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Effect of Sonication on Cotton Preparation with Alkaline Pectinase

Val G. Yachmenev, Noelie R. Bertoniere and Eugene J. Blanchard
Textile Research Journal 2001 71: 527
DOI: 10.1177/004051750107100610

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JUNE 2001 527

Effect of Sonication on Cotton Preparation with Alkaline Pectinase

NOELIER. BERTONIERE,
VAL G. YACHMENEV, AND EUGENE
J. BLANCHARD
USDA, ARS, Soirrherti Regiorial Research Center, New Orleans, Loirisiarta 70179, U.S.A.

ABSTRACT
Pectinase bioscouring of greige cotton fabric is a very promising new approach for
preparing cotton textiles for subsequent wet processing treatments such as mercerizing,
bleaching, dyeing, printing, or finishing. Such biopreparation of greige cotton fabric is an
energy efficient and environmentally benign process. Our research has shown that at the
laboratory scale, introducing ultrasonic energy into the reaction chamber during enzymatic
scouring of the greige cotton fabric significantly improves pectinase efficiency, but does
not decrease the tensile strength of cotton fabric. In line with our previous, data, current
research also confirms that sonication of pectinase processing solutions does not impair
the complex structures of the enzyme molecules, but significantly improves their perfor-
mance. Data show that alkaline pectinase appears to be a more efficient agent for
biopreparation of greige cotton than acidic pectinase, resulting in better wettability and
whiteness. We also establish that the combination of pectinase bioscouring with desizing
and after-washing insures sufficiefit fabric wettability with adequate uniformity. The
results are comparable to or better than those for fabric after traditional alkaline scouring.
Introducing ultrasonic energy into the reaction chamber during enzymatic treatment of
cotton fabric could help overcome the major disadvantage of pectinase scouring-a longer
processing time compared to conventional alkaline scouring.

Cotton continues to be the fiber of choice worldwide,
with up to 43.2 billion pounds consumed annually in
textile production [ 101. Raw unscoured cotton contains
-90% cellulose and various noncellulosics such as
waxes, pectins, proteins, fats, and coloring matter. The
goal of the cotton preparation process is to remove these
hydrophobic . noncellulosic components and produce
highly absorbent fibers that can be dyed and finished
uniformly. Most noncellulosic materials on cotton fibers
are solubilized and removed by conventional alkaline
scouring with sodium hydroxide solution at the boil in
the presence of wetting and sequestering agents [l].
There are, however, severe environmental issues associ-
ated with conventional alkaline scouring, which requires
large quantities of water and energy and generates a huge
amount of highly alkaline wastewater effluent [ 141.
Recently published work has indicated that certain
enzymes may be a valuable alternative to harsh alkaline
solutions for preparing cotton. In general, enzymatic
treatment of cotton textiles is a well known process that
has gained wide recognition for various applications
such as desizing, bleach cleanup, biostoning and biopol-
ishing [8, 13, 14, 16, 18. 211. But enzymatic bioprepa-
ration of cotton represents a fairly new approach and is
still mostly in the developmental stages [3-6, 9, 15, 241.
Typical temperatures for enzymatic bioscouring are
about 4O-5O0C, which means significantly decreased
energy consumption. Also important is that the waste-
water effluent from enzymatic treatment is readily bio-
degradable and does not pose an environmental threat.
In addition to numerous advantages, there are several
shortcomings of enzymatic treatments, such as more
expensive processing costs and slow reaction rates. En-
zymatic processing of cotton, like any wet processing
system, involves transferring mass from the processing
liquid medium (enzyme solution) across the surface of
the textile substrate. In general, large enzyme molecules
(12,000-150,000 Daltons) have low diffusion rates and
tend to react with external cellulose fibers in cotton yarn.
Mechanical agitation of an enzyme processing solution
usually improves the transport of bulky enzyme mole-
cules toward the surface of the cellulose fabric and into
the interior of the cotton yarn [6, 81, but it is well known
that mechanical agitation is not a very effective stirring
mechanism for the immediate border layer of liquid at a
solifliquid interface where the enzymatic reaction actu-
ally occurs.
In view of that fact, ultras'ound appears to be an
alternative technique that could provide a far more effi-
cient stirring mechanism for the border layer of liquid at
the fiber's surface. Introducing ultrasonic energy into
liquid causes two major phenomena: heating and cavita-

Textile Res. J. 71(6), 527-533 (2001) 00-10-5 175/$2.00

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528
tion-the formation of very small bubbles in the liquid,
which generate powerful shock waves when they col-
lapse. The powerful agitation of the liquid border layer
caused by cavitation could substantively improve the
transport of bulky enzyme molecules toward the fiber
surface and increase the overall reaction rate. Note that
the cavitation effect is several hundred times greater in
heterogeneous systems (e.g., all textile wet processes)
then in homogeneous systems [ 191.
Several researchers have reported that ultrasonic en-
ergy has been successfully used to intensify various
textile treatments such as mercerizing cotton and cotton
blends, desizing and scouring fibers and yams, and per-
oxide bleaching, dyeing, and finishing fabrics [ l l , 12,
17, 201. A thorough search of available literature did not
yield any information directly related to application of
ultrasound energy to the enzymatic treatment of natural
fibers. Also, it was unclear how ultrasonic energy could
affect the very complex and sensitive structure of en-
zyme molecules. Our objective in this work is to study
the influence of ultrasound on enzymatic bioscouring of
greige cotton fabric with acidic and alkaline pectinases.
This work is also a continuation of our initial study on
the influence of sonication on ehzymatic treatment of
various cotton fabrics with cellulase enzyme [22, 231.
Experimental
Original greige cotton printcloth (122 g/m2) from
Testfabrics, Inc., was used for all tests. The fabric sam-
ples (508 X 330 mm) were sewn around the edges to
prevent unraveling during processing. Each fabric sam-
ple weighted approximately 25 g. Two kinds of pecti-
nases were used in tests: acidic pectinase (Viscozyme L)
and the newly developed alkaline pectinase (Bioprep L),
both from Novo Nordisk BioChem Inc.' Enzyme'treat-
ments varied only in buffer, pH, and temperature (Table I).
TABLE
1. Enzyme assay and reaction conditions.
~
Activity,
Enzyme Uk Buffer pH
Viscozyme L 100 FBG/g acetate, 0.01 411 4.0
Bioprep L 3000 apsdg phosphate, 0.01 411 8.2
Enzymatic processing of all samples involved a par-
allel-plate near-field acoustical processor (NAP) (Figure
' Specific company, product, and equipment names are given to
provide exact descriptions of experimental details. Their mention does
not imply recommendation or endorsement by the U.S. Department of
Agriculture.
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TEXTILE
RESEARCH
JOURNAL
Circulation
FIGURE1. General arrangement of the experimental cell
for combined enzymelultrasonic treatment of textile samples.
l), a dual frequency ultrasonic reactor with thermal con-
trol capabilities specially designed and manufactured for
controlled sonication of textile samples by Advanced
Sonic Processing Systems [7]. The ultrasonic reactor
accommodates a single stainless steel frame with the
textile sample placed precisely between two opposing
diaphragm plates, which form two walls of the reaction
chamber of the NAP. Driven by magnetostrictive trans-
ducers with two different frequencies (16 and 20 kHz),
these diaphragms produce a bent freqrrency inside the
reaction chamber. This beat frequency develops a highly
energized zone that continuously moves back and forth
within the reaction chamber and insures consistent pro-
cessing. Both ultrasound generators (1.4 kW) feeding the
ultrasound transducers are equipped with variable power
features allowing precise control of the intensity of ul-
trasonic energy inside the reaction chamber in the range
of 0-3 W/cm2.
Wettability, breaking strength, and whiteness index
for all samples treated under various conditions with
enzyme a n d o r ultrasound were determined and com-
pared with samples of the original greige cotton print-
T,"C cloth. All fabric measurements involved constant condi-
40 tions of 21°C and 65% humidity. The wettability of
55 treated samples was evaluated in accordance with a new
AATCC \Vicking Test, which is currently under devel-
opment. This method is based on the measurement of
time during which water is wicked up for 3 cm through
a strip of tested fabric. Six (2.5 X 17.8 cm) strips for
warp and fill directions w6re cut from each sample and
tested under identical conditions to insure good repro-
ducibility of the wettability data. Breaking strengths in
the warp and fill directions were determined in accor-
dance with the standard method-ASTM D 5035-95
JUNE2001 529

(strip test)-on the Instron tester. The whiteness index of

all samples was measured in accordance with AATCC
Test Method 110-1995. General descriptions of a11 the
bioscouring tests and abbreviations are presented in
Table 11.

TABLE 11. A Eeneral description of bioscourin," ICStS.

Treatment time,
Test description hours Abbreviation

Bioscouring with acidic pcctinase I AcP- 1 Original Enzyme Enz.+Son.

Bioscouring with alkaline
pectinase
Bioscouring with alkaline
pectinase in combination \vith
desiring and/or after-nash
Conventional alkaline scouring
6 AcP-6
2 AIP-2 FIGURE 2. Evaluation of average weltability of the cotton
printcloth samples after acidic pcctinase bioscouring (test AcP-I).
2 AIP(c)-2
0.5 Alk-0.5
1200

Results and Discussion 6

1000
0,

ACIDICPECTINASE TESTS
BIOSCOURING v, 800

The two tests used identical enzyme concentrations, son-

f 600
ication power, and circulation rates of processing solution m
C
5 400
through the reaction chamber,of the acoustical processor u
with treatment times of 1 and 6-hours (Table 111). 2 200

0
TABLE
111. Test paramcters for tests AcP-I and AcP-6. Original Enzyme E m . + Son.
Enzyme Sonication Circulation
concentration, power, rate, U FIGURE
3. Evaluation of average \veltability of printcloth
Test Trial & amps minute after acidic pcctinase scouring (test AcP-6).

AcP- I 1-1 5.0 0.0 I .4

1-2 5.0 15
AcP-6 6-1 5.0 0.0
6-2 5.0 15
In each trial, three samples of the cotton printcloth
were treated with acidic pectinase solution withhvithout
sonication under identical conditions to insure good re-
producibility. After the enzyme/ultrasound treatment, all
samples were thoroughly rinsed in deionized water, tum-
ble-dried, and conditioned for 24 hours before evalua-
tion. The average wettabilities (warp + fill) for triplicate
samples in all trials (original and treated with acidic
pectinase with/without ultrasound) are presented in Fig-
ures 2 and 3.
In general, acidic pectinase bioscouring increased the
wettability of all treated samples in both tests compared
with control samples (original greige cotton printcloth).
The improvement was more pronounced in test AcP-6
because of the longer treatment time, but the resulting
wettability was still relatively poor. The wicking time
I .J
I .'I was in the range of hundreds of seconds, which is an
1.J
order of magnitude more than for conventional alkaline
scouring. Experimental data also show that introducing
ultrasound energy during enzymatic treatment signifi-
cantly enhanced the performance of acidic pectinase.
Note that this substantial improvement in the perfor-
mance of acidic pectinase resulted from sonication of
only half of the total surface area of the fabric samples,
because the active surface of the diaphragm plates with
ultrasound transducers was about 50% of the sample
surface.
ALKALINE
PECTINASE TESTS
SCOURING
A new alkaline pectinase, recently developed and in-
troduced by Novo Nordisk BioChem Inc. [2], does not
affect the cellulose of cotton fibers. It also works best
under mild alkaline conditions, which is beneficial in the
cotton preparation process.

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530 TEXTILE JOURNAL
RESEARCH

The experimental parameters in all tests with alkaline

pectinase were identical to those with acidic pectinase 5o fl
except for treatment time, which was reduced to a more
practical 2 hours. The average wettability of triplicate
samples of cotton printcloth bioscoured with alkaline
pectinase (test AIP-2) is presented in Figure 4. Data on
the average breaking strength and whiteness index of the
bioscoured samples are presented in Figures 5 and 6 ,
respectively.
Or.Greige Alk-0.5 PcP-I PcP-6 Alp-2
Printcloth ~.
0 Enzyme 1Enz.+Son.
2500

J 2000 FIGURE 6. Comparative effects of alkaline and acidic pectinax bio-

I) scouring and convenrional alkaline scouring on \\ hiteness of cotton
g 1500 printcloth.
i=
p1000 ing pectinase bioscouring significantly enhanced the per-
A
V formance of alkaline pectinase. Comparative data on the
5 500 breaking strength of treated samples showed that enzy-
0
matic bioscouring with acidic pectinase (tests AcP-1 and
Sample 1 Sample 2 Sample 3 AcP-6) or with alkaline pectinase (test AIP-2) did not
change the mechanical strength of bioscoured samples in
comparison with the original greige printcloth sample or
FIGURE 4.Evaluation of aettability of cotton'printcloth samples after
alkaline pectinase bioscouring ( [ a t Alp-2); I , 2, and 3 arc replicates. with the sample subjected to conventional alkaline scour-
ing (All;-0.5, earlier data). All samples that were soni-
cated and enzymatically bioscoured showed better me-
100 chanical strength than nonsonicated samples. Only the
n
u)
samples scoured with alkaline pectinase showed any
80 significant improvement in whiteness compared to the
0,
5 60 original greige sample. In general, the data showed that
L
bioscouring of greige cotton fabric with alkaline pectin-
FI
UJ 40 ase results in better wettability and whiteness than with
:
S
acidic pectinase,
20
E Our discussion of these data with Novo Nordisk Bio-
m O Chem about the poor uniformity of alkaline pectinase
Or. PJk-0.5 PcP-1 kP-6 PJP-2 bioscouring from sample to sample resulted in some
Greige changes in processing ,conditions. We incorporated a
Printcloth
0 Enzyme Enz.+Son. mild after-wash for removing products from pectinase
. .
hydrolysis of the pectic substances in the fiber matrix.
Table IV shows the general organization of the new set
FIGURE 5. Comparative effects of alkaline and acidic pectinase bio- of alkaline pectinase bioscouring treatments (test
scouring and convcntional alkaline scouring on breakinz strength (warp
+ fill) of cotton printcloth. AIP(c)-2) designed to study the influence of various
procedures such as desizing, sonication, after-washing,
and their combinations on bioscouring of greige cotton
On average, all samples bioscoured with alkaline pec- printcloth.
tinase showed some improvement in wettability com- Desizing and after-wash procedures involved 82°C for
pared with control samples, but the overall uniformity of 2 minutes in a 0.1% solution of nonionic surfactant,
the treatment was quite poor. For example, the resulting Triton X- 100 [2]. All other experimental parameters such
wettability of sample 3 (wicking time -
I10 seconds) as alkaline pectinase concentration, circulation rate of the
was approximately twenty times better than for sample 1 processing solution, sonication power, and treatment
-
(wicking time 2200 seconds. But, as in previous tests time in test AIP(c)-2 were identical to those in test AIP-2.
with acidic pectinase, introducing ultrasottiid energy dur- Figure 7 shows the comparative effects of alkaline pec-

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JUNE 2001
TABLE
IV. General arrangement of combined alkaline pectinase bioscouring treatments (test AIP(c)-2).
Sample Sample description
original greige cotton
bioscoured
bioscoured and sonicated
biowoured and after-washed
hioscoured, after-wazhed, and sonicated
desized
desizrd and bioscoured
desized, bioscoured, and sonicatcd
desized, bioscourcd, and after-wazhed
desized, bioscoured, after-washed, and sonicated
tinase bioscouring, desizing, and after-wash treatments
and their combinations on the average wettability of
cotton printcloth.
FIGURE7. Comparative effects of alkaline pectinase hioscourin_e,
desizing, after-wash, and their combinations on the \\ettability of
samples of greige cotton printcloth, test AIP(c)-2; I , 2 and 3 are
replicates.
Wicking time comparisons of replicate samples of
original greige cotton fabric (G-1, 2, and 3, Figures 2
and 3) with wicking time for samples bioscoured with
alkaline pectinase (replicates GS- 1 , 2 , and 3, Figure 7)
show that enzymatic bioscouring significantly im-
proved the wettability of greige cotton fabric; how-
ever, overall the uniformity of this treatment was still
quite poor. In general, data in Figure 7 show that
single-step treatments only, either bioscouring with
alkaline pectinase (replicates GS-I, 2, and 3) o r de-
sizing (replicates D-I, 2, and 3), did not provide
sufficient wettability for the treated samples. Only
combined treatments such as desizing/bioscouring
(replicates DS-I, 2, and 3) or a combination of desiz-
inglbioscouringlafter-washing (replicates DSW- I , 2,
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53 1
Alkaline pcctinase
DesizinS scouring Sonication After-wash
+
+
+ +
+
+
+ +
+ +
+ + +
and 3) insured adequate and uniform wettability of the
treated samples. The comparison of wicking times on
samples after such combined bioscouring treatments
with samples subjected to conventional alkaline scour-
ing showed that the combined bioscouring provided
' equal or even better wettability with good overall
uniformity. As in all previous tests, the experimental
data for AIP(c)-2 test showed that using ultrasound
energy during biopreparation of the greige cotton
printcloth significantly improved the performance of
alkaline pectinase, resulting in faster and more uni-
form treatment. Figure 8 shows the comparative ef-
fects of sonication on alkaline pectinase bioscouring
and desizing and their combinations with after-wash.
In all trials, ultrasound energy significantly enhanced
the performance of alkaline pectinase without any
adverse effects on specific enzyme activity. Likewise,
combined treatments such as desizing/bioscouring and
desizing/bioscouring/after-wash were also accelerated
by sonication, but to a lesser degree. A comparison of
breaking strengths of all treated samples with the
FIGURE 8. Comparative effects of ultrasound on alkaline pectinase
scouring. desizing, and after-wash treatments of greige cotton print-
cloth, test AIP(c)-2.

II
FIGURE 9. Coniparativc effects of al6aline pectinate bioscouring,
desizing, after-wash, and their cornbinalionc on breaking strength
(\varp + fill) of cotton printcloth, test AIP(c)-2.
breaking strengths of the original greige samples (Fig-
ure 9) showed that the alkaline pectinase bioscouring
itself and its combinations with hesizing and/or after-
wash procedures did not affect the mechanical
strength of the treated .samples. Note again that the
samples that were sonicated in addition to enzymatic
treatment actually showed slightly increased niechan-
ical strength compared to the treated samples or to the
original greige samples.
The general trend we observed was that introducing
ultrasonic energy into the reaction chamber during pec-
tinase bioscouring of the greige cotton fabric resulted in
significantly improved performance of both acidic and
alkaline pectinases. The observed enhancement in pec-
tinase performance induced by sonication may be caused
by various physical and chemical phenomena resulting
from the interplay of ultrasound waves, enzyme mole-
cules, and liquid media. Here is a summary:
1. Acceleration of the diffusion rate of pectinase mol-
ecules toward the fiber surface through the liquid border
layer: The concentration of pectinase molecules in this
layer is a controlling factor, which defines the overall
rate of reaction.
2. Improved removal of products of pectinase hydro-
lysis from the reaction zone, which accelerates the over-
all rate of reaction.
3. Improved transport of pectinase molecules through
cotton yarns, which results in more uniform enzymatic
treatment of cellulose fibers.
4. Degassing expulsion of dissolved or entrapped gas
or air molecules from fiber capillaries and interstices at
the crossover points of fabric in liquid and removal by
cavitation phenomena.
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TEXTILE
RESEARCII JOURNAL
Conclusions
This research shows that enzymatic bioscouring with
acidic and alkaline pectinases can be effectively used for
preparing greige cotton fabric for subsequent chemical
treatments. Data show that alkaline pectinase appears to
be a more efficient agent for biopreparation of greige
cotton than acidic pectinase, resulting in better wettabil-
ity and whiteness. We also establish that the combination
of pectinase bioscouring with desizing and after-wash
treatments insures sufficient fabric wettability with ade-
quate uniformity, comparable to or better than that after
traditional alkaline scouring.
At the laboratory scale, introducing ultrasonic energy
in the reaction chamber during enzymatic scouring of
greige cotton fabric significantly improves pectinase ef-
ficiency, but does not decrease the tensile strength of the
cotton fabric. Ultrasonic energy in the reaction chamber
for enzymatic treatment of cotton fabric could help over-
come the major disadvantage of pectinase scouring-a
longer processing time compared to conventional alka-
line scouring. Thus, the combination of alkaline pectin-
ase bioscouring with sonication could significantly re-
duce the amount of wastewater effluent, energy
consumption, and overall preparation costs.
ACKNOWLEDGMENTS
We wish to thank Mr. Alan Lanibert for his help with
experiments, Ms. Melissa Day for textile property mea-
surements, and Novo Nordisk BioChem, Inc. for provid-
ing samples of acidic and alkaline pectinases.
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Alniirtscripr received Ail) 7. 2000: accepted August 18. 2000.