Foam Technology

Introduction

The wet processing of textile materials includes highly energy consuming operations,
approximately to 80% of total energy requirement of all the operations. Out of this,
about 66% of the energy is consumed in heating and evaporation of water from the
fibers. That’s why an alternative of water to be introduced in textile wet processing.

Foam dyeing and finishing of textiles has demonstrated as an economically very

attractive technology to conserve energy. Foam finishing has a wide application on
cotton, synthetic fibers and their blends.

In foam finishing, most of the water is replaced by air, which leads to a reduction of
energy resulting in substantial savings in energy cost. A fabric is padded with foam
formed from an aqueous solution of a dyestuff, a foaming agent and a carrier for the
dyestuff and the padded fabric is maintained at elevated temperatures to fix the dye.

Foam and Foam generation

Foam is a colloidal system comprising of mass of gas bubbles dispersed in the liquid.
That is, Foam is a dispersion of a gas in a liquid. Here the liquid is generally water and
the gas is generally air but it may also be an inert gas. This is familiar as foam on beer,
shaving foam etc.

Mixing of water and air does not produce stable foam alone, other materials also
needed. Foam can be generated by mechanical air blowing, through excess agitation
or chemically by introduction of foaming agents or combination of these methods.

For the generation of foam, a surface active agent has to be added which will
accumulate at the water air interface of foam. This surface active or foaming agent
will make the foam stable. The relative proportions of air and liquid phases in the
foam are designated by blow ratio.

Emulsion

Emulsion is the mixture of two or more immiscible liquids which are mixed with the
help of an emulsifier. Emulsion looks like a solution but it is not.

Comparison between Foam & Emulsion

Foam Emulsion
1. Foam is a dispersion of a gas in a 1. Emulsion is the mixture of two or
liquid. more immiscible liquids.
2. Surface active agent is to be added for 2. Emulsion is generated with the aid of
foam generation. emulsifier.
3. Generally foam is unstable and 3. Emulsion is stable.
continuously changeable.
4. Foam formation is difficult than that of 4. Emulsion formation is easier than that
 Foam Technology

emulsion. of foam.
5. Foam has two distinct phases, namely 5. Emulsion has only one phase.
liquid phase and gaseous phase.

Reasons for using foam technology in wet processing

Foam dyeing and finishing of textiles has demonstrated as an economically very

attractive technology to conserve energy. Foam becomes familiar because of
following reasons:

1. Foam is used for the reduction of wet pick up & the quantity of water to be
evaporated.
2. By the use of foam, drying step can be eliminated. Hence saves cost.
3. About 12-16% cost of total processing goes for heat generation of water. So if we
use foam then this cost for heat generation will be less.
4. Foam can reduce the M:L ratio from 1:20 to 1:7 or 1:5 which is also beneficial.
5. The dye liquor is very harmful and poisonous for environment. It pollutes the
surrounding areas. If we use foam the amount of liquor will be reduced and
environmental pollution will also be reduced.
6. Foam is used to avoid the distribution problem of dye and finishing agents by
generating a sufficient volume to allow convenient volumetric control.
7. Foam reduces dyes and chemical cost and the processing cost.

Types of foam:

Broadly there are two types of foam namely

A. Dispersion foam
B. Condensation foam.

A. Dispersion foam: Dispersion foam is produced by the introduction & mixing of gas
from an external source into a liquid phase. In textile field, dispersion foam is used.

B. Condensation foam: Condensation foam results from the generation of a gas

within the liquid either by chemical reaction or by a physical change. This type of
foam is not used in textile field.

Again, depending on the concentration of foaming agent used and method of foam
properties there are two types of foam
A. Dry foam (0.2 gm/L)
B. Wet foam (0.35 gm/L)

A. Dry foam: General features are:

1. Density 0.2 gm/L
2. Polyhedral structure which may vary in size.
3. Contain less liquid in bubble
4. More stable.
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B. Wet foam: General features are:

1. Density of wet foam is least 0.35 gm/L
2. Spherical bubble size.
3. Less stable.
4. Not suitable for textile use.

Foaming agents:

Pure water cannot create foam by mechanical agitation. For generation a surface
active agent has to be added which will accumulate at the water air interface. A
foaming agent is a material that facilitates formation of foam such as:
1. Surfactant
2. Blowing agent.

1. Surfactant: A surfactant, when present in small amounts, reduces surface tension

of a liquid or increases its colloidal stability by inhibiting coalescence of bubbles.
Foaming agents permits the conversion of small volume of a dye solution into a large
volume of micro foam which can be distributed evenly over the fabric at a shorter
time.

Surfactants are most usual foaming agents. Linear alkaline derivatives such as
sodium Lauryl sulphate is one of the most effective agents. e.g. Nekanil LN (BASF),
Sancowad Foamer NT (Clariant).

2. Blowing agent: A blowing agent is a gas that forms the gaseous part of the foam.
There are two main types of blowing agents:

a) Gases at the temperature that the foam is formed: Carbon dioxide, pentane, and
chlorofluorocarbons are examples of this type.

b) Gases generated by chemical reaction: Blowing agents that produce gas via
chemical reactions include baking powder, azodicarbonamide, titanium hydride, and
isocyanates (when they react with water).

Requirements of Foaming Agents:

1. It should generate foam readily.

2. It should offer a good wetting capability.
3. It should exert fast and uniform wetting action.
4. It should show little or no effect on color fastness.
5. It should be compatible with other products of the finishing mix.
6. It should be least affected by water hardness.
7. It should not cause yellowing of white materials.
8. It should be easily stabilized.
9. It should be capable of producing various bubble sizes to meet specific
requirements.
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Factors considered in foam application process

In foams insoluble air is entrapped in water or liquid. Foam cells are separated by
lamellae consisting of surfactant film. The following factors are considered in foam
application process.
a) Stability of foam.
b) Uniformity of application.
c) Ratio of dilution.

a) Stability of foam: Stability of foam depends on blow ratio and size of bubbles. The
more viscosity of foam the more will be its stability. Foam should not collapse before
being deposited on material. Nip rollers and other frictional devices crush the foam.
Increase in temperature reduces foam stability.

b) Uniformity of application: For uniform application, foam should not collapse

prematurely and also should not be too stable. The foam must have uniform density.
The viscosity and flow of foam should be such that uniform application is ensured.

c) Ratio of dilution: Fabric with high porosity should be treated with dense foam,
whereas heavy and tightly constructed varieties are best treated with light foam.

Stabilizer

Foam stabilizers slow down the drainage of the liquids from the bubbles and impart
workable flow properties. The basic role of a stabilizer in foam is to reinforce the
bubble cell wall to a controllable level.

Hydroxy ethyl cellulose (HEC), methyl cellulose, Polysaccharide gums, Ammonium

stearate etc. are the most effective foam stabilizers. Of them, HEC offers many
advantages. It is a non-ionic stabilizer and so is compatible with most anionic and
cationic finishing components. HEC may be used in the concentration range of 0.2-
0.5% in durable press formulations.

Requirements of a stabilizer

1. It should be effective at low concentration.

2. It should be compatible with all foam finishing systems.
3. It should be easily soluble.
4. It should be least affected by fabric handle.
5. It should be resistance of bacterial attack.

Lamellae

Foam cells are separated by lamellae. These may be called foam wall or surface of
the foam wall. Lamellae consists of surfactant film i.e. air is entrapped within
surrounding lamellae.
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Foam specification: The foam evaluating criteria are:

1. Blow ratio.
2. Bubble size.
3. Homogeneity.
4. Ionic nature.
5. Half-life period of foam decay or drainage.
6. Drop escape time.
7. Viscosity.

1. Blow ratio: Blow ratio expresses the volumetric ratio of liquid to foam. It is a
measure of dilution of foam. Blow ratio can be expressed as below.
������ �� ������
Blow Ratio = ������ �� ���� �� ����� ����ℎ� �� ������

Higher the blow ratio, the greater the dilution of the liquid. Blow ratio is used to
measure- (a) foam density and (b) extent foaming. Stable foam can be produced at
blow ratio of 1:3 to 1:5. But the ratio 1:8 to 1:15 is suitable for modern textile
machinery.

2. Bubble size: The size of foam bubbles normally ranges from 0.1-0.3 mm. For
textile application the desirable bubble dia is 50-100μm. Size of foam bubbles
normally depends on: (a) Type of foaming agents and (b) Method of application The
size of the bubble and its rate of change determine foam penetration into the
textiles. Foam of smaller bubble size is generally more stable than that of larger ones.

3. Homogeneity: For uniform application homogeneous bubbles of smaller size is

essential. They should be made of constant size as nearly as possible.

4. Ionic nature: Ionic nature of foam depends on the product on which foam is
applied and ionic nature of surface active agent. So depending on the foaming agent,
we can produce anionic foam, cationic foam, nonionic foam. The anionic surfactant
has more foaming power than that of nonionic. Anionic surface active agents are
sensitive to temperature changing but nonionic surfactant are not so. Their foaming
power is not reduced with increasing temperature and addition of electrolytes.

5. Half-life period of foam decay or drainage: The half-life of foam indicates the rate
of drainage and is a measure of the stability of the foam. The half-life period of foam
decay is the time taken for one half of the liquid in a definite volume of foam to
drain. In practice the period may be anything form 4-6 mins for semi stable foam but
for stable foams it may be much longer.

6. Drop escape time: This is the time to drain out the first drop of liquid from the
foam. The drop escape time normally ranges from 45-90 seconds.

7. Viscosity: If blow ratio increases viscosity of foam decreases. If viscosity increases

foam stability also increases. So viscosity of foam depends on the quality of foaming
agent and blow ratio.
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Foam density and liter weight:

Foam density is given as the weight of foam in gm/cc i.e. weight of 1 cc foam in gm.
Liter weight is given as the weight of foam in gm/liter i.e. weight of 1 liter foam in
grams. Foam density and liter weight are responsible for blow ratio measurement.

Technology of continuous foam application:

A common sequence for a continuous processing method for applying foamed

finishing and dyeing formulation to textile materials have the following steps.
a) Formulation to achieve formability.
b) Generation of foam.
c) Application of foam to substrate.
d) Destruction of foam.

Foam application system:

1. Foam application on a horizontal padding mangle.

2. Foam application with a coating blade, foam collapse with squeeze rollers.
3. Foam application by indirect doctor blade dosage foam collapse by vacuum
cylinder suction.
4. Foam application by pressure nozzle.
5. Foam application with a rotary printing screen and slit doctor.
6. Two sided foam application with transfer rollers and dosage shoots (James mini
foam applicator).

1. Foam application on a horizontal padding mangle: This system contains two

horizontal padding bowls placed side by side. The foam is applied to both sides of
the fabric in the nip of the bowls. This method is suitable only for the woven fabrics
of open construction and not for non-woven.

Fig: Horizontal Padder for foam application

Advantages

 Here foam can be applied on both sides of the fabric.

 With less absorbent thick fabrics horizontal padder is preferred unless one sided
application is desired.
 Requires least modification of currently available machinery.
 Wetting power and foam decay is better due to heavy pressure.
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Disadvantages

 It is difficult to control the level of foam in the mangle due to foam rigidity and
poor flow property.
 Uncontrollable degree of penetrating causes relatively high pick up as the
material passes through the layer of foam prior to the mangle nip.

2. Foam application with a coating blade, foam collapse with squeeze rollers: This
process is developed by Valchem and United Merchants and Manufactures. So it is
called Valchem process.

 In this method, uniform and consistent foam is generated and a fixed amount of
the foam is deposited on the fabric being treated.
 The rate of dosing is controlled by setting of blade.
 Both must be accurately controlled to achieve consistent results.
 The foam is deposited by laying it on the fabric surface, then knifing it of a fixed
thickness.
 The fabric then goes through the nip of two rollers to completely collapse the
foam.
 A double coating knife coater is useful for applying two different finishes on two
different sides (face and back) of the fabric.
 For the success of this process two things are necessary:
a) Uniform speed of the material and
b) Even capacity of absorption.

Fig: Foam application by knife over roller

Advantages

 No possibility of tailing effect.

 Economical from the view of machinery investment.
 Can be used to apply finish on both sides of the fabric.

Disadvantages

 Friction to the knife against the fabric.

 Uneven coverage of fabric surface flaws.
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3. Foam application by indirect doctor blade dosage foam collapse by vacuum

cylinder suction:

 This process is developed by MINFORTS.

 Here a doctor blade doses the foam onto an endless rubber belt which comes
face to face with the fabric at the point of contact with a vacuum cylinder.
 The rubber belt seals the cylinder creating high vacuum which draws the foam
forcibly into the fabric.
 There the bubbles expand and break and the foam collapse. The dosage rate is
controlled by the slit setting of doctor blade on blanket.

Fig: Foam application by pressure nozzle

Advantages

 Better Wetting power.

 Better foam decay.
 More even application.
 Foam application is independent.
 Moisture content has no effect.
 Foam stability is of minor importance.

Disadvantages

 Requires suction pressure.

 More energy consuming and costly.
 Suitable only for woven and knit.

4. Foam application by pressure nozzle: The method of foam application by pressure

nozzle is called FFT method. This is developed by GASTON COUNTY/UNION CARBIDE.

 Here a specified amount of active chemical is delivered to a mixing head and

then to the fabric.
 The foam is applied in a pressurized done through the slot of about 4 inch in the
travel direction of fabric.
 The pressure is slightly above the atmospheric pressure.
 The pick-up of foam system depends on whether light or dense foam is applied.
 Foam Technology

 Since the penetration of the foam depends on the air pressure of the system,
this process automatically adjusts itself if there is any variation in porosity of the
fabric.
 The foam is driven upward through the slot nozzle.
 The foam causes rapid collapse as soon as it touches the fabric.

Advantage

 Process is economical.
 Use of foaming agent is lower.
 Popular for applying optical brightening agent on the fabric.
 For both side applications two such m/c will be required. Disadvantages:Not
suitable for applying finishes on both sides of the fabric

5. Foam application with a rotary printing screen and slit doctor: “STORK”
developed this system of foam application and its brand name is “RSF Foam
Application”. Foam is pressed through the cylindrical screen by a specially designed
slit doctor. For both side applications a dual application is available. This Process is
developed by “MITTER” which is suitable for carpet.

Advantages

 Widely used for carpet printing; carpet back coating.

 Normal quality foam can be used.
 Low viscosity foam can be used.
 Less stable foam can be used.
 Both side applications are possible by dual arrangements.

Disadvantages

 More energy consuming and costly.

 Suitable only for woven and knit.

6. Two sided foam application with transfer rollers (Janus mini foam applicator):
This method of foam application is developed by KUSTER. It is known as Janus mini
foam application”. It is a roller system.
 Foam Technology

 Foam formed by inclined plates at the base of which an adjustable doctor

presses the foam against the roller. It is a both side foam application.
 Here foam is trapped between the fabrics and roller.
 As fabric is in tension and is passing against the roller which is also revolving the
foam collapses.
 The uniformity of foam application depends on fabrics moisture content, roller
pressure etc., but is independent of running speed and nature of textile
substance.

Advantages

 Foam can be applied on both sides of the fabric.

 The m/c is suitable for delicate fabric.
 Doctor blade can control foam.
 The pick-up can be determined by (a) blow ratio and (b) slit setting at the point
of application.

Disadvantages

 Costly.
 Foam collapse is not good.

Advantages of foam finishing

 Significant energy savings as there is minimal water used.

 Savings in dyes, auxiliaries and chemicals.
 More effective use of chemicals and dyes is achieved.
 In printing there is virtually no need of gums or thickeners.
 Can be applied on all kinds of fabric blends and compositions.
 Reduces the loss of fiber strength and improves the product quality.
 Reducing environmental pollution has good social and ecological benefits.
 Minimized down time as compared to pad dry cure technique.
 Scope for the development of novel effects.
 Greater productivity which is around 25-50% more than conventional ones.
 Improved hand feels of fabrics and enhanced distributions of chemicals.
 Can shorten the device length, plant size and reduce investment.

Disadvantages of foam finishing

 High capital investment cost for equipment.

 Greater care and skill is necessary in foam application.
 Limited range of applicable products.
 In some cases, problems arise in penetration of levelness.
 Speed and absorbency of the fabric vary the pick-up in the application system.
 Limitations in foam finishing with too heavy starch combination and special
water repellents.