What are the benefits of Hot Mercerization?

Short and hot

During hot impregnation the lye penetrates faster and more evenly into the yarn core. Swelling therefore does not take place only on the fabric surface. As Compared with cold impregnation the swelling behavior is considerably better and has a positive influence on the dimensional stability. The more uniform swelling gives, with dyed goods, a more equal appearance. With the wet-on-wet method the exchange factor is increased thus permitting a shorter impregnation zone than with conventional processes. In addition, the lye volume is kept very low. The lye concentration is simple to control. The lye bath has been kept purposely small and under it there is one single lye tank integrated into the machine.

The process lye is continually circulated and the temperature and concentration monitored. The automatic lye control permits the addition of fresh lye, water or recovered lye of 20 to 40 B from recycling. Reaction heat is emitted when mixing the process lye. In hot mercerizing this is utilized, while in cold mercerizing it causes an energy consuming lye cooling process. Squeezing to lower lye content is possible with hot mercerizing. The lower lye consumption provides savings in water and steam at lye extraction.

This is achieved by objective selection of the process parameters such as: Lye temperature Lye concentration Lye reaction time Fabric lengthwise and crosswise tension The thus optimized process provides the best mercerizing effect with savings in lye, water and steam. In comparison with other mercerizing ranges the small lye volume permits very fast changes in concentration and, therefore, short roduction interruptions. No lye losses occur at changes. Therefore change over to a lower lye concentration is profitable in addition to the covering of immature cotton. Savings of lye, washing water and steam are money for your account. Instead of 4550 seconds as with cold mercerizing, the same effect can be obtained in only 25 30 seconds with hot mercerizing. In order to keep width contraction as low as possible, the fabric is kept under constant tension during the reaction phase. No selvedge to middle differences occurs with the DIMENSA. In the retention compartment of the DIMENSA the proven chainless principle with lifting top rolls is employed. The retention compartment is not flooded. On the DIMENSA MS the cloth is pinned onto the integrated stenter at the end of the retention compartment. On the DIMENSA ML the retention zone consists of a chainless reaction compartment only. To summarize the benefits of Hot mercerization: Faster caustic soda penetration speedier swelling

High swelling uniformity no ring mercerizing Better dye penetration Smoother cloth appearance softer handle Shorter impregnation times No cooling needed for mercerizing Maximum squeezing action at in feed squeeze Lower investment cost through shorter impregnation sections Further positive features of tensioned mercerizing are: Orderly orientation in the crystal areas Removal of fiber unevenness increasing the number of micropores Unification of the pore size And from this result: Better residual moisture Better luster [Comparison of Hot & Cold Mercerization] Better dyeing behavior with an increased dyestuff yield Better handle Coverage of immature cotton Courtesy: Benninger AG

How to improve the tear and tensile strength of the fabric?

1. i. There are many reasons for the loss of tensile and tear strength. Right from singeing, if the intensity and height of the flame is higher than the required; the fabric is likely to be scorched. To avert this, various speeds ranging from 70, 80, 90 meter/minute are to be tried in singeing and the efficiency can be ascertained by pilling test over specified measurements (10 x 10 sq.in). 2. ii. Excessive emerizing may lead to strength loss. 3. iii. Resin finishing (for DP value) : A loss of 20 per cent fabric strength is unavoidable if the chemicals after application and curing are not properly washed by suitable alkali treatment (2 gpl soda ash in cold water and then washing etc.). We also suggested a suitable recipe for obtaining a better DP value onn their fabric. 1. DMDHEU Resin = 60 gpl 2. Magnesium Chloride = 15 gpl 3. Poly-ethylene emulsion = 24 gpl 4. Silicone emulsion = 15 to 20 gpl 5. Acetic Acid = 2 gpl 6. 100% Non-ionic wetting agent = 2 to 3 gpl 1. PAD DRY @ 120 to 130C CURE @ 140 to 150 C for 4 to 5 minutes 2. Fabric is washed in an open soaper with 2 gpl soda ash at cold in the 1st compartment and then cold wash in all other compartments.