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FORNITURE TESSILI RIUNITE

S.p.A.

INNOVA®

Starch sizes removalExcellent swelling

in only ONE STEP

Textile Chemical Solutions

The innovative Bleaching Treatment

Perfect deep cleannessExcellent hydrophility

INNOVA® preparation system

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SIZES ON WARP YARN

sizes sizes

FIG. 1 - COTTON FABRIC SECTION

The preparation in width of cellulosic fibers is characterized by different application stages, well separate one to each other. Among them we can distinguish:

• Desizing stage: with which we eliminate from fabric surface all those protective substances, named sizes, that were applied for optimizing the weaving process. Moreover, during this operation, we partially remove those waxes/fats substances normally present on cellulosic fibers and also some kind of salts and metals typical of cotton;

• Scouring stage: with which we deeply clean the cotton fibers and we have an axial swelling (expecially in case of alkaline scouring) and a demineralization of them (expecially in case of acid scouring);

• Bleaching stage: with which we whiten by bleaching the cellulosic fibers.

The sizing agents on warp yarns (starch, polyvinyl alcohol, CMC, acrylic polymers, starch ethers or esters, etc...) are the cause of the formation of a very thin protective film on fibers surface ( Fig. 1).

INNOVA® PREPARATION SYSTEM WAY OF ACTION

This surface normally acts as a protective barrier that strongly reduces the penetration, into the fibers and yarns, of the treatment baths (Fig. 2).In fact bleaching treatments, directly carried out on sized materials, put in evidence a limited whiteness on the external yarn fibers.The white we obtain in this cases is quite poor (white degrees 30-40% lower than the ones we obtain on a previously desized material) and, in case we need a very good white degrees it is absolutely imperative to operate a bleaching with an extremely high amount of alkali and oxidizing agent.The sizes, besides avoiding the bleaching bath penetration into the fibers may, in those baths

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POOR PENETRATION INTO THE SIZED YARN

Bleaching bath

The new INNOVA® preparation system gives the possibility to perform bleaching treatments directly on the raw material without any previous desizing.

This behaviour is clearly explained by visualizing the way of action of INNOVA® system:

• After impregnation phase, the sizing substances on cotton fabric surface enter in direct contact with the active ingredient of INNOVA®, going through a quick modification of the molecular aggregation state, which we will name “fluidification” (Fig. 3).

The “fluidification” of sizes occurs thanks to the hydrolizing and swelling action of INNOVA®

system. This behaviour is clearly visible at the end of the impregnation phase, when padded fabric

rolls emphasize a high dripping of the “fluidificated” sizes. It is a factor of fundamental importance that also the starch based sizes are fluidificated and

then chemically demolited, thanks to the oxidizing and hydrolizing action of the hydrogen peroxide and caustic soda.


containing hydrogen peroxide, drastically reduce their stability.Due to the above mentioned difficulties it is clear that we'd better remove the sizes first, in order to make the following steps easier.


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“FLUIDIFICATION” OF SIZES


• INNOVA® system is characterized by a strong stabilizating action against the oxygen generated by the hydrogen peroxide. As a matter of fact the “fluidificated” sizing substances, which are dissolved into the padding bath and normally would cause a quick and energetic development of the hydrogen peroxide, are made “inert” thanks to the peculiar stabilizating INNOVA® system.

• The direct consequence of the sizes “fluidification” is the increase of the penetration inside the fabric of the treatment bath (Fig. 4). This means a better whitening effect and a deeper cleaning of fabric ground, thanks to the elimination of the fat-waxy substances. Considering the high amount of metallic salts usually existent on cotton fabric, the INNOVA® system is characterized by an energetic inhibitory action against the catalyzation caused by these metallic ions.

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EXCELLENT PENETRATION INSIDE THE SIZED FIBERS


Through the combined action of the chemical compounds of INNOVA® system it is possible to obtain the following application advantages:

• Excellent removal of waxy/fat substances initially existing on fabric,• Excellent removal of all sizes initially existing on fabric (including starch),• Excellent hydrophility,• Good white degree of cellulosics,• Complete elimination of existing cotton shells,• Minimal chemical damage of cellulosic component.


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BLEACHING BATH PREPARATION PROCEDURE

It is well known that the method used for the preparation of a bleaching bath is very important and may drastically influence the bath stability during process.Bleaching baths with a limited stability take to poor, unsteady and non repeatable results.For this reason it is important to use a precise chemical and auxiliaries dosage method.In the last years, modern industrial equipments have been developed facilitating this procedure.Automatic and preset dosage systems allow a very precise and correct sequence of dosage, together with a reduction of preparation times and constancy in quality.

The correct chemical and auxiliaries dosage is extremely important in order to avoid precipitations, agglomeration, thickening, etc…

Implementing INNOVA® system, during baths preparation, it is essential to comply with the following procedures:

SEQUENTIAL DOSAGEAutomatic/manual dosage in stock tank

Addition of about 70-80% of settled water quantity

Maintaining everything under constant, slow stirring, we proceed to the sequential adding of the following products:

Addition of total amount of NaOH

Addition of total amount of INNOVA® 1010

Addition of total amount of INNOVA® 2000 (or BASE CONC 2000)

Addition of total amount of INNOVA® DD

Addition of total amount of IDROPOL X 100

Addition of total amount of H2O

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SIMULTANEOUS DOSAGEAutomatic dosage in padding tank or expansion vase

Feeding pipes disposition for each chemical:

hydrogen peroxide

water

caustic soda

INNOVA® 2000

(or BASE CONC 2000)

INNOVA® DD

IDROPOL X 100

INNOVA® 1010

In every automatic dosage equipment, it is important to observe the following operational precautions:

• Keep a certain distance between a dosage device and the other, independently from the kind of product pumped;

• Execute a quick mixing of each product added;• Perform a constant dosage of water;• Do not leave, for long periods, the dosage system without water addition;• Always dose water at room temperature (max. 25°C);• Never dose hydrogen peroxide near caustic soda;• Keep caustic soda as far away as possibile from the other auxiliaries.


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INNOVA® SYSTEM APPLICATION BY COLD PAD BATCH AND FOLLOWING CONTINUOUS WASHING

Applying the INNOVA® system directly to cold pad batch, after a singeing treatment, we obtain an article which evidences the following features:

• Excellent removal of greasy/waxy substances existing on the fabric,• Excellent removal of sizes,• Excellent hydrophylity degree,• Good white degree of cellulosic substrate,• Complete elimination of existing cotton shells,• Minimal chemical damage of cellulosic component.

Subsequently the treated article is washed in continuous at boiling temperature.

With INNOVA® system we can prepare a cotton fabric, which will be afterwards allocated to dyeing stage, with the following quality parameters:

• Excellent cleanness of fabric,• Good white degree,• Very low damage of cellulosic components.

APPLICATION FIELDS

• Fabrics dyed in piece using KKV system with reactive dyes,• Popeline fabrics for piece-dyed shirts,• Piece-dyed cotton fabric ready for printing,• Elasticized fabrics dyed in piece.

APPLICATION ADVANTAGES

• Drastic reduction of passages and bleaching operations,• Drastic reduction of treatments times,• High saving in water consumption,• Possibility of bleaching even without preparation lines or steamers,• Excellent quality performances of the fabrics.

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Cold padding with:NaOH 48°BéINNOVA® 1010INNOVA® 2000 (or BASE CONC 2000)INNOVA® DDIDROPOL X 100H

2O

2 50%

The choice of the most suitable INNOVA® recipe is according to the type of sizes on the raw fabric and to the destination of the fabric after preparation stage (ready for dye, ready to print, garment dyeing and so on…).The identification of the sizes can be quickly done by using a Tegewa iodine-iodide solution.

Fabrics with starch sizes: (positive to the iodine-iodide solution test, blue/violet coloration)

light recipe standard recipe

NaOH 48°Bé 30 ml/l 50 ml/l INNOVA® 1010 8 ml/l 10 ml/l INNOVA® 2000 12 ml/l 18 ml/l INNOVA® DD 3 ml/l 3 ml/l IDROPOL X 100 2 ml/l 2 ml/l H

2O

2 50% 50 ml/l 60 ml/l

Instead of using INNOVA® 2000 it is possible to use the concentrated form of it, named BASE CONC 2000 (dosing 9 ml/l in light recipe and 12 ml/l in standard one).

During padding stage it is possibile to reach a very high speed of operation, because bleaching bath with INNOVA® recipe permits to obtain an extremely high pick-up (absorption).

In this phase padded rolls, obviously according to the type of treated fabric, will drip very much (phenomena that we will not see in case of very tight fabrics like popeline or similar) and this means a very good absorption of the padded fabric.We suggest to cover the treated rolls with a polyethylene film, preferably dark, and let them slowly turn, in order to reach a uniform bleaching effect on all fabric height.

Afterwards the rolls have to be kept turning for a minimum period of 18 – 24 hours. When possible, stock period of 48 hours are suggested because, from our industrial experience, it provides excellent results.


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INNOVA® AC

After stocking period, in order to obtain a good washing, it is important to:

• use an appropriate water quantity (possibly with a hardness near 20°F), in the amount of 8-10 liters/Kg of fabric;

• the water temperature in the tanks have to be near to the boiling point (compatibly with the equipment);

• the first washing tank have to be separated from the others;• the other tanks have to be in counter-current one to each other (from the last to the second

one);• dose a proper amount (i.e. 1-2 g/liters) of INNOVA® AC (or the concentrated version named

BASE CONC AC 504) in the last but one tank till the second one in counter-corrent. INNOVA® AC permits to obtain the complete removal of sizes, surfactants, salts and the neutralization and removal of alkali residual.

In the event that the operation of mercerization is requested, we may proceed as usual.

In order to obtain an excellent mercerizing action, it is worthy to wash adequately the fabric, before its impregnation into the alkaline bath.

INNOVA® ACINNOVA® AC

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INNOVA® 2000 – BASE CONC 2000 (concentrated version 150%)

It is a special auxiliary created for INNOVA® cellulosics preparation system. Thanks to its particular composition, the product acts as follows:

• fluidify sizes allowing their chemical demolition during bleaching and their perfect elimination from fabric during the washing phase (in the bath, the starch sizes are destroyed by hydrogen peroxide oxidative action and by the hydrolytic reaction of sodium hydrate);

• fluidify and emulsify the oily, waxy and greasy substances on cellolusic (spinning oils or lubricants and waxes naturally present on fibers), permitting their complete elimination;

• provide an excellent hydrophility degree to treated articles;• in the following mercerization or caustification stage, it allows a deep and perfect penetration

of caustic soda. We will than obtain, in the following dyeing, a brilliant and better looking.

INNOVA® 2000 can be used in desizing process (it is compatible to alpha amylase based enzymes), in alkaline scouring (it resists till 9°Bé caustic soda concentrations, i.e. to about 200 g/l of NaOH 30%) and in bleaching (particularly indicated for cold Pad-Batch).Due to its peculiarity we do not suggest the combination to other textile auxiliaries unless those of INNOVA® system.

INNOVA® 2000 has to be washed out well after every production step, in order to avoid, in the following dyeing, eventual influence to dyestuffs. Due to its fluidifying and emulsifying action, the risk could be a slowing down or, in some case, a blocking of dyes fixation to cellulosic. For this reason it cannot be used in dyeing or in combination to optical bleachers that, eventually, have to be applied later.

ENZYMATIC DESIZING

The usage of INNOVA® 2000 in desizing phase permits to obtain an effective and better elimination of starch based sizes, waxes and oils. We will obtain an article already with a good hydrophility (quite rare after the desizing step only). Moreover, INNOVA® 2000 is very useful for particularly thick and dense cotton fabrics (popeline and gabardine), for which the elimination of sizes is, in many cases, too difficult and often incomplete.

ALKALINE SCOURING

It is well known the swelling and the saponificating action of alkaline scouring on cellulosic, especially if done at hot temperatures. The addition of INNOVA® 2000 in this process increases a lot the saponificating, hydrolizing and desizing properties of alkaline scouring. With this operation it is possible to eliminate all the starches, waxes and oils still on fabric.In order to appreciate INNOVA® 2000 performances at their best it is suggested to well wash the fabric using boiling water since we have to remove extraneous substances chemically modified.

N.B.: it is a good rule, after a bleaching with INNOVA® 2000, to proceed with an operation of mercerizing or scouring, in order to optimize the preparation stage.


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INNOVA® 1010It is a special auxiliary created for INNOVA® cellulosics preparation system. Thanks to its particular composition, the product acts as follows:

• It has a complexing action towards alkaline-earth salts existing in the bleaching bath and on cellulosic fabric and a chelating action against metallic ions (Fe, Cu, etc...). In this way it is possible to avoid catalytic reactions from hydrogen peroxide development with consequent degradation of cellulosic fibers;

• Avoid the sedimentation of any kind of impurity on fabric and on equipments, particularly on the internal parts of the steamer, thanks to its high dispersing power;

• Give to INNOVA® bleaching bath an excellent time stability, regulating the development of "bleaching" oxygen, due to its high stabilizing power towards hydrogen peroxide;

• Reduce to a minimum every catalytic action towards hydrogen peroxide, caused by metallic ions (iron, copper, zinc and manganese salts), found on cotton/linen yarn, in water and on equipments.

• INNOVA® 1010 can be used in alkaline scouring (it resists till 36°Bé caustic soda concentrations) and in bleaching (particularly indicated for both cold Pad-Batch or Pad-Steam continuous system).

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INNOVA® DDConsidering the remarkable solubilizing properties of the INNOVA® system to all kind of sizes, fats and waxes originally present on the fabric, it is easy to find high residual amounts of these substances directly in the Pad-Batch bath.This problem is accentuated when the bleaching or scouring processes are prolonged for several hours, without ever changing the impregnation bath.

The absence of recirculation and filtration systems in the padding tanks, dramatically worsens this issue. The result is a rapid dirtying of the padding bath with obvious risks of damage or soiling of textile material.

To avoid this, we recommend the addition to the bleaching bath of a product with strong emulsifying and dispersing properties such as INNOVA® DD.

After the addition of INNOVA® DD the residue in the treatment bath (carbon residual from singeing, silicone oils, starches, PVA, CMC, fatty substances present on the cotton fiber), are maintained in dispersion, preventing the deposition on the fabric surface.

INNOVA® DD is normally dosed to the bath together to other bleaching chemicals.It is also possible to dose the product manually when solid waste are appearing in the padding bath.


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IDROPOL X 100IDROPOL X 100 is an excellent wetting and de-aerating agent and has a very good action at cold temperature too. It has a good de-foaming power and, above all, does not lose its features in strong alkaline medium, resisting till concentration of 100 cc/l of caustic soda at 36°Bé.

It is compatible to alpha-amilase enzymes usually used for fabric desizing and increases the bath penetration, thus reducing treatment times.

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INNOVA® AC - BASE CONC AC 504 (concentrated version 200%)

It is a neutralizing strongly acid product with a dispersing, suspensive and complexing action, expecially made for the washing treatment after the INNOVA® bleaching system.

Thanks to its particular composition INNOVA® AC acts immediately towards alkaline substances normally present on the fabric after bleaching and mercerization processes.Moreover, thanks to its dispersing-suspension power, it helps the removal of all impurities already present into the fibers, like mineral salts, size residuals, fats and degradation compounds, avoiding their re-deposition after bleaching process.

Its usage permits to obtain very high hydrophilic degrees, further increasing the whiteness degree of the bleached material.

Practical test have shown that the usage of INNOVA® AC during the neutralization process after mercerizing-bleaching, allows to obtain an increase of whiteness degree between 2-5 points higher (Berger formula).

Furthermore, due to its high sequestering action towards alkaline-earth ions and metallic salts, it can be widely used in every preparation step of cellulose and its blends, in order to reduce to the lower value the ash residual on the fabric, and assure a perfect oxidative reaction during all the bleaching process.

INNOVA® AC is normally used either in discontinuous or continuous process, in replacement of organic (acetic or citric) acids.

A further advantage in the usage of INNOVA® AC stands in its high stability to high temperatures, which gives to textiles pH constancy on all fabric height. This peculiarity is highly appreciated in the continuous washing processes after bleaching, mercerizing or caustification.

Moreover INNOVA® AC does not unveil any odour and, during high temperature washing, do not cause any unpleasant smell formation.

The amounts of INNOVA® AC to be used may vary a lot according to fabric alkali residual quantity. For a better and a constant application, we suggest dosing it by an automatic equipment (pHmeter or dosing pump).

FORNITURE TESSILI RIUNITE S.p.A.Via Galvani, 12/B - 24061 Albano S. Alessandro (BG) - Italyphone: +39 035 581236 - [email protected] - www.ftrspa.it

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