May 2012

Saturday, May 26, 2012

Jute Products | Some Important Products of Jute

Christmas Bags, Jute Sacking Bag, Jute Promotional Bags, Jute Bottle Bags, Jute Hessian Cloth Bags, Jute Hydro-Carbon Free Bags, Jute Food Grade Bags

Jute bag

Jute Handicrafts: Notebook, Pen holder, Greeting cards, Photo frame, file folder, Gift Box, Memo Box, Tissue Box, Slip Pad Holder, Jute Wall Hangings, Jute Coasters, Jute Table Mats, Jute Hammocks, Jute Lamp Shades, Jute Stationery

Jute Gift box

Jute Textile: Jute Hessian Cloth or Burlap, Jute Geo Textiles, Jute Yarn, Jute Hydro-Carbon Free Cloth, Jute Carpet Backing Cloth (CBC), Jute Canvas,

Jute apparel

Jute Apparel: Jute Jacket, Jute Footwear, Jute Fashion Accessories

Jute fashion bag

Jute footwear

Jute Furnishings: Jute Mats & Durries, Jute Cushion Covers, Jute Fabrics, Jute Blinds, Jute Rugs, Jute Carpets

Jute furnishing

Industrial Jute Goods: Jute Felt, Jute Webbing

7:01 AM

Classification of Jute Fiber

District

Northern

Jat:

Jat is the finest quality jute with firm

It has good color and length

It has good luster

This type of jute fiber grows in the district of Mymensingh, Dhaka and Comilla.

Jute plant

District:
District jute is close to jat in quality.

The fiber is not uniform in textures and strands

Its color varies from light ream to dull grey

Its length is shorter.

There are two types of District jute. They are-

Hard district

Soft district

Hard district:
The hard district jute is better than the soft district.It mainly grows in the district of Faridpur

Soft district:
This type of jute grows in district of Noakhali,Pabna,Barisal,Jessor,Khulna,Sylhet,Lower Comilla,Chittagong and some part of Dhaka.

Northern:

Northern jute is of somewhat inferior quality.

The fiber is dull-colored fluffy hairy and barky

Generally medium length and weak.

This type of jute grows in District of Rangpur, Dinajpur, Bogra and Rajshahi.

7:00 AM

What is Jute Grading? | Grading System of Jute Fiber

subcontinent, which make up of the present day West Bengal of India and plains of Bangladesh. Grading is done after the barky ends are cut off. There are six grades both for White and Tossa jute. The characteristics specified for various grades are given below.

Grading System of Jute Fiber:

Jute fibers are graded according to three qualities of fibers. They are-
On a basis of fiber properties:

I.Length
II.Strength
III.Fineness
IV.Color
V.Lusture
VI.Roots and cleanliness and uniformity in color.

On the basis of color:
There are two colors-

White and golden

Brown to red Corresponding to the main varieties capsularies and olitorius.

On the basis of export:

A bottom

B bottom

C bottom

X bottom

On the basis of quality of raw jute

Pucca grading

Kutcha grading

Pucca Grading:

Raw jute from which roots have been cut.

White Jute:
Bangla white special (BWS): White or creamy Finest texture Very good luster, clean, well hackled Completely free from any defects of jute Entirely free from red ends

Bangla White-A (BW-A): White to light cream Fine texture Strong and very good luster, clean Completely free from red ends and any blemish

Bangla White-B (BW-B): Light cream to straw color Good texture Strong and good luster, well hackled Free from blemish and red ends excluded .

Bangla White-C (BW-C): Light grey or light reddish to straw color Sound strength Average luster Clean but free from croppy or hard gummy Tops and roots and red soft ends are permissible.

Bangla White-D (BE-D): Any color Average strength Occasional bark and specks permissible Slightly croppy and gummy tops permissible Red ends also permissible.

Bangla White-E(BW-E): Any color Any strength but free from perished fibers Unretted jute.

Tossa Jute:
Bangla Tossa Special (BTS):

Uniform golden or reddish color

Finest texture

Very strong

Very good luster

Clean cut and well hackled

Completely free from any defects.

Bangla Tossa-A(BT-A):

1 .Uniform sliver grey to golden color

Fine texture

Strong and good luster

Clean cut and well hackled

Completely free from any blemish.

2.Uniform light golden to reddish color

Fine texture

Strong and good luster

Clean cut and well hackled

Completely free from any blemish.

Bangla Tossa-B (BT-B):

1.Light to medium grey color

Sound clean

Good texture

Average luster

Clean cut and well hackled

Free from any defects

2.Light grey or reddish excluding dark gray color

Sound clean

Good texture

Average luster

Clean cut and well hackled

Free from any defects

Bangla Tossa-C (BT-C):

Mixed colors

Average strength

Occasional bark and soft specks allowable

free from runners

Slightly croppy and gummy tops permissible

Well cut and hackled but free from black root ends.

Bangla Tossa-D(BT-D):

Mixed colors

Average strength

Occasional bark and specks allowable

Free from runners

croppy and gummy tops permissible

Rough cut and hackled

Free from black root ends

Bangla Tossa-E(BT-E):

Any color

Any strength but free from unretted jute

Stick and perished fibers

Rough cut and hackled bark and hard Centre permissible

Kutcha Grading:

Raw jute from which roots have not been cut.

Kutcha bales are graded as follows-

Tops

Middle

Bottoms

B-bottoms

C-bottoms

X-bottoms

Tops:

Very strong fiber

Excellent color and luster

Free from all defects

Cutting not more than (White 15% Tossa 10%)

Middle:

Strong sound fibers

Average color and luster

Free from all specks runners and harsh crop end (White 25% Tossa 15%)

Bottoms:

Sound fibers

Medium strength

Free from all hard centered jute (White 30% Tossa 20%)

B-bottoms:

Sound fiber

Medium strength

Not suitable for higher grade(White 35% Tossa 25%)

C-bottoms:

Medium strength

Any color

Free from runners and choppiness.

X-bottoms:

Weak, harsh jute

Free from tagled jute and stick

Habijabi:

Tangled jute

Free from any dust and cuttings

6:59 AM

Jute Yarn Manufacturing Process | Production Process of Jute Yarn

Raw Jute fiber

Selection of Raw Jute:

In the selection process, raw jute bales are opened to find out any defect and to remove the defective portion from the mora by experienced workers. Raw jute bales are of two types i.e. 150 kg weight and 180 kg weight with or without top portion cutting. The bales are assorted according to end use like Hessiean weft, Sacking wrap, Sacking weft etc. After selection, jute bales are carried to softning section by workers called Gariwala and Bajawala.

Softning Process Jute:

In softning process jute morahs are made soft and pileable. Two methods are used for softning; use of softening machine and use of jute good spreader. Generally an emulsion plant with jute softner machine is used to lubricate and soften the bark and gummy raw jute. The emulsion plant consists of gear pump, motor, vat, jet sprayer, nozzles, emulsion tank and the jacket. In this softning process jute becomes soft and pileable and suitable for carding.

Carding:

Carding is a combining operation where jute reeds are splitted and extraneous matters are removed. Jute fibres are formed into ribbon called "sliver". There are three different carding sections:

(i)Breaker carding
(ii)Inner carding
(iii)Finisher carding

In the Breaker carding machine soften jute after piling is feed by hand in suitable weight. The machine by action with different rollers turns out raw jute in the form of jute sliver for finisher carding. In this process root cutting is necessary before feeding the material to the hand feed breaker carding machine.

Finisher carding machine make the sliver more uniform and regular in length and weight obtained from the Breaker carding machine.

Finisher carding machine is identical to the Breaker carding machine, having more pair of rollers, staves, pinning arrangement and speed.

Nearly 4 to 12 slivers obtained from Breaker carding machine is fed on this machine.

The material thus obtained is send to drawing section.

Drawing:

Drawing is a process for reducing sliver width and thickness by simultaneously mixing 4 to 6 sliver together. There are three types of Drawing Frame machine. In most mills 3 Drawing passages are used in Hessian and 2 Drawing passages are used in Sacking.

The slivers obtained from finisher carding machine is fed with four slivers on to the first drawing frame machine. The first drawing frame machines makes blending, equalizing the sliver and doubling two or more slivers, level and provide quality and color. This machines includes delivery roller, pressing roller, retaining roller, faller screw sliders, check spring, back spring, crimpling box etc..

In second drawing, the Second Drawing Frame machine obtain the sliver from the First drawing machine and use six slivers and deliveries per head. The Second Drawing machine makes more uniform sliver and reduce the jute into a suitable size for third drawing.

In the third drawing, the Third Drawing frame machine uses the sliver from second drawing. The Third Drawing machine is of high speed makes the sliver more crimpled and suitable for spinning. The comparison of the three drawing process:

Drawing Process	Efficiency Range(%)	Productivity Mt/mc/shift
1st Drawing	55 - 73	1.75 – 2.2
2nd Drawing	64 - 74	1.62 – 1.9
3rd Drawing	67 - 70	1.31 – 1.4

Spinning:

Spinning is the process for producing yarn from sliver obtained from Third drawing. The jute spinning frame machine is fitted with slip draft zone and capable of producing quality yarns at high efficiency with auto-dofting arrangements also

6:59 AM

Types of Jute Yarn | Batch Composition for Jute Yarn | Batch Selection Techniques

Now we will discuss about the types of jute yarn and batch selection technique of jute yarn.

Jute yarn

1. Hassian Warp:

These types of yarn are good, clean and free from specks with high lusture. For manufacturing this type of yarn, clean and defect free jute is required. To make this type of yarn clean and defect free jute is required.

Batch Selection:

Hard jute .......................................70%
Soft jute ........................................30%

Example: For 8 lbs/spyndle hassian warp

White C........................................40%
White X ...................................... 40%
Tossa ...........................................20%

2. Hassian Weft:

Hassian weft yarn is cleaner and softer than hassian warp yarn. So for hassian weft clean fibre is required, but fibre of lower strength can be used to hassian weft yarn.

Batch Selection:

For Heavy Yarn

Hard jute..................................30%
Soft jute ...................................70%

For Light Yarn

Hard jute .................................50%
Soft jute ...................................50%

Example: For 8.5 lbs/spyndle hassian weft

White C ...................................40%
White X ...................................40%
Tossa ........................................20%

3. Sacking Warp:

Sacking warp juteyarn is good and strong. Specks and colour is not important when manufacturing this type of yarn. So, 70 to 80% Tossa jute can be used.

Batch Selection:

Hard jute ................................... 60%
Soft jute .....................................40%

Example: For 8 lbs/spyndle sacking warp

X bottom ..................................67%
S M R ......................................33%

4. Sacking Weft:

Sacking weft yarns are low quality yarn. It is coarse and is made from low grade jute fibre. It may contain line cuttings, bale cuttings, soft and hard waste, rope waste, jute dust, habijabi and entangled jute.

Example: For sacking weft

NC .......................................................70%
S M R ..................................................15%
Caddis ..................................................5%
Thread waste and gunny cuttings............10%

5. C.B.C (carpet breaking cloth):

Batch Selection:

Hard jute ................................... 100%

Example: For 8 lbs/spyndle C.B.C warp

B.W.B ....................................... 40%
B.W.C ...................................... 60%

Example: For 8 lbs/spyndle C.B.C weft

6:57 AM

Chemical Composition of Textile Fiber (Natural) | Chemical Composition of Cotton Fiber/Jute Fiber/Linen/Flax Fiber/Hemp Fiber/Sisal Fiber/Coir Fiber/Wool Fiber/Silk Fiber

Chemical Composition of Cotton Fiber:

Cellulose 94%

Protein 1.3%

Ash 1.2%

Pectin 1.2%

Oil, Fat and Wax 0.6%

Sugar 0.3%

Pigment trace

Others 1.4%

Chemical Composition of Jute Fiber:

Cellulose 65.2%

Hemicellulose 22.2%

Lignin 10.8%

Water soluble 1.5%

Fats and wax 0.3%

Chemical Composition of Linen/Flax Fiber:

Cellulose 92%

Hemicellulose 2%

Lignin 4%

Others 2%

Chemical Composition of Hemp Fiber:

Cellulose 77.77%

Hemicellulose 10%

Lignin 6.8%

Pectin 2.9%

Fat & wax 0.90%

Water soluble 1.73%

Chemical Composition of Sisal Fiber:

Cellulose 71.5%

Hemicellulose 18%

Lignin 6%

Pectin 2.3%

Fat & wax 0.5%

Water soluble 1.7%

Chemical Composition of Coir Fiber:

Husk 14%

Fiber 22%

Pith 16%

Kernel 30%

Water 18%

Chemical Composition of Wool Fiber:

Keratin 33%

Dirt 26%

Suint 28%

Fat 12%

Mineral matter 1%

Chemical Composition of Keratin:

Carbon 50%

Hydrogen 12%

Oxygen 10%

Nitrogen 25%

Sulfher 3%

Chemical Composition of Silk Fiber:

Fibroin 76%

Sericin 22%

Fat & wax 1.5%

Mineral salt 0.5

6:44 AM

Different Methods of Reactive Dye Application | Pad-batch Method | Pad Dry Method | Pad Steam Method

2) Pad dry method
3) Pad steam method.

1) Pad-batch method

a. Pad (alkali)-batch (cold) process.

Figure: Pad-batch method

Steps:
1) The fabric is first padded in a padding mangle with reactive dye in presence of an alkali.
2) The padded fabric is rolled in a batch and the batches are wrapped by polyethylene sheets and stored in wet condition for 1-24 hours at 200-300C in a room.
3) During the storage period, the rolls may be kept slowly rotating to prevent seepage of the dye liquor.
4) After storing time is finished fabric is washed in a rope washing machine to remove the unfixed dye from fabric surface.

b. Pad batch (hot) process:

Figure: Pad batch (hot) process

Steps:
1) The fabric is first padded in a padding mangle with reactive dye in presence of an alkali.
2) The fabric is then passed in between infrared heater to preheat the padded fabric to 500C to 900C.
3) The fabric is then batched on a large diameter roller in a hot chamber. The batching is done under controlled conditions of temperature and humidity for a sufficient time to ensure diffusion and fixation of the dye in the fibre. During this period the batch is kept slowly rotating to avoid the seepage of dye liquor.
4) The cloth is then washed in a rope washing machine to remove the unfixed dyes.

2) Pad dry method:

Figure: Pad dry method

Steps:
1) Fabric is first padded in a padder with reactive dye in presence of an alkali.
2) Padded fabric is then passed through a squeezing roller into a dryer. As a dryer cylinder, stenter etc may be used. During drying due to higher temperature fixation of dye in fibre increases and at the same time water is removed by evaporation.
3) After drying fabric is washed in a washing machine to remove unfixed dye.

3) Pad steam method:

Figure: Pad steam method

Steps:
1) Fabric is first padded in a padder with the dye.
2) It is then passed through between two squeezing roller in a dryer. Drying should be done slowly; otherwise precipitation of dye due to quick removal of water may take place leading to lower color value.
3) After coming out from dryer fabric is padded in a padder containing salt and alkali. Due to salt exhaustion of dye takes place and due to alkali fixation occurs.
4) Fabric then passed through a steamer where it is kept for 15-19 second. Due to high temperature here fixation rate increases.
5) In this step fabric is washed in a washing machine to remove the unfixed dye.

6:43 AM

Why So Called Reactive Dye | History of Reactive Dye | Which Fibers Can be Dyed with Reactive Dye?

Here the dye contains a reactive group and this reactive group makes covalent bond with the fibre polymer and act as an integral part of fibre. This covalent bond is formed between the dye molecules and the terminal –OH (hydroxyl) group of cellulosic fibres on between the dye molecules and the terminal –NH2 (amino) group of polyamide or wool fibres.

Reaction of Reactive Dye:

D-SO2-CH2-CH2-OSO3Na +OH-cell --- D-SO2-CH2-CH2-O-cell + NaHSO3
D-SO2-CH2-CH2-OSO3Na + NH2- wool ----D-SO2-CH2-CH2-NH-Wool + NaHSO3

Here, D= dye part.
Wool = wool polymer.
Cell = cellulosic polymer.

Reasons for so named:

Reactive dyes are so called because this is the only type of dye, which has reactive group, and that reactive group reacts chemically with fibre polymer molecules and form covalent bond. This covalent bond is formed between the reactive group and terminal –OH (Hydroxyl) group of polyamide and wool fibre or between reactive group and terminal -NH2 (Amino) group of cellulosic fibre polymer. The strength of this covalent bond is more than ionic bond, hydrogen bond and Vander Waal’s force of attraction. Thus the reactive group becomes an integral part of the fibre.

For this reasons the dyes are so called. They are also called ‘fibre reactive group’.

History of Reactive Dye:

On the occasion of 100 year’s celebration of synthetic dye manufacturing, two chemists of ICI company (UK) named Stephen and Rattee tried to manufacture a new dyestuff. Thus they succeed to invent a new dye in 16965, which was named REACTIVE DYE. This was manufacture for dyeing cellulosic fabrics. The first three reactive dyes were PROCION YELLOWR, PROCION BRILLIANT RED 2B and PROCION BLUE 3G.for this effort they were awarded gold medal of the society of dyes and colorists for the year 1960.

Which Fibers can be dyed with Reactive Dye:

By reactive dyes the following fibres can be dyed successfully:

1) Cotton, rayon, flax and other cellulosic fibres.
2) Polyamide and wool fibres.
3) Silk and acetate fibres.

It covers a wide range of color spectrum and includes shades varying from bright to heavy dark like,

a. Violet
b. Blue
c. Green
d. Red
e. Black
f. Yellow
g. Etc.

1) On the basis of reactive group:
a) Halogen(commonly chlorine) derivatives of nitrogen containing heterocycle, like 3 types-

· Triazine group
· Pyridimine group
· Quinoxaline dyes

Example:

Triazine derivatives: procion, cibacron.
Pyridimine derivatives: reactone
Quinoxaline derivatives: levafix.

b) Activated vinyl compound:

· Vinyl sulphone
· Vinyl acrylamide
· Vinyl sulphonamide.

Example:

Vinyl sulphone: remazol
Vinyl acrylamide: primazine
Vinyl sulphonamide: levafix.

2) On the basis of reactivity:

a) Lower reactive dye:
Here ph is maintained 12-12.5 by using NaOH in bath.

b) Medium reactive dye: here pH is maintained 11-12 by using Na2CO3 in dye bath.
c) Higher reactive dye: here pH is maintained 10-11 by using NaHCO3 in dye bath.

3) On the basis of dyeing temperature:

a) Cold brand:
These types of dyes contain reactive group of high reactivity. So dyeing can be done in lower temperature i.e. 320-600C.
For example: PROCION M, LIVAFIX E.

b) Medium brand:
This type of dyes contains reactive groups of moderate reactivity. So dyeing is done in higher temperature than that of cold brand dyes i.e. in between 600-710C temperatures.

For example, Remazol, Livafix are medium brand dyes.

c) Hot brand:
This type of dye contains reactive groups of least reactivity. So high temperature is required for dyeing i.e. 720-930 C temperature is required for dyeing.

For example PRICION H, CIBACRON are hot brand dyes.

Trade name	Manufacturer	Country
Procion	I.C.I	U.K
Ciba cron	Ciba	Switzerland
Remazol	Hoechst	Germany
Levafix	Bayer	Germany
Reactone	Geigy	Switzerland
Primazin	BASF	Germany
Drimarine	Sandoz	Switzerland

Textile Technology

Pages

Saturday, May 26, 2012

Jute Products | Some Important Products of Jute

Classification of Jute Fiber

What is Jute Grading? | Grading System of Jute Fiber

Jute Yarn Manufacturing Process | Production Process of Jute Yarn

Types of Jute Yarn | Batch Composition for Jute Yarn | Batch Selection Techniques

Chemical Composition of Textile Fiber (Natural) | Chemical Composition of Cotton Fiber/Jute Fiber/Linen/Flax Fiber/Hemp Fiber/Sisal Fiber/Coir Fiber/Wool Fiber/Silk Fiber

Different Methods of Reactive Dye Application | Pad-batch Method | Pad Dry Method | Pad Steam Method

Why So Called Reactive Dye | History of Reactive Dye | Which Fibers Can be Dyed with Reactive Dye?

Chemical Structure of Reactive Dyes | Commercial Names of Reactive Dye | Properties of Reactive Dye | Popularity of Reactive Dye

Classification of Reactive Dyes

Dyeing Mechanism of Reactive Dye

Knit Dyeing with Reactive Dyes(Hot Brand) | Knit Dyeing with Hot Brand Reactive Dyes