Textile Industry Dependable online, inline, and atline solutions for your process needs. 02 There is a dizzying array of clothing and other goods atline, or online instead of manual offline laboratory made from textiles – available in nearly every size, color, ana lysis saves time and optimizes process efficiency and shape, created from both natural and synthetic while reducing operation cost. Real time analysis as an fibers. Synthetics are created from specific polymerization integrated part of process control and automation will reactions which benefit from constant monitoring and help you increase yields and improve production quality. bath adjustments. Fibers are later dyed (either as rope or in pre-woven sheets) and depending on the material, Metrohm Process Analytics offers several ana ly tical tech dye composition, pH and other parameters of the dye niques in many different ana ly zer con fi gu ra tions for any bath, and the finish, specific dyeing techniques must be need: titration, photo metry, ion chro ma to gra phy, NIR used. spec troscopy, and ion­selective mea sure ments. Our online process ana lyzers and cus tom sample preconditioning In order to run each part of these processes optimal y, sys tems are manu fac tured in the Netherlands and supconstant quality checks and analyses should be per ­ ported by our local service engineers world wide. for med. Analyzing crucial process parameters inline, Denim: Indigo Dyeing Process In order to achieve a uniform blue color, multiple dips boxes exposed to oxygen. Loop dyeing occurs in a single may be necessary in the dye vats. There are three com indigo bath, and the color density of the yarn is adjusted mon dyeing processes in use: rope, slasher, or loop by dipping in the vat multiple times. dy eing. Rope dyeing offers better color uniformity, though more yarn breakage can occur in the process. Together with the plant circulation system, our fast­res ­ Con tinuous slasher dyeing offers faster throughput by ponding online process analyzers can help keep the dye dyeing a yarn sheet at once, with shorter immersion bath throughput high without losing money from excess and developing times needed. However, the slasher chemical consumption due to inefficient processes, en - dyeing process consumes more hydrosulfite (dithionite) suring the quality of the dyed fabric re mains constant. because of the larger surface areas of multiple indigo Synthetic Textiles Creation of synthetic textiles begins with a polymerization By control ing the proportions of sulfuric acid, sodium process in which a liquid mixture is forced through tiny sulfate, and zinc sulfate in a viscose spin bath for holes (spinnerets) into a spin bath, developing small example, the amount of cross­linking between cel ulose threads via chemical reactions. These fine threads are molecules can be adjusted, resulting in fibers with then dyed and woven into fabric. different qualities. There are many types of synthetic fibers created in this Optimization of the process through online analysis manner such as nylon, polyester, acetate, spandex, of these compounds in the bath combined with com ac rylic, and rayon (viscose). The properties of these munication to the central chemical distribution system is synthetic materials, such as elasticity, can be modified possible with Metrohm Process Analytics. much easier than for natural fibers. Applications Online determinations of several parameters in 03 dye and spin baths Many parameters need to be control ed during continuous dyeing processes: the pH for proper NaOH (alkali) dosage, the concentrations of both hydrosulfite and indigo (in the denim dyeing process), as well as the temperature and redox potential of the bath. For synthetic viscose spin baths, the concentrations of sulfuric acid and zinc are especial y important to control in order to produce fibers with specified properties. In order to monitor such important parameters and more, we offer the 2045TI Process Analyzer from Metrohm Process Analytics. With its modular configuration and rugged housing, this analyzer is built to tackle chal enging applications even in extreme process environments. ADI 2045TI Process Analyzer NIRS Applications in the Textile Industry For fast, reagent­free, nondestructive and non­contact analysis, near­infrared spectroscopy can be used. This technique has been long used in the textile recycling industry to sort fabrics based on fiber types. Accurate determination of blend ratios between natural and synthetic fibers can be performed in less than 1 second. Other possible applications for the textile branch include real­time analysis of the application of polyvinyl alcohol (PVA or PVOH) sizing to warp yarn, or the analysis of sulfur­based dyes in dye baths. NIRS Analyzer PRO Cost savings during dye production and bleaching Some textile manufacturers have begun to produce their own dyes on­site to help reduce costs of raw materials. Purity and concentration of the dye (whether indigo, reactive dyes, or others) are important aspects, having a direct influence on many factors downstream. To determine the concentration of indigo in dye production, a 2035 Process Analyzer can be integrated in the process, ensuring production runs within specifications. The 2035 Potentiometric Process Analyzer is also ideal for the determination of hydrogen peroxide in oxidation and bleaching steps. The concentration of H O affects 2 2 the brightness of fabrics, and control ing this parameter online ensures the same brightness characteristics in the final product from batch to batch, without manual laboratory testing. Process Analyzer 2035 Potentiometric www.metrohm.com witzerland G, CH-9100 Herisau, S ohm A V. Printed by Metr ohm Applikon B. -09 Subject to change without prior notice Layout by Alyson Lanciki, Metr 8.000.5229EN – 2017