IRJET- Reduction of Fibrillation of Lyocell Knitted Fabric with Defibrillator Process

IRJET- Reduction of Fibrillation of Lyocell Knitted Fabric with Defibrillator Process

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  International Research Journalof Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 04 | Apr 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 13 Reduction of Fibrillation of Lyocell Knitted Fabric with Defibrillator Process Alkesh Darji1, Somes Bhaumik2 and Abir Chakrabarti3 1Assistant General Manager, Textile Research & Application Development Centre, Grasim Industries ltd., Kosamba, Gujarat, India 2Vice President, Textile Research & Application Development Centre, Grasim Industries ltd., Kosamba, Gujarat, India 3Senior Vice President & Head, Textile Research & Application Development Centre, Grasim Industries ltd., Kosamba, Gujarat, India ---------------------------------------------------------------------***-------------------------------------------------------------------------- ABSTRACT - Fibrillation of lyocell i.e. regenerated cellulosic fibers occurs during its wet processing and usage. This leads to consumer dissatisfaction due to pilling or appearance after repeated home laundering. Fibrillation is the splitting of fibril bundles and its subsequent exposure to the fiber surface. The fibrillation tendency of lyocell fabrics and the degree of fibrillation of lyocell fabrics, can be reduced by either doing wet processing in open width form followed by treating with a cross-linking agent or by enzymatic treatment. In this research study, orthogonal experiments were carried out with a new defibrillator process, considering full factors to invent the low fibrillated Birla Cellulosic Lyocell knitted fabric. We examined various parameters like Bursting strength, Pilling, fibrillation tendency after repeated home washing and fabric hand feel of defibrillator untreated and treated samples. By full factors experiment, it was found that by optimizing the defibrillator process, it is operated successfully having almost clean fabric surface even after repeated home washing with excellent hand feel without affecting the fabric strength. Keywords: Lyocell knitted fabric, Defibrillator process, Pilling, hand feel, Fabric bursting strength, Home washing etc. 1 INTRODUCTION Lyocell fibers, produced by cellulose solution in N methyl morpholine N-oxide (NMMO) hydrate[1], attracts much attention owing to better drape and mechanical properties in wet state than other cellulose fibers[2]. Lyocell, a novel cellulosic fiber, has superior mechanical properties along with Sustainability factors [3]. Nevertheless, in some applications, its fibrillation behavior is considered to be a drawback [4]. This behavior can be easily measured by the so-called fibrillation index [5], which is a value indicating the degree of fibrillation. Fibrillation of lyocell fabrics occurs during its wet processing and usage[6]. This leads to consumer fabric dissatisfaction phenomenon such as pilling [7]. Fibrillation is the splitting of fibril bundles and its subsequent exposure to the fiber surface [8]. When abraded in the wet state, these exposed fibrils may form aggregates (as pills) on the fiber surface or break away as lint. This also causes problems during dyeing and finishing processes [9]. Basically fibrillation can be controlled by either doing wet processing in open width form followed by treating with a cross- linking agent or by enzymatic treatment[10]. A novel approach for reducing the fibrillation is a mechanical process where in the lyocell fabric is treated mechanically with or without chemicals [11]. In this paper, a through and systematic study is carried out to compare impact of mechanical process i.e. defibrillator process to get reduced fibrillation in Birla lyocell knitted fabric with best optimum bursting strength, soft hand feel. The fabric utility parameters are also examined against the untreated fabric lyocell fabric. 2 MATERIALS AND METHODS 2.1 Materials and Sample Preparation Knitted 100% Birla lyocell fabric with spandex was considered for the experiment. The specifications of the grey fabric is listed in Table 1. Parameter 100% Birla Lyocell with Spandex knitted greige fabric Material 40s Lyocell + 20D Spandex Yarn Technology Ring WPI x CPI 32 x 96 Weave Single Jersey
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  International Research Journalof Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 04 | Apr 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 14 GSM (gms /sq. mt) 190 % Fabric Blend Lyocell/Spandex 95/5 TABLE 1 SPECIFICATION OF THE FABRICS 2.2 Experimental Process Sequence Figure 1 shows the Experimental process sequence followed in this experiment. FIGURE 1: OPTIMISED PROCESS SEQUENCE Lycra setting process was done on stenter machine, Defibrillation process on Biancalani defibrillator machine (Aquaria), all the wet treatments were done on soft flow dyeing machine, drying & chemical finish on the stenter and mechanical finish on knit compaction machine. Recipes and conditions are shown in the table 2. Sr. No. Process Condition 1 Lycra Setting At 195 -200o C for contact time of 50-60 seconds. 2. Defibrillation process Wetting agent – 1-2%, Alkali– 30gpl, Temp – 70o C, followed by enzymatic defibrillation at 55oC with cellulose based enzyme, followed by Washing. Contact time - 25 mins, 3 Pretreatment Washing agent – 1%, Sequester – 1%, Lubricant – 1%, Peroxide Stabilizer – 0.4%, Soda ash – 2%, Hydrogen Peroxide (50%) – 2%, Temp – 85o C, Time – 30 mins, followed by Washing 4 Drying 110-120o C 5 Chemical Finish Resin Finish : Cross linking agent – X gms/lit, Catalyst – 1/5th of the Cross linker quantity, Poly ethylene emulsion – 10- 30 gms/lit , Micro Silicone Softener – 10 - 30 gms/lit, Macro Silicone Softener – 10-30 gms/lit, dry at 110-120o C followed by curing at 160-170o C for 30- 40 seconds contact time Greige Fabric Lycra Setting Defabrilator Process Pretreatment Drying Chemical Finish Mechanical Finish Assessment
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  International Research Journalof Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 04 | Apr 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 15 Soft Finish : Poly ethylene emulsion – 10 - 30 gms/lit , Micro Silicone Softener – 10 - 30 gms/lit, Macro Silicone Softener – 10 – 3- gms/lit, dry at 110-120o C 6 Mechanical Finish Blanket pressure – 4-6 kg, speed 20 – 30 mtr/min TABLE 2 PROCESS RECIPE AND CONDITIONS USED The greige fabrics, ready for finishing fabrics and final finish fabrics were evaluated for fabric quality norms like Pilling, Bursting strength, surface appearance, hand feel etc. 3 RESULTS AND DISCUSSIONS 3.1 Physical Fabric Testing In order to evaluate the impact of defibrillator process on the lyocell knitted fabric, fabric testing of greige, and ready for finishing and finish fabrics were carried out. Table 3 shows the results of all fabrics. Test Greige Ready for Finishing Final finish Soft Finish Resin Finish Without Defibrillate process With Defibrillate process Without Defibrillate process With Defibrillate process Without Defibrillate process With Defibrillate process WPI x CPI 48 x 64 52 x 68 54 x 70 52 x 66 54 x 70 52 x 66 54 x 72 GSM in gms 195 215 220 210 218 213 221 Bursting strength in PSI 61.5 58.4 56.6 57.1 56.1 52.3 51 Martindale pilling@ 500 Rev 1 1 3-4 1 3 3-4 4-5 Martindale pilling@ 1000 Rev 1 1 3-4 1 3 3-4 4-5 Martindale pilling@ 2000 Rev 1 1 3-4 1 3 3-4 4-5 %abrasion Weight loss@2000 Rub 1.2 1.5 1.0 1.4 0.9 1.2 0.9 TABLE 3 FABRIC TESTING VALUES From the table 3, it is seen that 1. Defabrilator process fabrics are showing drastic improvement in pilling rating i.e. 3 in soft finish and 4-5 in resin finish, compare to without defibrillator process fabrics i.e. 1 in soft finish and 3-4 in resin finish even upto 2000 revolution. 2. Defabrilator process fabrics are showing least abrasion weight loss compare to without defibrillator process fabrics 3. Defabrilator process fabrics are showing comparable bursting strength compare to without defibrillator process fabrics
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  International Research Journalof Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 04 | Apr 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 16 3.2 Fabric surface appearance In order to check the impact of defibrillator process on the lyocell knitted fabric, fabric surface appearance was visually evaluated. The images are shown in figure 2. Before Defibrillator Process after Defibrillator Process FIGURE 3: IMPACT OF DEFIBRILIATOR PROCESS ON LYOCELL FABRIC SURFACDD From the figure 3, it is seen that, defibrillator process fabrics showing clean fabric surface even after 20 home laundering washes whereas without defibrillator process fabrics are showing heavy hairiness and fibrillation even at unwashed rigid stage. 3.3 Fabric hand feel evaluation A subjective blind test was carried out with group of persons for the hand feel i.e. softness, smoothness and drape of finish fabrics. Based on the outcome, it is found that defibrillator processed fabrics are softer, smoother and fluid compare to untreated fabrics even after 20 home laundering washes. 4 CONCLUSIONS The following inferences are drawn from the above experiment, 1. Defibrillator process fabrics are softer, fluid and smoother compare to untreated fabrics. 2. Defibrillator process fabrics show clear fabric surface even after 20 home laundering washes. 3. Defibrillator treated fabrics showing comparable bursting strength to untreated fabrics. 4. Least abrasion weight loss found in defibrillator processed fabrics. 5. Defibrillator processed fabrics are pill free even upto 2000 rub cycle. REFERENCES [1] Fink. H.-P., Weigel P., Purz H. J. and Ganster J. 2001. Structure formation of regenerated cellulose materials from NMMO- solutions. Prog. Polym. Sci. 26: 1473-1524. [2] Chae D. W., Choi K. R. and Kim B. C. 2003. Effect of cellulose pulp type on the mercerizing behavior and physical properties of lyocell fibers. Textile Res. J. 73(6): 541-545.12. [3] R. S. Blackburn-Biodegradable and sustainable fibers- Woodhead Publishing Limited and CRC Press LLC © 2005. [4] Marini I., Fibrillation, Textilveredlung 9/10, 1996, p. 194 [5] Periyasamy A.P., Shirai B and Kandasamy T. A study on fibrillation properties of Lyocell fiber, Colourage 58(1):45-48 · January 2011 [6] Chavan RB, Patra AK (2004) Development and processing of lyocell. Indian J Fiber Text Res 29:483–492
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  International Research Journalof Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 04 | Apr 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 17 [7] Okubayashi S. and Bechtold T. 2004. A Pilling Mechanism of Man-Made Cellulosic Fabrics – Effects of Fibrillation. Textile Res. J.01. [8] Papkov, S.P., New Methods of Fabrication of Cellulose Fibres: Some Comments on the Problem, Fibre Chem. 28(1), 1-5 (1996). [9] Jaturapiree A, Manian AP, Bechtold T (2006) Sorption studies on regenerated cellulosic fibers in salt-alkali mixtures. Cellulose 13:647–654 [10] Mortimer, S. A., and A. A. Peguy. "Methods for reducing the tendency of lyocell fibers to fibrillate." Journal of applied polymer science 60.3 (1996): 305-316. [11] Kongdee, A., Bechtold, T., Burtscher, E., & Scheinecker, M., (2004). The influence of wet/dry treatment on pore structure- the correlation of pore parameters, water retention and moisture regain values. Carbohydrate Polymers, Vol. 57, No. 1, pp. 39- 44,