c running at speed. Remedies: The incorporation of whit pigment improves visibility; fugitive, contrasting sighting colors help, as do fluorescent agents used with ultraviolet light. This is an inevitable difficulty of the discharge style. 2. Controlled rapid drying: of discharge printing is imperative if loss of reducing agent is to be minimized . Remedies: This may mean wrapping the first drying cylinders to prevent boiling and on the other hand, the use of hot air blowers to accelerate drying on hand screen tables. 4. Facing or scumming : Another problem encountered is that of facing or scumming, which is due to partial discharge of the unprinted areas of the dyed group. This occur mainly in r/r printing and aries of the thin film or scum of discharge paste left on the un engraved surface of the printing r/r is transferred to the fabric . As a result the full bloom of the ground color is lost. 5. The reductive atmosphere existing in the steamer can similarly affect the dyed ground. Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Remedies: -These problems are avoided by meticulous attention to the basic printing technique. - Factors such as carefully maintenance of doctor blades and correctiveness of engravings. - by the application to the fabric before printing of a mild oxidizing agent , such as sodium nitrobenzene- sulphonate or NaCl , which is preferentially reduced by the reducing agent and thus protects the dyed ground . Sometimes resist salts are also used.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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3.1Dyeing of cotton fabric by Direct dyes In case of discharge style of printing we used direct dyes for dyeing purpose of the fabrics. We know, direct dyes are one of the most versatile classes of dyes stuff applicable to cellulose, wool. Silk and nylon fibers. Although the direct classes of dyes have deficiency in wet color fastness but it exhibits a wide range of fastness properties as shown by this use in apparel, upholstery, lining and automotive fabrics in 1884. Fabric used: 1. Woven Fabric (100% cotton) 2. Knit Fabric (100% cotton single jersey) Typical RecipeAnticreasing agent = 1 g/l Wetting agent = 1-2 g/l Sequestering agent = .5-1 g/l Soda ash = 1- 5 g/l Glauber salt / common salt = 5 -20 g/l Temperature = 95 5 C Time = 30 50 min PH = neutral to alkali M: L = 1: 10 Direct dyes = 2% /3 % / 4%
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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3.3Calculation: Sample wt = 5 gm Total liquor = 5 * 20 = 100 Wetting agent = 100* 1/ 1000* 1% = 10 Sequestering agent = 100*1/1000*1% =10 Leveling agent = 100*1 /1000*1% =10 Anticreasing agent = 100*1/1000*1% =10
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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3.4Dyeing curve:
100 Dyeing 80
60
Aftertreatment
40 TempC 20
30
20
30-50
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
3.9 steps in textile printing 1. preparation of the fabric to be printed 2. preparation of the print paste 3. making an impression of the print paste on the fabric 4. drying of the printed fabric 5. steaming of the printed fabric 6. after treatment (neutralizing/ soapingetc 1. preparation of the fabric: The fabric to be printed is pretreated first that is from singeing to bleaching /mercerizing operation. 2. Preparation of the print past: A number of printing ingredients are essential for preparing print paste including dyes or pigments. The number of ingredients depends on the nature of fabric to be printed and class of the dyes to be applied. 3. Making an impression of the print paste: The print paste is applied on to the prepared fabric according to a particular style and method (m/c).
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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= 15 gm =55 gm
Total
= 1000gm
= 100 gm
27
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
3.11 Printing procedure: Dyed the fabric with direct dyes to be printed
Making an impression of the print paste on the fabric by hand screen printing and by discharge style Now dry the fabric which is printed Steaming of the printed fabric After treatment (Neutralizing soaping etc.)
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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3.12 Color Fastness to Perspiration: Principle The garments which come into contact with the body where perspiration is heavy may suffer serious local discoloration. This test is intended to determine the resistance of color of dyed textile to the action of acidic and alkaline perspiration. Equipment: - Perspiration tester - Oven , maintained at 37 2 C temperature - SDC multifibre test fabric Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Sample size : 10*4 cm Reagent Materials L Histidinemonohyrochloride Disodium Hydrogen phosphate dihydrate Sodium chloride (NaCl) Disodium hydrogen ortho dehydrate (Na2HPO42H2O) Distilled water PH (adjusted with 0.1 N NaOH) Alkaline 0.5gm/L 2.5gm/L 5.0 gm phosphate 2.5gm Acidic 0.5gm/L 2.5gm/L 5.0 gm 2.2gm
1L PH= 8
1L PH = 5.5
Soda ash
1-1.5 gm/L
Acetic acid
1-1.2 gm / L
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Test procedure: - Wet out the composite test sample in mentioned alkaline or acidic solution at room temperature M: L ratio 1:50 and leave for 30 min. - Pour off excess solution and place the composite sample between two glass plate or acrylic plate under a pressure of 4.5 Kg and place in an oven for 4 hours at 372C temp. - Remove the specimen and hang to dry in warm air not exceeding 60C - Evaluation is done by grey scale in a color matching cabinet and rated from 1 to 5. -
Fig: Perspirometer
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Procedure: Washing solution containing 5g/l mettle soap (anionic), 2g/l soda ash. The specimen was treated at 60C for 30 min. And then it was dried. The adjacent multi fiber tape of a specimen was compared with a fresh multi- fiber tape in terms of change in color and the degree of staining and it was evaluated using geometric gray scales. Before the wash fastness test, dyed fabric was treated with 2% ( owf ) ALBAFIX ECO fixative (cationic, Huntsman ,UK )At room temperature (25C)for 20 min and the pH 6-7 is adjusted with acetic acid . Recipe: Soda Ash Standard soap Temperature Time : 2 g/L : 5 g/L : 60C : 30 min
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Fig: Multifibre 3.14 Scales for Assessment: 1. Grey Scales Numerical rating 1 2 3 4 5
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Method used: ISO 105 X 12 : 1987 method was followed to measure the rubbing fastness .
Sample size:Two pieces not less than 14 cm * 5cm are required for dry rubbing and two for wet rubbing. One specimen of each pair shall have the long direction parallel to the warp yarns or wales and the other parallel to the weft yarns or courses.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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AATCC Crock meter Cotton rubbing cloth (desized, bleached without finish) Grey Scale for staining Stopwatch Standard lighting chamber.
Procedure: For dry rubbing a specimen was mounted on the crock meter. Undyed cloth was mounted on the tip of the finger. The crock meter was operated to rub the specimen in a straight line along a track of 10cm long for times in 10seconds with downward force of 900g.For wet rubbing, the undyed bleach cloth was soaked in water to have 100% expression and mount on the tip of the finger. After rubbing, the degree of staining on the undyed fabric was evaluated using grey scale.
Fig: Crockmeter
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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THE
M/C WORKS IN
PENDULUM
ASSUMING
FR = MGR = MGRSIN As the value of M, g, R and r are constant, therefore F sin. According to the applied force the m/c dial gives us the Strength in lb on the basis of this.
J1 R
u j2 p mg
J2
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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M/c specification: The Fabric Strength Tester Good brand & Co. Ltd. Capacity: 250lb Testing atmosphere: Temperature 29oC and relative humidity 76% Standard atmosphere: temperature 20oC and relative humidity - 65%. Sample: Size 8inch X 2inch. No. of sample 20 (For warp way-10, for weft way-10).
Working procedure: 1. At first 12inch 2inch fabric was cut out from a big piece of fabric. The excess amount of fabric was cut because the two jaws will require at least 2inch each to grip the fabric. Thus 10 samples were cut down for testing. 2. Now, the first sample is fixed with the upper jaw J1 and the lower jaw J2. 3. The m/c is started and observed the dial until the sample is torn out. Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Hydroze: Shade 2% ( knit) 2% (woven) 3% ( knit) 3%(woven) 4% ( knit) 4% (woven) Alkali 3-4 3 3-4 3 3 2-3 Acid 3-4 3 3-4 3 3 3
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Chart Title
5 4 Axis Title 3 2 1 0 knit alkali knit acid Hydroze SnCl2 Rongolite
woven alkali
woven acid
From this chart we can figure out that Rongolite is better than the others in case of fastness to perspiration. Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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SnCl2 Shade 2% ( knit) 2% (woven) 3% ( knit) 3%(woven) 4% ( knit) 4% (woven) Grey Scale 4 4 3-4 3-4 3 3
Hydroze Shade 2% ( knit) 2% (woven) 3% ( knit) 3%(woven) 4% ( knit) 4% (woven) Grey Scale 4 4 3-4 3-4 3 3
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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3% knit
3% woven
4%knit
4% woven
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Hydroze: Shade 2% ( knit) 2% (woven) 3% ( knit) 3%(woven) 4% ( knit) 4% (woven) Dry 3-4 34 34 34 34 3-4 Wet 4 3 3-4 3 3-4 3
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Rongolite:
5 4.5 4 3.5 3 SnCl2 2.5 2 1.5 1 0.5 0 2% knit 2%woven 3%knit 3%woven 4%knit 4%woven Hydroze Rongolite
Fig: Rubbing test for dry state Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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5 4.5 4 3.5 3 SnCl2 2.5 2 1.5 1 0.5 0 2%knit 2%Woven 3%knit 3%woven 4%knit 4%woven Hydroze Rongolite
From the charts it has been assumed that Rongolite exhibits better fastness properties to rubbing than the other two agents.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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4.4 Tensile Strength: Warp way: Fabric Readin strength g (lbs) 1 2 3 4 5 Weft way: 62 62 63 63 62 62.4 .93 1.52 Avg strength SD (lbs) CV%
60.4
.93
1.54
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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FOR SnCl2
For Rongolite
Printed fabric strengt h(lb) Net stren gth loss Shad e % Pretrea ted fabric strengt h (lb) 60 Printed fabric strength (lb) Net stren gth loss
Shad e %
2%
58
2%
55
2%
56
3%
60
58
3%
60
55
3%
60
56
4%
60
57
4%
60
54
4%
60
55
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Fig: comparison for strength loss in woven fabric for different reducing agent
From this chart we can assert that Hydrose displays low strength loss of fabric where the others cause significant losses.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Cost analysis:for 1 kg For hydroze Chemical name Thickener (Naalginate) TiO2 Egg albumin R.A Total/Kg 200 1490 200 1490 600 600 Unit Prize 650 Total price 650 For SnCl2 Chemical name Thickener (starch) Unit Prize 120140 120140 Total For Rongolite Chemical name Thickener (Naalginate) TiO2 Egg albumin 9000 9760 9000 9760 R.A Total/Kg 1500 1500 2790 2790 600 600 Unit Prize 650 650 Total
600
600
40
40
40
40
40
40
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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After analyzing the cost comparison we have reached in this decision that Hydrose costs the least whereas SnCl2 costs a significant amount of money to prepare one kg paste.
Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.
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From this comparative study of different types of reducing agents used in discharge printing we can submit that1. Rongolite displays higher color fastness to perspiration than the others. 2. Rongolite exhibits higher color fastness to rubbing than the others. 3. Rongolite shows higher color fastness to wash than the others. 4. Hydrose is better than the others in case of loss in tensile strength of fabric than the others. 5. In case of cost comparison Hydrose is less expensive than the others whereas SnCl2 is the most expensive.
After justifying the terms - cost, color fastness, washing fastness, perspiration fastness, rubbing fastness, light fastness, fabric strength and quality of printing, we find that Rongolite shows better result in almost all aspects than other two competitors. So, thats why it is widely used in mills and factories for attaining better results in discharge printing.
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REFERENCES
1. Miles L W C ,Textile Printing 2nd Edition, p-(196 217) 2. Trotman ER, Dyeing And Chemical Technology Of Textile Fibres, p-431 3. Broadbent A D, Basic Principles Of Textile Coloration, p-(287,493) 4. Clarke W, An Introduction to Textile Printing, p-(189-204) 5. Shenai V A, Technology of Printing Vol-4, p-(212-221) 6. Knecht E & Fothergill J B, The Principles And Practice Of Textile Printing, p-(664-669) 7. Booth J E, Textile Testing & Quality Control. 8. http:// en. Wikipedia.org/wiki/printing.
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SAMPLES RONGOLITE
KNIT
KNIT
SnCl2
WOVEN
KNIT
HYDROSE
WOVEN
KNIT
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Wet Processing Tech. | Study on the Effect of Reducing agent on discharge printing of different textiles.