Benninger Merceriser


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Benninger Merceriser

  1. 1. An in plant training at Bombay Dyeing and Mfg. Co. ltd. Presented By NIKHIL S. SHAIWALE VJTI (VII L.T.C.) MATUNGA, MUMBAI 400 019
  2. 2. <ul><li>Mercerization (the actual process) </li></ul><ul><li>Conventional Merceriser & Problems faced </li></ul><ul><li>Concept of Hot mercerization & parameters </li></ul><ul><li>Benefits of hot mercerization </li></ul><ul><li>Benninger Mercerisers </li></ul><ul><li>Padless chain merceriser </li></ul><ul><li>Comparative description of the machines </li></ul><ul><li>Specialties of the design and machine </li></ul><ul><li>Disadvantages and advantages </li></ul>
  3. 3. <ul><li>Mercerization is a treatment of cotton fiber under tension with about 280-290 gpl caustic at low temp (RT instead of low temp) for 45 to 60 seconds. </li></ul>
  4. 4. <ul><li>Gives excellent luster and drape with considerably increased dye uptake. </li></ul><ul><li>The machine consists of a trough containing caustic through which cotton fabric is padded. </li></ul><ul><li>Machine speed is set according to dwell time required. (dwell time = loop length/speed of machine in mpm) </li></ul><ul><li>Problems faced </li></ul><ul><li>Difficulty in achieving reproducible results. (Due to RT variation) </li></ul><ul><li>Poor mercerization at yarn core resulting poorly dyed core of yarns in fabric. </li></ul><ul><li>More consumption of utilities. </li></ul><ul><li>Low production speeds (Due to larger dwell time) </li></ul>
  5. 5. <ul><li>A mercerization process carried out at 60-70˚ C. </li></ul><ul><li>Affinity of caustic towards cellulose decreases. </li></ul><ul><li>At this temperature, caustic has low viscosity. </li></ul><ul><li>Cotton yarns swell more slowly allowing the diffusion of lye upto yarn core. </li></ul><ul><li>Core gets mercerized achieving core mercerization. </li></ul><ul><li>Hot mercerization – parameters </li></ul><ul><li>Concentration: - The concentration of the caustic lye should be strictly controlled between 28 – 30˚ Be as rise or fall in conc. does not achieves the desired result. </li></ul><ul><li>Temperature: - The temperature must be controlled in a range of 60 - 70˚ C. </li></ul><ul><li>Dwell time: - The dwell time required is 25-30 seconds. </li></ul>
  6. 6. <ul><li>We will discuss the merceriser from following point of view. </li></ul><ul><li>Design </li></ul><ul><li>Important parts </li></ul><ul><li>Utility consumption </li></ul><ul><li>Parameters </li></ul><ul><li>Variation according to process </li></ul>
  7. 7. <ul><li>The merceriser can process both heavy and light varieties while processing. </li></ul><ul><li>The sequence of processing is impregnation - > dwell time - > stabilization - > washing. </li></ul><ul><li>This one has better control over shrinkage both weft wise and warp wise. </li></ul>
  8. 8. <ul><li>Impregnator: For impregnation. </li></ul><ul><li>& Timer: For dwell timing </li></ul><ul><li>Stabilizer: For stabilization and recuperation </li></ul><ul><li>C.R.P. (caustic recovery plant): For recovery of the caustic from wash liquor. </li></ul>
  9. 9. <ul><li>IMPREGNATOR </li></ul><ul><li>Hot 28 ° Be caustic is sprayed through pipes in the gap between engraved and hollow rubber roller. </li></ul><ul><li>This saves the unnecessary amount of caustic and low amount allows rapid change in concentrations according to the quality. </li></ul><ul><li>The overflowed caustic liquor is recirculated with recirculation pumps. And thus this also adds to saving of the caustic lye. </li></ul><ul><li>TIMER </li></ul><ul><li>This compartment is same as the impregnator. But the caustic is not sprayed on the fabric. This compartment is only used to give a dwell time of 25 to 30 seconds. </li></ul>RECIRCULATION PUMP
  10. 11. Impregnator concept
  11. 13. <ul><li>Stabilizer </li></ul><ul><li>In this unit the fabric is stabilized i.e. caustic conc. is lowered in this zone to 8 ˚ Be. making the fabric stable . </li></ul><ul><li>Also in this unit steam is employed to achieve the temperature of about 85˚ C. This further lowers the affinity of caustic towards fabric to serve easy removal during washing. </li></ul><ul><li>CRP </li></ul><ul><li>In this plant caustic from wash liquor is recovered by means of evaporation technique to recover about 95% of pure caustic recovery. It delivers the caustic of about 35˚ Be. </li></ul>
  12. 14. <ul><li>These are the important sections of the machine. The parts are mentioned below which are present in these sections. </li></ul><ul><li>Engraved roller & Rubber coated rollers (small and big) </li></ul><ul><li>Baumy sensor </li></ul><ul><li>Chain </li></ul><ul><li>Extracta compartments </li></ul>
  13. 15. <ul><li>Engraved roller has a engravings on its surface which ensures firm grip & yarn slippage. </li></ul><ul><li>Baumy sensor : it sences the concentration of caustic </li></ul>Rubber coated hollow roller
  14. 16. The chain is the most important part of this merceriser which enables weft wise control over shrinkage.
  15. 17. Pins & water sprayers
  16. 20. <ul><li>The roller arrangement is unique that is sequence of rollers is engraved steel roller and rubber roller. </li></ul><ul><li>The liquor lies between engraved steel roller and hollow rubber roller. </li></ul>steel steel steel steel RC RC RCS. Caustic lye RC:- Rubber coated roller RCS. Small rubber coated roller Steel:- Engraved roller
  17. 21. <ul><li>Reduced power consumption due to Hollow rollers </li></ul><ul><li>The arrangement of rollers reduces the amount of caustic to the considerable extend. </li></ul><ul><li>Better & faster control over concentration (Low amt of processing caustic). </li></ul><ul><li>Less labour handling and minimal stoppages. </li></ul><ul><li>Counter current washing has been provided. </li></ul><ul><li>Low consumption of lye, water and electricity (up to 30% less lye consumption). </li></ul><ul><li>The range is totally automated. Thus once the values are set rest of the parameters are governed by a computerized system. </li></ul><ul><li>Increased efficiency due to heat exchangers </li></ul>
  18. 23. <ul><li>The advantages of these hot mercerization ranges are as follows- </li></ul><ul><ul><li>Uniform core mercerization is achieved. </li></ul></ul><ul><ul><li>Controlled temperature ensures excellent shade reproducibility. </li></ul></ul><ul><ul><li>Dwelling time is theoretically reduced upto 20-25 seconds giving higher productivity. </li></ul></ul><ul><ul><li>Upto 30% less consumption of lye, water and electricity. </li></ul></ul><ul><li>The disadvantage of this process is that it gives poor luster as compared to cold mercerization. </li></ul>
  19. 25. Difference between the chain & chainless principle.
  20. 26. <ul><li>This process gives core mercerization. </li></ul><ul><li>Also the dwell time is reduced from 45-60seconds to 25-30 seconds. </li></ul><ul><li>This increases higher production speeds thus higher productivity. </li></ul><ul><li>Also the temperature is strictly maintained at 60 ˚C thus giving excellent shade reproducibility. </li></ul><ul><li>This gives enhanced luster uniformly. </li></ul>
  21. 29. <ul><li>Thank you for your patient co-operation. </li></ul>