Needle punched nonwoven

1. PSG COLLEGE OF TECHNOLOGY
DEVELOPMENT OF NEEDLE PUNCHED NONWOVEN FABRIC
FROM TEXTILE FIBER WASTES FOR TECHNICAL TEXTILE
APPLICATIONS
1
G u i d e d b y
D r . N . M U T H U K U M A R
A s s i s t a n t P r o f e s s o r
D e p a r t m e n t o f Te x t i l e Te c h n o l o g y
P S G C o l l e g e o f Te c h n o l o g y
P r e s e n t e d b y
K . G O K U L R A J
( 1 9 M T 0 2 )
M . Te c h Te x t i l e Te c h n o l o g y
P S G C o l l e g e o f Te c h n o l o g y

2. The energy and environmental context of the
beginning of the 21st century is marked by the
question of sustainability at all level, the
imbalance between energy and consumption of
energy based on limited mineral resources [1].
Supply vs demand
Is sustainable needed?
2
From the environmental point of view,
human activities exploit the resources
provided by the terrestrial biosphere and
emit residues from their productions in the
form of waste in the biosphere [2].

3. Sustainable development is a carefully planned
strategy to embrace growth while using resources
more efficiently, with utmost consideration of
immediate AND long-term benefits for our planet and
the humans who live on it.
3 PRIMARY OBJECTIVES OF SUSTAINABLE
DEVELOPMENT:
1. Environmental protection
2. Social inclusion
3. Economic growth
3

4. Most of these emissions come from the
combustion of fossil fuels to provide
heating, cooling and lighting, and to
power appliances and electrical
equipment [6].
The increase in energy efficiency and the
integration of renewable energy through
the reduction of greenhouse gases
represent the main challenges to be faced,
especially since the building has great
economic potential to contribute to this
objective [9].
Green house gases
NEED FOR STUDY
4
The building sector accounts for more than 32%
of final energy consumption and contributes
about one third of CO2 [4].

5. Thermal insulation is often the first step to
reduce energy requirements in a building,
According to the literature, a good insulation
could save about 65% of energy consumption
[10].
A study reported that effective building
insulation alone will save over one
hundred times the impacts of carbon foot
print [2].
The widely used insulation material in the
construction industry is the glass fiber.
Glass fiber based materials known to have
carcinogenic effects [4].
With new regulations and increasing
demand for alternative materials,
development of materials as a sustainable
alternative.
5

6. Textile waste integrates the group of reusable
materials which have different possibilities
of application.
It is estimated that up to 95% of textile waste
could be recycled into different valuable
products (30) but still the rate of recycling is
relatively low. This may be due to the diversity
of fibrous waste and structure (Serra et al.,
2017)
Textile reuse:
6

7. • Roos et al. found that by using
recycled cotton fiber over one-
year carbon footprint and water
consumption can be reduced by
around 2.4 × 106 tons equivalent
CO2 and above 900 billion liters
of waters respectively.
• Similarly, by using recycled
polyester, carbon footprint and
water consumption can be reduced
by around 2.3 × 106 tons
equivalent CO2 and above 1000
billion liters of waters respectively
(34).
7

8. The use of high quality textile waste thermal and acoustic insulation materials can reduce strain on
the environment, energy consumption, space required for landfill, virgin fibrous materials,
greenhouse gases ,pollution (noise, air, water, land), can save petroleum, fuel, and natural
resources; and can improve the healthiness of human habitat (31,32). It also helpful in development
of model of circular economy (33).
8

9. • Transfer of energy between
molecules
Conduction
• Transfer of heat by another
agent (air/water)
Convection
• Transfer of heat through wave
motion; similar to light wave
Radiation
Several studies show that their
thermal insulation properties are
highly related to the properties and
configuration of their components,
namely to the capillary structure,
surface characteristics of yarns and
air volume distribution in the fabrics
[11-13].
Thermal insulation Heat transfer:
9

10. Nature of
fibre
Fineness of
fibre
Inter and intra
fibre pores
Distribution of
fibres in
structure
Overall bulk
density of
structure
Thickness of
structure
Heat transfer through conduction and radiation
can be reduced by increasing the thickness of
fibrous assemblies (22).
Thicker webs entrap a higher amount of air that
reduces conduction (23). Thicker webs also
create a tortuous path that increases the
absorption or scattering of radiation and reduce
heat transfer.
As thermal insulation properties of materials
depend on porosity (24), textile fabrics that
have a huge fraction of interconnected voids
(25) have become good choice to produce
thermal insulation materials
Fibrous insulation materials produced by non-
woven techniques possess adequate small void
spaces with entrapped air layers which are
ideal to prevent convective heat transfer (26).
Factors affecting thermal
insulation
10

11. 11
OBJECTIVES
 The aim of this work is to evaluate the potential of textile recycled material application in
Technical textile insulation in the form of a nonwoven fabric, and also to investigate the
properties of needle-punched non-woven fabrics.
 To utilize the textile comber noil, silk cocoon waste and recycled polyester fiber in proper
manner as value added product that produced into nonwoven fabric.
 Investigation of the product, Both the thermal and sound insulation properties and with their
degradation studies.
Recycled fibres and textile waste fibres can be used to develop innovative sustainable product
and help manage waste and reduce the production of virgin fibers.

12. PROCESS METHODOLOGY Comber noil, r-pet, silk waste
RAW MATERIAL
Trytex carding machine
CARDING PROCESS
Trytex needle punching
machine
NEEDLE PUNCHING PROCESS
GSM, Thickness, Density,
Porosity , Liquid absorption
capacity, Thermal resistance ,
Sound insulation and
decomposition
FABRIC EVALUATION
CONDUCTED
COMPARISION WITH
COMMERCIAL PRODUCT
Development Of Sustainable
Thermal Insulation Non-
woven From Silk Cocoon
Waste, Recycled Polyester
And Comber Noil

13. MATERIALS AND METHODOLOGY
SILK FIBER PROPERTIES
Fiber length (mm)
38.0
Fiber fineness (denier)
1.03
Tenacity (gms/denier)
4.68
Elongation 19.90
Materials used:
• Three different fibers that
are to be used as a thermal
insulating material are
collected.
• The recycled PET fibers
were obtained from
Sulochana cotton mills pvt
ltd., Tirupur. Silk cocoon
waste and comber noil
used in this study were
sourced from in and
around Coimbatore, India.
Silk Cocoon Waste Silk Fiber
13

14. RECYCLED PET FIBER PROPERTIES
Fiber length (mm)
38.0
Fiber fineness (denier) 1.40
Strength(cN/tex) 5.06
Elongation 44.75
Melting Temperature 240
COMBER NOIL PROPERTIES
2.5% span length (mm)
19.38
50% span length (mm) 8.42
Fineness (micrograms/inch) 2.54
Strength (gms/tex) 15.50
Elongation (%) 7.40
Recycled PET Fiber Comber Noil
14

15. Needle punching was
performed with needle Loom
– DI-Loom OUG-II 6 at a
total punch density of 200
punches/cm2 and needle
penetration depth of 15 mm
Mini Carding Needle punching m/c
15
COMBER
NOIL 100%
RECYCLED
POLYESTER
100%
SILK 100% SILK50% &
PET50%
SILK50% &
COMBR
NOIL50%

16. 1
COMBER
NOIL 100%
2
RECYCLED
POLYESTER
100%
3
SILK 100%
4
SILK50% &
PET50%
5
SILK50% &
COMBR
NOIL50%
Fabric thickness gauge was used for measuring the thickness with a capacity of
0.01 mm according to ASTM D-1777 (1996).
SAMPLES:
16

17. 17
Liquid absorption capacity characterization
• The liquid absorption capacity of the developed nonwovens was tested as per ISO 9073-6 (2000)
standard. The samples were weighed on a balance before the experiment (initial sample mass,
Mo).
• The samples were then immersed approximately 20 mm below the liquid surface. After 60 ± 1 s,
the samples were removed from the liquid. They were hung vertically so that the liquid was
allowed to drain freely during 120 ± 3s. Finally, they were weighed again (final sample mass, Mc).
• The liquid absorption capacity of the nonwovens was calculated using the following equation .
Liquid absorption capacity Mc – Mo * 100
Mo

18. Thermal Conductivity:
Nonwoven thermal conductivity was measured using Lee’s disc method steam is passed through
the top disc. When steady state temperature T1 ºC is reached, heat is conducted through the
sample and imparted to the lower disc which raises the temperature gradually and finally attains
the steady state temperature T₂ºC.
Lee's Disc Apparatus
18

19. 19
Sound insulation characterization
• The sound absorption coefficient of nonwovens was tested as per ASTM E 1050 using the
impedance tube method. The impedance tube is a hollow cylinder with a sound source at one end
and a sample holder at other end. Microphone ports are mounted at two locations along the wall of
the tube as shown in Figure .

20. 20
Soil burial test
• The fabrics were cut into dimensions of 5 x 5 cm2 . The fabric samples were buried at a depth of
8.5 cm in the soil and were allowed to degrade .
• During the different periods of degradation, distilled water was added to the samples to retain the
moisture content of the soil before the analysis of the degradation of the fabrics for each period,
the samples were rinsed with distilled water and dried under standard room temperature
conditions.
• The dried samples were analysed quantitatively. The quantitative analysis involved the analysis
of the weight of the samples before and after the degradation to analyse the loss of carbon dioxide
in the degradation.

21. ASTM D5729 was followed to calculate the thickness of the material. The thickness is measured
using the thickness gauge at an applied 1.0 psi and the value of the thickness was measured in the
mm.
Density
Thickness
The areal density of the needle punched nonwoven was calculated by dividing measured basis
weight by measured nonwoven thickness.
Porosity
Calculated porosity
Porosity of the nonwovens was calculated
as
P=1−𝜌 / 𝜌𝑓
Where P is the porosity of the nonwoven
sample,
ρ is the density of the fabric sample,
ρf is the density of component.
The density of the component fibers was
calculated based on a weighted average as
follows,
ρf = wa ρa + wb ρb
Where wa is the weight fraction of component
fiber a,
wb is the weight fraction of component fiber
b,
ρa is the density of component fiber a and
ρb is the density of component fiber b. 21

22. MEASURED PROPERTIES OF NON WOVEN SAMPLES
S.n
o
Sample
Code
Sample Description Thickness
(mm)
GSM Density
(Kg/m3)
Porosity(%)
Liquid
absorption
capacity
(%)
1 S1 100% Comber Noil 3.98 565 141.9 89.71 47
2 S2 100% Recycled
Polyester
4.10 536 130.7 90.52 42
3 S3 100% Silk Waste 4.00 490 122.5 90.85 36
4 S4 50% silk waste & 50%
Recycled Polyester
4.08 512 125.4 90.77 31
5 S5 50% silk waste & 50%
Comber Noil
3.95 498 126.0 91.25 30
22

23. MEASURED PROPERTIES OF NON WOVEN SAMPLES
S.no Sample Code Sample Description
Thermal
conductivity
(W/mK)
Thermal
resistance
(m2 K/W)
1 S1 100% Comber Noil 0.0247 0.161
2 S2 100% Recycled Polyester 0.0213 0.192
3 S3 100% Silk Waste 0.0197 0.203
4 S4 50% silk waste & 50% Recycled
Polyester
0.0147 0.277
5 S5 50% silk waste & 50% Comber Noil 0.0169 0.233
23

24. y = 0.0529x - 4.5806
R² = 0.4737
0
0.05
0.1
0.15
0.2
0.25
0.3
89.6 89.8 90 90.2 90.4 90.6 90.8 91 91.2 91.4
THERMAL
REISTANCE
(m2
K/W)
POROSITY(%)
24

25. S1 S2 S3 S4 S5
Thermal resistance
(m2 K/W)
0.161 0.192 0.203 0.277 0.233
0
0.05
0.1
0.15
0.2
0.25
0.3
1
COMBER
NOIL
100%
2
RECYCLED
POLYESTER
100%
3
SILK 100%
4
SILK50%
& PET50%
5
SILK50%
& COMBR
NOIL50%
25
Comber noil had lowest thermal
resistance value compared to others. It
is purely due to the fact that cotton has
higher thermal conductivity compared
to silk and polyester fibers .
silk and polyester fiber have more
over same thermal conductivity values.
It was also observed that the
nonwoven made from 50/50 silk
cocoon waste /Recycled polyester had
better thermal insulation value
compared to nonwoven made from
50/50 silk cocoon waste /Comber Noil.
It may be due to higher porosity value
of the nonwoven and lower thermal
conductivity value of silk fibers

26. COMPARISION OF DEVELOPED NONWOVENS WITH COMMERCIALLY AVAILABLE PRODUCTS
S.No Insulators Density
(Kg/m3)
Thermal Conductivity
(W/m K)
Thermal Resistance
(m2 K/W)
1
SILK/R-PET
125.4 0.0147 0.277
2 SILK/COMBER NOIL 126 0.0169 0.233
3 ROCK WOOL 40-1200 0.0037-0.040 0.270-0.250
4 PERLITE 32-176 0.040-0.060 0.250-0.166
5 VERMICULTILE 64-130 0.063-0.068 0.158-0.147
6 GLASS WOOL 24-112 0.032-0.035 0.312-0.285
7 EXPANDED
POLYSTRENE
16-35 0.037-0.038 0.270-0.263
The developed 50/50% Silk cocoon/Recycled PET nonwoven and 50/50% silk cocoon/Comber noil
have the thermal conductivity 0.0147 and 0.0169 W/mK respectivelythe developed S4,S5 nonwovens
have comparable thermal insulation with commercially available insulating materials
26

27. 27
FREQUENCY
SOUND
ABSORPTION
COEFFICIENT
16.00 0.06
630.00 0.08
1250.00 0.26
1600.00 0.43
2000.00 0.54
2500.00 0.64
4000.00 0.82
5000 0.90
6300.00 0.98
SOUND INSULATION PERFORMANCE
SILK50% & COMBER NOIL50%
FREQUENCY
SOUND
ABSORPTION
COEFFICIENT
16.00 0.00
630.00 0.07
1250.00 0.20
1600.00 0.35
2000.00 0.54
2500.00 0.60
4000.00 0.70
5000.00 0.80
6300.00 0.93
SILK50% & PET50%

28. 28
0.66
0.70
0.80
0.93
0.69
0.82
0.90 0.98
0.00
0.20
0.40
0.60
0.80
1.00
1.20
0.00 1000.00 2000.00 3000.00 4000.00 5000.00 6000.00 7000.00
Silk & PET Silk & comber noil
SOUND INSULATION PERFORMANCE

29. 29
SOIL BURIAL TEST FOR BIOLOGICAL DEGRADATION OF
FABRIC
SILK50% & PET50%
SILK50% & COMBER
NOIL50%
8.5 CM

30. 30
5 DAYS
20 DAYS
10 DAYS
15 DAYS
10 DAYS
5 DAYS
0 DAYS
0 DAYS
SILK50% & PET50%
SILK50% & COMBER
NOIL50%
20 DAYS
15 DAYS

31. 31
0
2.1
1.6
1.9
2.2
0
4
3.9
3.2
3.3
0
1
2
3
4
5
6
7
0 5 10 15 20
Chart Title
silk 50% &
comber noil 50%
silk 50% &
polyester 50%
DAYS
WEIGHT
LOSS
%

32. • It is observed that 50/50% silk cocoon/recycled polyester have higher thermal insulation
property of 0.277 (m2 K/W) and followed by 50/50% silk cocoon waste / comber noil of
0.233 (m2 K/W) . For increases in thickness and porosity, the thermal resistance of the
material get increased.
•Along with good sound insulation property from MID (2500 Hz) to HIGH frequency
(6300 Hz ) range make the material to used in acoustic buildup. Sound absorption
coefficient (α) of 50/50% silk cocoon/recycled polyester α 0.60 – 0.93 and 50/50% silk
cocoon waste / comber noil of α 0.64 – 0.98.
• The developed nonwovens can be used as low-cost and environment-friendly insulation
materials in automotive and building insulation panel. minimize the carbon footprint,
during disposing-off the samples after their service life.
• This type of alternative materials must contribute to the development of green materials
and conserve the environment, in which sample are recyclable and biodegradable.
Conclusion
32

33. REFERENCES :
1. Palmer J. Environmental education in the 21st century: theory, practice, progress and promise. London: Routledge, 2000.
2. Bergstrom JC and Randall A. Resource economics: an economic approach to natural resource and environmental policy. Edward Elgar
Publishing, 2016.
4. Pe´rez-Lombard L, Ortiz J and Pout C. A review on buildings energy consumption information. Energy Build 2008; 40: 394–398.
5 U¨ rge-Vorsatz D, Cabeza LF, Serrano S, et al. Heating and cooling energy trends and drivers in buildings. Renew Sustain Energy Rev 2015; 41:
85–98.
6. Wright A. What is the relationship between built form and energy use in dwellings?. Energy Policy 2008; 36: 4544–4547.
8. Zeinab, S.; AbdeL-Rehim, Z.S.; Saad, M.M.; El-Shakankery, M.; Hanafy, I. Textile fabrics as thermal insulators. Autex Res. J. 2016, 6, 148–
161.
9.Torcellini P, Pless S, Deru M, et al. Zero energy buildings: a critical look at the definition. US: National Renewable Energy Laboratory and
Department of Energy, 2006.
10.Hadded A, Benltoufa S, Fayala F, et al. Thermo physical characterization of recycled textile materials used for building insulating. J Build Eng
2016; 5: 34–40.
11. Matusiak Malgorzata. Investigation of the thermal insulation properties of multilayer textiles. Fibers Text East Eur 2006;14(5(59)).
12. Stankovic Snezana B, Popovic´ Dusan, Poparic´ Goran B. Thermal properties of textile fabrics made of natural and regenerated cellulose
fibers. Polym Test 2008;27:41–8.
13. Bhattacharjee Debarati, Kothari VK. Heat transfer through woven textiles. Int J Heat Mass Transfer 2009;52:2155–60.
14. Zhou Xiao-yan, Zheng Fei, Li Hua-guan, Lu Cheng-long. An environment friendly thermal insulation material from cotton stalk fibers.
Energy Build 2010;42:1070–4.
15. Kymalainen Hanna-Riitta, Sjoberg Anna-Maija. Flax and hemp fibres as raw materials for thermal insulations. Build Environ 2008;43:1261–
9.
16. Zach J, Korjenic A, Petra´nek V, et al. Performance evaluation and research of alternative thermal insulations based on sheep wool. Energy
Build 2012; 49: 246–253.
17. El Wazna M, El Fatihi M, El Bouari A, et al. Thermo physical characterization of sustainable insulation materials made from textile waste. J
Build Eng 2017; 12: 196–201. 33

34. 18. Usage of Recycled Technical Textiles as Thermal Insulation and an Acoustic Absorber
19. Development, characterization and thermal performance of insulating nonwoven fabrics made from textile waste
20. Zeinab, S.; AbdeL-Rehim, Z.S.; Saad, M.M.; El-Shakankery, M.; Hanafy, I. Textile fabrics as thermal insulators. Autex Res. J. 2016, 6, 148–161.
22. Zakriya, M., Ramakrishnan, G., Gobi, N., Palaniswamy, N.K., Srinivasan, J., 2017. Jutereinforced non-woven composites as a thermal insulator and sound absorber–A
review. J. Reinf. Plast. Compos. 36, 206–213.
23. Obendorf, S. K., & Smith, J. P. (1986). Heat Transfer Characteristics of Nonwoven Insulating Materials. Textile Research Journal, 56(11), 691–
696. doi:10.1177/004051758605601107
24. Smith, D.S., Alzina, A., Bourret, J., Nait-Ali, B., Pennec, F., Tessier-Doyen, N., et al., 2013. Thermal conductivity of porous materials. J. Mater. Res. 28, 2260–2272.
25. Stanković, S.B., Popović, D., Poparić, G.B., 2008. Thermal properties of textile fabrics made of natural and regenerated cellulose fibers. Polym. Test. 27, 41–48
26. Woo, S.S., Shalev, I., Barker, R.L., 1994. Heat and moisture transfer through nonwoven fabrics: Part I: heat transfer. Text. Res. J. 64, 149–162.
27. Barker, R.L., Heniford, R.C., 2011. Factors affecting the thermal insulation and abrasion resistance of heat resistant hydro-entangled nonwoven batting materials for use in
firefighter turnout suit thermal liner systems. J. Eng. Fibers Fabr. 6, 1–10.
28. Asdrubali, F., D'Alessandro, F., Schiavoni, S., 2015. A review of unconventional sustainable building insulation materials. Sustain. Mater. Technol. 4, 1–17
29. ElNashar, E.A., Bashkova, G., 2014. Comfort of thermal insulation of bulky woven fabrics for clothes. In: International Conference on Technics, Technologies and Education
ICTTE, pp. 30–31.
30. Dissanayake, D.G.K., Weerasinghe, D.U., Wijesinghe, K.A.P., Kalpage, K.M.D.M.P., 2018. Developing a compression moulded thermal insulation panel using postindustrial
textile waste. Waste Manag. 79, 356–361
31. del Mar Barbero-Barrera, M., Pombo, O., de los Angeles Navacerrada, M., 2016. Textile fibre waste bindered with natural hydraulic lime. Composites Part B 94, 26–33.
32 . Pichardo, P.P., Martinez-Barrera, G., Martinez-Lopez, M., Urena-Nunez, F., Avila- Cordoba, L.I., 2017. Waste and recycled textiles as reinforcements of building materials.
In: Gunay, E. (Ed.), Natural and Artificial Fiber-Reinforced Composites as Renewable Sources. IntechOpen, London, pp. 89–104.
33. Rubino, C., Liuzzi, S., Martellotta, F., Stefanizzi, P., 2018. Textile wastes in building sector: a review. Modell., Meas. Control, B 87, 172–179.
34. Roos, S., Zamani, B., Sandin, G., Peters, G.M., Svanstrom, M., 2016. A life cycle assessment (LCA)-based approach to guiding an industry sector towards sustainability: the
case of the Swedish apparel sector. J. Clean. Prod. 133, 691–700.
35. Drochytka, R., Dvorakova, M., Hodna, J., 2017. Performance evaluation and research of
alternative thermal insulation based on waste polyester fibers. Procedia Eng. 195,
236–243
36. : Govindaraju R, Jagannathan S. Certain Properties of Needle Punched Nonwoven Fabrics Made from Silk and Wool Fibers. Trends Textile Eng Fashion Technol. 1(2).
TTEFT.000507. 2018. DOI: 10.31031/TTEFT.2018.01.000507
37. Yamada, K., Miyamoto, S., Nagata, I., Kikuchi, H., Ikada, Y., Iwata, H., & Yamamoto, K. (1997). Development of a dural substitute from synthetic bioabsorbable polymers.
Journal of Neurosurgery, 86(6), 1012–1017. doi:10.3171/jns.1997.86.6.1012
34

35. THANK YOU
35