Yarn Mercerization

Gaurav Dhawan B.Tech(Textile Chemistry) 4th Sem

CONTENTS

Introduction to yarn mercerization Typical mercerizing cycle in yarn mercerizing Convensioinal machine design Hank length change during mercerization Yarn mercerizing machines References

INTRODUCTION
Mercerizing plays an important part in the pretreatment of yarn. Yarns are mercerized continuously in hank form or as a continuous run of yarn. For yarns in hank form the following method is still in use in some cases: yarn is soaked in caustic soda solution 2550B (at 1020C), it is squeezed off and tensioned to the original length. Washing takes place under tension. This type of finishing is wrongly known as tension-free mercerizing. Lye treatment of the tensioned yarns is more important. There are two types of yarn mercerization
Raw yarn or dry Mercerization Boiled yarn or Wet Mercerization

TYPICAL MERCERIZING CYCLE IN YARN MERCERIZATION

Loading of material on the rollers

Squeezing

Lowering of rollers Caustic tray movement Pre tensioning

First wash and tensioning Final wash

Squeezing

Free shrinkage

Lifting Of Rollers Unloading the hanks.

Lye tensioning

CONVENSIOINAL MACHINE DESIGN

HANK LENGTH CHANGE DURING MERCERIZATION

IMPORTANT TO KNOW
The final caustic content should be below 10%,because if it is more it will be sufficient to carry out further mercerizing effect and the material will shrink back. During the storage of mercerized material , the water from the exposed areas will evaporate and got concentrated locally causing mercerizing effect ,which is called local mercerizing and will lead to patchy dyeing.

YARN MERCERIZING MACHINES

Mather & Platt Yarn Mercerization Machine

Model MV56 Yarn Mercerizer

Extensa Hank Yarn Mercerizing Machine By Jaeggli- Meccanotessile ,Italy Continuous Beam Mercerizing Range By Jaeggli-reggiani,Italy Aurora Hank Mercerizing Machine By Ri.Te Spa,Italy

MATHER AND PLATT MACHINE

Process time-5 min. Pressure of squeezing 4000lb Tension-12 tons

LINE DIAGRAM OF YARN ON ROLLERS

(a) water trough on trolly ; (b) in stretched state ; (c) in slack state.

Model MV56 Yarn mercerizer

EXTENSA JAEGGLI MECCANOTESSILE MACHINE

EXTENSA MACHINE OVERVIEW..

The brand new hanks mercerizing machine Extensa by Jaeggli launched in July 2008,equipped with completely new electronic control and operative system.The high operational flexibility,easy repetitiveness and absolute evenness, helps in achieving top results in the final yarns quality. The machine has a fixed-tank system that allows to use always completely new soda at constant parameters and a Eco-Block system for caustic preparation and recycling. The high efficiency squeezing rollers helps firstly the saving of money squeezing out most of the residual soda from the hanks. The model Extensa is finished with steel cases and automatic covers and it can be equipped with manual or robotized loading system (optional).

HANK WINDING

HANK MEASURING DEVICE

Since constancy of hanks reeling size is a critical aspect for repeatibility of the process; this Hank Measuring Device has an facility of measuring intial reeling size of hanks which helps in setting-up and making a finer adjustment of the mercerizing cycle.

Nominal reeling size: 54 Stretching force up to 100 kg. Rotating speed:10 mt/min

AUTOMATIC LOADING SYSTEM

The two loaders ALS are equipped with revolving carbon-Kevlar shovels and the moving technology, driven by long lasting belts, is improved by new reliable and more efficient sliding rails. The new robotized system improves the quality of the hanks reducing largely the handling.

The ALS decreases the total cycle and makes the manual operation easier and more comfortable for the operators.

ECO BLOCK
The Eco-Block is all-in-one compact device for
preparation and recycling of the caustic soda lye for mercerizing machines.

It is an all-in-one system for filtration (or micro filtration), soda lye concentration regulation, wetting agent dosing, temperature control, cooling device by heat exchanger.
ECO-CHILLER:-The Eco-Block is predisposed for installation of supplementary chilling unit to cool down the soda lye by means of cooled water through the heatexchanger. Eco-Block is absolutely necessary to obtain easy repetitiveness of the top quality in the mercerizing process, batch after batch.

WORKING OF EXTENSA

TECHNICAL DATA OF EXTENSA

PARAMETERS Yarn type Nominal hanks size Hanks size Max. loading capacity Max. production Mercerizing cycle time Hanks weight Counts range Stretching force Soda consumption DATA Cotton and all cellulosics fibers 1370 mm (54) 1180/1510 mm (46/59) 12 kg/cycle (average 10 kg.) 132 kg/h (with ALS) 320 sec. (std. cycle) double mercerization available from 250 up to 1250 gr up to Ne 200/2 including single yarns and multithreads up to 80 tons 19.5gm - NaOH 100% per each kg of - dry yarn at 30B and 20C 200 lt/cycle at 80C (recovery) 100 lt/cycle (recovery) 8 kW Extensa +3kW Eco-Block + 7 kW Eco-Chiller 7200 lt/h (tank capacity approx. 1300 lt) 3.4 x 1.6 x 2.7 mt (static weight max. 3 tons)

Hot water Cold water power Caustic soda flow Dimensions (l/w/h):

CONTINUOUS BEAM MERCERIZING RANGE

This range by Jaeggli-Reggiani is mainly suitable for the spinning mills. The delivery of the mercerised yarns is generally onto small beams which is then wounded onto soft cones for dyeing or compact cones for knitting/weaving . Eventually all the yarns can be also delivered onto one warp-beam which are suitable for weaving directly. The biggest benefits coming from this system are the short ROI time (return of investment) which is due to the low processing cost and the reduced manpower.

PROCESSING OF BEAM MERCERIZING RANGE

AURORA MACHINE

MACHINE PROCESSING

The AURORA hank mercerizing machine is divided into two parts which operate symmetrically, in each side there are two rolls where the hanks are loaded (by AHL 12H automatic hank loading system).

The operator loads manually the hanks to be processed on to the blades of the loader (AHL 12H), which moves on the rolls and rotates the blades to deposit the hanks on the rolls.
The rolls are lowered and fitted on to four hooks, a single cylinder controlled by an oil pump moves the four hooks to stretch the hanks inside the tanks where the mercerization treatment takes place. During this phase (about 300 sec), where the hanks are inside the tank with a succession of traction and relaxation movements. Two additional rolls are squeezing the hanks during the entire process. The mercerizing phase is followed by a washing phase. After this the rolls moves up from the hooks and now the hanks are ready to be unloaded by the automatic hank loading system.

TECHNICAL DATA AURORA

PARAMETERS Nominal feeling size DATA 137 cm(54)

Workable counts Ne 140/2 Hanks weight 0.250-1.2kg Stretching roller diameter 210mm
Max. production Maximum loading capacity Stretching force Squeezing pressure Water consumption Soda consumpstion Power Dimensions 130 kg/hr 12 kg 70 ton 25 kg/cm 300lt/cycle 380-400g/kg 12 kw-three phase-50/60Hz L=4.8m , H=1.2m

REFERENCES
Prof. Dr. rer. nat. Hans-Karl Rouette Encyclopedia ofTextile Finishing http://textilelearner.blogspot.in/2012/02/mercerizing-object-ofmercerizing.html http://www.scribd.com/doc/80362666/JMT-Extensa http://forlong88.en.madeinchina.com/product/MeSEdbtXQocF/C hina-Automatic-Hank-Yarn-Mercerizing-Machine.html http://www.ritespa.it/auroraeng.htm#aurora http://www.jaegglimeccanotessile.it/

Thank you

Time for clearing

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