The document describes the process of jute manufacturing. It involves several steps: selection of jute batches, piecing up, softening and lubricating the fibers using an emulsion of oil, water and emulsifier, batching and conditioning, carding using breaker and finisher cards, drawing and doubling, and spinning. The objectives and requirements of batching, emulsion preparation, and carding are explained. Key aspects like fiber selection techniques for different end products and common defects in emulsions are also summarized.

1. JUTE
Md. Reajul Islam
Lecturer, BUTex

2. FLOW CHART OF JUTE MANUFACTURING
PROCESS
Selection of Jute for a batch
↓
Piecing up
↓
Softening and lubricating
↓
Batching, conditioning or piling
↓
→ Breaker card
Carding
→ Finisher card
↓
→ 1st
Drawing and doubling → 2nd
→ 3rd
↓
Spinning

3. Bappi BUTex

4. Batch
A number of bales of jute selected for the purpose
of manufacturing a particular type of yarn in
known as “Batch”.
Batching
Batching covers all the processes preparatory to
carding.
Or,
the term batching strictly refers to the addition
of oil and water to the jute.

5. OBJECTS OF BATCHING
 To make the fibre flexible and extensive.
 To remove hardness, stiffness of lower jute fibre.
 To prevent the production of lower quality yarn.
 To make the fibre for effective carding.

6. Emulsion
Jute fibre is consists of lignin, so it is hard and
brittle. Easily breaks down due to abrasion and
mechanical treatment. To make it soft and easy a
mixture of some lubricating agent is used.
The mixture of these elements is called emulsion.
 Oil → 25%
 Water → 74.5%
 Emulsifier → 0.5%

7. CHARACTERISTICS OF EMULSION
 Should be stable for the specific time.
 No harmful effect on either machine or jute.
 Should have high softening capacity.
 It must be colorless, odorless, cheap and
available.
 The droplet of emulsion will have to be very small
that it can penetrate in to fibre easily.

8. REQUIREMENT OF JUTE BATCHING OIL
 No harmful; effect on either machine or jute.
 Color must be acceptable.
 It should not sticky.
 Not have any objectionable odor.
 Cheap and plentiful supply.

9. Requirement of Water
 Should be free from color, odors, suspended
matter and hardness.
Requirement of Emulsifier
 Reduce surface tension and stabilizes the
emulsion.

10. EMULSION PREPARATION TECHNIQUE
1. Pedal type machine
2. Colloidal machine
3. Ultrasonic machine
Procedure:
Equal quantity oil and emulsifier
↓ (Agitation)
Rest of the oil
↓
Water
↓
Agitation


11. SELECTION TECHNIQUE OF JUTE
A).HESSIAN WARP YARN:
 Must be good, strong, clean and free from specks
with high luster.
 Batch containing 70% hard jute and 30% soft jute
give good result.
 Tossa Jute has good spinning quality

12. SELECTION TECHNIQUE OF JUTE
B). HESSIAN WEFT YARN:
 Should be clean and softer than Hessian warp
jute.
 For light Hessian weft yarn a batch of 50% hard
jute and 50% soft jute is quite satisfactory.
 For heavy Hessian weft yarn a batch containing
30% hard jute and 70% soft jute.
 In this case as much as 30% Tossa may be used.

13. SELECTION TECHNIQUE OF JUTE
C). SACKING WARP YARN:
 Sacking warp jute should be good and strong but
specks do not matter much in this case.
 Batch containing 60% hard jute 40% soft jute
give good result.
 70% to 80% low grade Tossa jute can be used in
the sacking warp batch.

14. SELECTION TECHNIQUE OF JUTE
D). SACKING WEFT YARN:
Sacking weft batch may contain
 Runners and rejections.
 Line cuttings.
 Bale cuttings.
 Soft and hard waste.
 Rope waste and jute dust.
 Habijabi and tangled jute.
Rejection long jute varies from 10% to 20% of the total of
batch. Jute dust may not exceed 10%.

15. STAINLESS EMULSION
In an emulsion the oil percentage is less and the
water percentage is high. Jute yarns which are used
to make carpet are applied stainless emulsion.
Stainless emulsion is prepared by following recipe →
Water → 92 to 95%
Oil → less than 1%
Emulsifier → 0.5% to 1%

16. DEFECTS OF EMULSION
1.CREAMING
When an emulsion is prepared it is not possible to make all
the drops exactly same size. Some will be smaller than
others and there will be quite a few large drops. In general
the smaller drops less is the scatter in the diameter,
comparatively the larger, droplets will slowly move up to
surface of emulsion as larger the droplets lower is the
specific gravity in comparison to water and forms a layer at
the surface causing uneven distribution of emulsion. This
defect is called creaming.

17. 1.CREAMING
Causes:
 Oil selection improper.
 Oil water and emulsion are not mixed accurate ratio.
 Agitation solution is not to be good.
Remedies:
 Keeping the size of droplets as small as possible.
 By using oil having high specific gravity.
 After make the emulsion should not be more time
storage

18. 2.BREAKING
If by mixing internal oil phase droplets become a
large droplet then its float upwards of the
emulsion surface and it cannot be broken re –
agitation.
Remedy:
 This breaking fault removed by the high speed re
– agitation.

19. TYPES OF SOFTENING MACHINE
 Single softener (long jute is used)
 Tandem softener (cutting)
 Good spreader (for long jute)

20. JUTE CARDING
The process by which long reeds of jute which
passing through high speed pinned rollers and
broken down into an entangled mass and
delivered in the form of ribbon of uniform weight
per unit length called Jute Carding.

21. OBJECTS OF JUTE CARDING:
 To break down and split up to the fibre.
 To make the sliver of uniform weight/unit length.
 To remove dirt, dust.
 To individualize and parallelism the fibre.
 To extent the fibre by drafting and reduce weight
per unit length.
 To produce spin able fibre.
 To mix different quality of jute.