WO2007017906A1

WO2007017906A1 - Novel flash process and washing technique of wet processing of textiles for saving of energy, time and water

Info

Publication number: WO2007017906A1
Application number: PCT/IN2006/000284
Authority: WO
Original assignee: Subramaniam, Udhaya, Marthandan
Priority date: 2005-08-08
Filing date: 2006-08-08
Publication date: 2007-02-15

Abstract

Today's textile processing industry is loomed with major crisis on grounds of pollution, effluent treatment problems, increasing energy costs and time oriental delivery factors. Major steps to counter are - energy conservation, low material to liquor ratio machines and adoptions of continuous process methodologies. The chemical recipe formulation the flash process technique, pre-cleaning prior to washing and water immersed air washing, vacuum suction etc. involved in the presented methodology solves the expected and results of effective energy utilization, saving in water, time, energy and enhance very high processing speed levels. The ETP load is also substantially reduced, apart form heat recovery and reuse scope internally. Overall, the system as an eco-friendly affair, promotes a clean technology option and solves pollution problems.

Description

TITLE : NOVEL FLASH PROCESS AND WASHING TECHNIQUE OF WET PROCESSING OF TEXTILES FOR SAVING OF ENERGY, TIME AND WATER.

FIELD OF INVENTION

This invention is related to wet processing ( Preparation ) of Textile fabrics by the way of process methodology of various tasks and the subsequent washing methodology to remove reaction residues from the substrate. With the looming, water scarcity, need for conservation, energy crisis, time factors, pollution potential of process effluent water, ease of effluent treatment, scope for reuse - a comprehensive technology and machinery system is derived to accomplish the above requirements, mainly saving of energy, time and water.

A brief note on various preparatory processes:

PREPARATORYPROCESSES FOR 100% COTTON:

1. Singeing: The removal of protruding fibres from yarns of fabric surface. The principle is burning of protruding fibres from yarn surface by subjection to hot gas flame under speed. This treatment gives a smooth surface to the fabric. Singeing can be done at yarn stage or fabric stage, depending upon requirement Singeing is proceeded by shearing and cropping in order to raise and release the hairy fibres from fabric surface.

2. * Desizing: The process of removal of warp size on fabric by solubilisation. Starch based sizes are removed by Acid hydrolysis or by rot steeping ( swelling by soaking in water ) or by enzymatic treatment ( Digestion and hydrolysis of starch to soluble fragments ). In case of polyvinyl alcohol or acrylic sizes, alkaline boil will solublize and remove size matter. A post washing removes the reaction products and leaves fabric free of size.

3. * Scouring: The process of removal of hydrophobic ( Insoluble )traces like oils, waxes, pectins, proteins, etc. from cellulosic cotton substrate, thereby improving its absorbency and improved reactivity with chemicals, dyes in further processing. The principle is boiling treatment with alkali, along with surfactants which convert many of the above hydrophobic residues to soluble fragments, which are washed and removed. In case of synthetic fibres like polyester desizing, scouring can be accomplished by a single alkaline boil.

4. Mercerizing: The process of swelling of cotton by impregnation in caustic solution under tension. This process imparts strength, dimensional stability, luster and improved dye uptake of cotton and fastness.

5. * Bleaching: The process of removal of natural colouring matter in cotton by subjecting to oxidative / reductive destruction of colouring matter and obtaining a better whiteness. Optical brightening agents (OBA) are normally added to improve whiteness.

* Marked processes are relevant to the invention. SYNTHETICS & BLENDED FABRICS:

Ih case of synthetic fibres like polyester, nylon, acrylic etc. and their blends of cotton or viscose - Singeing, desizing, scouring, bleaching operations are designed as per type of fibre apart from heat setting.

A NOTE ON WASHING PROCESS:

Irrespective of type of preparatory process, at the end of each process, it is necessary to wash off ( clean ) the adhering reaction residues from substrate fabric, suitable for further processes like colouration ( Dyeing / Printing ), finishing etc.

Current industrial batch wet processing activities like desizing, scouring, bleaching, etc., consume considerable time, energy and large quantities of water towards effective achievement of process end results. As a matter of improvement, continuous process techniques using high energy, short time &reduced water consumption are in practice. The above methods involve steam as heating medium.

Washing is the essential activity in domestic as well as textile wet processing industry. All process involved in preparation, dyeing, printing and washing involves tremendous quantities of water for washing, by way of over flow wash, cold wash, hot wash, hot soaping, speciality treatments like oxidation, reduction clearing dye fixing treatments etc. Current attempts at machinery manufactures level involves suitable modifications to reduce water consumption. However, due to very high cost of such equipments and lack of proper effectiveness of such systems, the goal of reduced water consumption is not practically achieved. Literally in most existing machines, washing is merely passage of material through water.

All the above preparatory processes and washing are currently done by the following ways: i) BATCH PROCESS:-Using Tanks, Winches, Jiggers, Kiers, Drum washers etc. ii) COMBINED PROCESS :- applying one or more process activity in a single stage. iii) SEMI CONTINUOUS METHODS: Batch reaction followed by continuous washings iv) CONTINUOUS PROCESS METHODS: Preparation process and washing in a continuous manner

The invention prescribes a novel system of preparatory and washing process of Textile fabrics by a methodology in which Time, Energy, water and pollution load are saved drastically.

PRIORART

REVIEW ON CURRENT PREPARATORY PRACTICES:

Now a days the pre-treatment in wet processing is done by batch and continuous processes.

DESIZING:

Desizing using enzymes is the most effective and wildly used method for the removal of starch.

Fig.2 Jigger

In the batch process by exhaust method, desizing can be done using amylases at required pH and temperature conditions according to the type of enzymes used. Depending on the type of amylase used the concentration required for desizing varies from 0.5-8% taken on weight of the material. The fabric is treated under the above conditions in a jigger or winch for a period of 30-90minutes.

Desizing can be done using pad-roll-storage method by padding the fabric with 4-5gpl. Enzyme at corresponding temperature and pH. The fabric is then passed through an infra red heating zone (preheating) and into a steam chamber inside which the fabric is batched on a roll. The roll is kept rotating in the chamber for 4-8 hours at the required temperature.

Alternatively batching can be done in concrete pits by storing it in layers. The top layer is covered by sacks or polythene bags. The time of storage may even go to 12hrs as heating is nor possible here.

Continuous process:

The fabric can also be stored in J - box where steaming to maintain temperature is also possible. Steaming can also be done using an open width steamer. The dwell time in the storage box may vary from 20seconds to 20minutes depending on the temperature range of 100⁰C to 65⁰C maintained in the storage box. After the desizing is completed, the degradation products of starch (sugars) are relatively easy to remove from the fabric as they are water soluble. A hot wash will give more efficient removal of starch than cold wash. For washing purpose, a rope washing machine or an open width washing range is preferred depending upon the form (rope or open width) in which it is processed. Fabric

Fig.3 Continuous Desizing

Most commonly used way to express the efficiency of the enzyme is by the term enzyme activity. It is defined as the amount of enzyme required to catalyze the conversion of one mole of substrate into products per minute. With a amylase having an activity of 120, the quantity of enzyme required for the use in various machines are given,

Concentration of Enzymes used in various machines

Advantages:

• The time of treatment is very less and hence high production rate

• Most efficient and complete removal of starch compared to the other processes

• The fabric is not affected by the enzyme.

Desizing can also done using 0.25-0.5% Wg (on weight of good) mineral acid (eg. NCE) for 30-60 minits at Room Temperature.

SCOURING:

The scouring of cotton fabrics can be done in rope or open width form in batch and continuous processes.

This is done at Jigger, winch, pad-roll machineries.

Scouring by batch process:

Scouring can also be done using jigger for smaller lots. Mostly it is done at atmospheric pressure. Although there are jiggers available which permit operating under pressure (closed jiggers). The time of treatment is about 2-4hours. Liquor ratio employed is 1:4. During the scouring process, the fabric is circulated through the scouring liquor taken in the trough, by winding it from one roller to other roller.

Recipe:

Caustic soda - 5%

Tri sodium phosphate - 1%

Soda ash - 1.5%

Soap - 0.5%

Wetting agent - 0.75% pH - 10

Temperature - 9O⁰C

Time - 4 hrs

M:L ratio - 1:4 In order to avoid air induced cellulose de gradation it is preferable to maintain a liquor level up to half of the fabric rolls. Improved versions of jiggers which can process higher capacities if 500-750kgs. man conventional jiggers which can process only 100kg are available these days.

Kier:

Kier is a traditional pressure vessel used to provide the conditions needed for through scouring of cotton goods. It is available in various processing capacities of 250 kgs to 5000 kgs of fabrics. Kiers are huge vertical cylindrical vessels made up of cast iron. Kier boiling may be carried out either at atmospheric pressure in a open Kier or under pressure when closed. Normally a liquor ratio of 1:3 is employed.

Fig.4High Pressure Kier

The wet fabric in rope form is loaded by mechanical pilling or manually to about 80% of capacity. Filling to the fullest capacity may create hydraulic pressure, which will give false reading in the pressure gauge. Pilling should be regular without air gaps. If the regularity of pilling is not achieved there will be preferential bath circulation, and treatment irregularity in the less packed areas. Scouring liquor is prepared separately by mixing caustic soda and other assistances in appropriate quantities with water.

This liquor is pumped from bottom to the desired volume in order to sweep out the air. The top of the fabric is covered by a jute fabric and heavy stones are placed over that, in order to avoid raising of fabrics when the pressure inside develops.

Heating and circulation of scour liquor is done externally by passing through a multi tubular heater where indirect stream is used for heating. A valve is left open for the air from inside of Kier to get displaced by steam. The circulation of hot alkaline liquor through the fabric is carried out under pressure (at 25-30 psi. and 130-135⁰C) for a period of 6-12 hours depending on the type of fabric.

Typical treatment for atmospheric scouring process (open Kiering) are at 95-98⁰C for 4-6 hrs.

After the boiling is over the scouring liquor is run off by opening the bottom valve, at the same time, an equal amount of hot water is let in from the top till the concentration of caustic soda is diluted. This is done to avoid the top layer of fabric to get into contact with air. After that hot and cold washes are given to complete the process.

Scouring by continuous process:

The continuous process used two designs of machines such as J-Box and steaming chambers for the caustic impregnated fabric to be processed while J-box works in atmospheric pressure and the steaming chamber in high pressure. J - Box:

Recipe:

I chamber: (Scouring)

Caustic soda - 4% II Chamber: (Bleaching)

Temperature - 9O⁰C Hydrogen peroxide 10-20 ml/lit

Time - 60 mins Sodium silicate 2-3 ml/lit

M:L ratio - 1:4 Sodium hydroxide 3-5 gpl

Wet pick up - 60-80% Time 60 mins

Temperature 9O⁰C

M:L ratio 1:4

Wet pick up 60-80%

J - Shaped fabric storage and steaming unit. Called j - box, can be used for scouring as well as for bleaching with hydrogen peroxide. Scouring and bleaching can be carried out successively and continuously by using 2 j - box systems, arranged in sequence. J -Box is an open ended tube of rectangular cross- section. In which the fabric is fed into long arm of j and is insulated or jacketed for steam heating. In j - box the fabric can be treated in open- width and rope from. For impregnation of the fabric, it is passed through the scouring liquor kept in a saturator containing 40-60gpl of caustic soda at 50-60⁰C. Saturator ensures sufficient dwell time to bring about liquor interchange. They provide a longer immersion path for the fabric than a padding mangle. After leaving the saturator, the fabric is squeezed to a constant and uniform pick- up white processing in the form of rope, me liquor pick- up is higher compared to open width. The impregnated fabric is allowed through a pre-heater, before it enters the J- box. In the J-box, the fabric is piled and resides for a period of 1- l/2hrs at 95-100⁰C. The speed of the fabric may vary from 60-180m/min. depending on the type of fabric. The capacity of J - Box should be accordingly chosen. Continuous scouring in rope form is not suitable for varieties lot laborites mat have a tendency to crease e.g.: heavy, closely woven cotton fabrics. In both processes after the necessary period of time in steaming chamber or J-Box, the fabric is taken for washing.

Fabric

Fig.5 Continuous Scouring Using J - Box

Finer fabrics made out of fine yams and fabrics with coloured threads either in warp weft (Dhoties, Sarees & striped shirting) are not to be scoured under pressure. Only atmospheric pressure scouring is recommended. Medium and course varieties of cotton can withstand strong alkaline conditions at high pressure and therefore they can be scoured at high pressure.

BLEACHING:

• The bleaching of cotton fabrics can be done at rope and open width form in batch and continuous processes.

• Batch process is done in Jigger, winch and soft flow.

• Continuous processes are done in vapourloc chamber, J-box.

Batch process:

The use of jigger for bleaching cotton is widely practiced. Bleaching in jiggers has the advantages of easier removal of stabilizers at a liquor ratio of about 1:5, particularly organic stabilizers of typical recipe used in Jigger consists of 2-5% H₂O₂ (35%), 0.5-1.5%. Organic stabilizer, 1-1.5% NaOH and 0.1-0.2% wetting agent.

Recipe:

Hydrogen peroxide - 1 - 2%

Sodium silicate 0.5%

Soda ash 0.5%

Caustic 1%

Temp 8O⁰C

Time l'/z hrs pH 10- 11

M:L ratio 1:4 It is added over two ends and temperature is raised gradually to 80-95⁰C and the bleaching is carried out for 1-3 hours, and then washed thoroughly over two ends in hot water and several ends in warm water.

Continuous process:

In an open width J-box bleaching the fabric is padded at room temperature with 20-30 ml/litre H₂O₂ (35%), 5-10 gpl sodium silicate or organic stabilizer, 3-6 gpl NaOH and a wetting agent. After bleaching for 20 minutes at 95-100⁰C in J-box, the fabric is washed in an open soaper, with two tanks at 95⁰C, one tank at 6O⁰C and one tank of cold water.

In another method, bleaching in J-box can be done with extended time and reduced concentration of chemicals. In this kind of process, the fabric is padded with 10-20 ml/lit OfH₂O₂ (45%), 2-3 ml/lit sodium silicate, 3-5 gpl organic stabilizer, 3-5 gpl NaOH and a wetting agent, then stored in J-box for 1-2 hours at 85-9O⁰C and washed thoroughly in open soaper.

Fig.6 Continuous Scouring and Bleaching Using J Box

Recipe: π chamber:

I chamber: Hydrogen peroxide - 10-20 ml/lit

Caustic soda - 4% Sodium silicate - 2-3 mMit

Temperature - 9O⁰C Sodium hydroxide - 3-5 gpl

Time - 60mins Time - 60 mins

M:L ratio - 1:4 Temperature - 9O⁰C

Wet pick up - 60-80% M:L ratio - 1:4

Wet pick up - 60-80%

Caustic scouring and hydrogen peroxide bleaching can be done by having two J-boxes in tandem. In the process, the washed fabric is saturated in open width and piled in the J-box in twistless rope form / open width. The Process Sequence Is As Follows:

1. Pad with 4% caustic soda at 7O⁰C

2. Steam in J-box for at least 60 min. at 95-99⁰C

3. Hot wash and cool

4. Pad with H₂O₂ (30%) 3-5% at 4O⁰C

5. Steam for 60 min. at 95-99⁰C

6. Wash off in water

Pad - steam - wash - Dry process

PAD - STEAM - WASH - DRY PROCESS

Currently fabric preparation is done by in open width form using Pad-Steam-wash process. Unlike J-Box, the fabric is impregnated with the requisite chemicals by padding followed by transport to steamer unit. The cloth is transported in a tensionless manner on slow moving rollers or conveyor belt and subjected to steaming for 30 to 60 minutes. After leaving steamer, it is taken for washing in series of tanks and dried finally. The above system is presently adopted in most of the continuous process units.

Advantages: Speed, process efficiency, Productivity

Disadvantages: Steam energy cost, inferior washing efficiency, water consumption, pollution load of wash water etc.

REVIEW ON CURRENT WASHING PRACTICES:

The textile fabric after processing treatments like desizing, scouring, bleaching (additional after dyeing and colour fixation, after printing and colour fixation) needs thorough washing, in order to remove hydrolysed size mater (after desizing ), surfactants, soaponified oils, fats, waxes, proteins, pectins etc. ( after scouring ), wetting agents, alkali, bleaching agents etc. ( after bleaching ), unfixed dyes, additives, gums etc. ( after dyeing / printing and colour fixation ) to make the fabric suitable for further process. Normally over flow washing ( cold ), hot, neutralizing, soaping etc. are being done.

Current washing practices:

The current washing methods are conducted in two forms of fabric handling. 1. Rope form 2. Open width form

Rope form:

1. Manual washing in rope form — suitable for cold wash only

2. Rope washing machines

Two types of machines are generally used for washing the fabrics in rope form in a bleach - house.

They are, cor_Merunϋ

1. Tight rope washing machine

2. Slack rope washing machine fabric

Fig.8 Tight rope washing machine

The former is suitable for ordinary goods, while the later is suitable for delicate goods.

The machine consists of two cast iron side frames and a pair of heavy and wide squeezing bowls made of wood. This affords better removal of dirt by squeezing. The machine has a shallow wooden trough or tank for holding water and two freely rotating tank guide rolls and wood or ebonite. The pressure is applied by simple lever and weight. Two ropes of cloth are generally washed at a time. One rope enters at each end of the machine through a pot eye, passes into the nip of the squeezing bowls. A strong dose of water plays on the cloth at the point, where it leaves the machine and gives it a final rinse.

Roller washing machine:

Pressure by lever and weight is not sufficiently elastic for squeezing delicate fabrics. This is overcome by replacing levered pressure by spring pressure.

Slack Rope washing machine:

It is nearly similar to tight rope washing machine. But in this machine, the rope is in slack form. Hence the tension is minimum. It is therefore suitable for delicate fabrics. 3. Winch

WINCH WASHING MACHINE

FIG.9

In this system the fabric in rope form is cycled in a slant trey with excentrix plaiting fall into water. Due to less tension, this is suited for knits and delicate goods.

Draw Backs - High M : L ratio ( 1 : 20 ), water consumption, ineffective washing etc.

4) Soft flow / over flow / Air flow - The fabric in rope form in carried through water jets from nozzles and driven reel into washing tube. M:L ratio varies from ( 1 : 15 to 1 : 5 ). Fabric tension is reduced compared to winch. Nozzle water jets give better washing. Draw back: Consumes more water, batch process, more time requirement etc.

5) Jet washing: The fabric is transported in ducts, along with water and water jets. This improves washing efficiency and speed of washing

Draw back: More water consumption, chemicals, and chance for fabric entanglement etc.

Open width washing machine:

They are used to wash the fabric in open width form. Open width washing gives more uniform results, than the rope form, but the open width form permits higher speeds.

OPEN WIDTH FORM

1) Jigger (Refer Fig.2) Cloth Form I roll, passes through water and is wound on II roll and the sequence in reversed. M:L ratio 1 : 4. Simple system for open width washing in batches.

Drawback: Time consumption, considerable water consumption, poor efficiency of washing ( left over residues on substrate )

2) Continuous open width washing machines: (Refer Washing Tank units in continuous Scouring and Bleaching Using J Box Fig.6)

Series of tanks with guide rolls for cloth passage are arranged. After leaving each tank, the cloth in squeezed and enters other tanks and finally dried.

Advantages: Continuous multi effect washing, reasonably effective and scope for continuous washing and drying.

Drawbacks: More water consumption by way of overflow, scope of contamination from one bath to another, ineffective washing (mere dip wash only ), energy losses etc. Few of the features of current washing machines are;

1. Tension controls

2. Water jet application

3. Counter current washing

4. Low bath volume

5. Improved heating

6. Synchronized drive

7. Vacuum suction prior to washing etc.

Comments on current practices of Fabric preparation process:

i) Batch process: The preparatory processes like desizing, scouring, bleaching by batch process are done in jiggers, winches, kiers, soft flow machines or tanks etc., in a discontinuous manner. Material to liquor ( water ) ranges from 1 : 4 to 1 : 20 depending on machine type.

Disadvantages

a) Time consuming b) Consumes more water for process and washing c) Batch process lacks continuity d) Higher energy by increased time and water. e) Poor energy utilization leading to wastage of energy. f) More laborious g) Process and wash water pose treatment problem of effluent due to imparted suspended and dissolved solids.

ϋ) Continuous Process: The preparatory process like desizing, scouring and bleaching can be carried out by continuous process and washing by J-Box ( rope / open width ); pad-steam-wash - dry systems etc. These systems give the advantages of reduced time and continuity, but suffers the following disadvantages.

Disadvantages

a) Very huge energy cost b) Steaming chamber consumes 30 -60 minutes leading to steam energy c) Washing units are only dip wash units consuming more water d) Increased pollution potential of process and wash water. e) Not suitable for small lots. f) Poor energy utlisation g) More water consumption SUMMARY OF THE INVENTION

The invention is related to a novel method of wet processing of Textile fabrics namely Desizing, Scouring and Bleaching etc. and the subsequent washing method. The invention results in major savings of energy, water, time, less pollution load and more reuse scope of process water ( effluent )

The overall system comprises of the following units:

A. FEED UNIT To feed fabric in open width form

B. CHEMICAL IMPREGNATION UNIT For application of chemicals as per process requirement by padding

C. FLASH HEAT APPLICATION UNIT To supply required heat energy for process reaction

D. PRE-CLEANINGUNIT CONSISTING i) Water sprinkler Unit To wet out process completed fabric ii) Vacuum suction unit To remove reaction products from substrate by vacuum suction

E. WASHING UNIT To totally remove reaction product residues from textile substrate

F. DRYING UNIT To dry the wet fabric after washing.

Principle and Working Method

The fabric in open width form is fed to chemical padder unit from feed unit. The chemical pad liquor is designed as per process requirement like Desizing, Scouring, bleaching or combined process dosage, mild reaction ( for e.g. ammonium salt instead of acid ) organics in place of during flash heat application, apart from induction of a higher boiling point fluid (glycerin, DEG, PEG or propylene glycol etc.) in the chemical pad recipe. The chemical padded fabric (pickup as per requirement) is taken to flash head unit. In the flash heat application unit, dry heat is directly applied on chemical padded substrate. Due to the presence of higher boiling point fluid, the evaporation is restricted, better diffusion of chemicals, intense and penetrated reactivity are enhanced. The reaction is specific and accomplished in a very short span of time.

After process reaction, the reaction residues are solublized by water sprinkling on substrate followed by vacuum suction. This process removes maximum contaminants from wet substrate and enhance less washing load.

The washing unit comprise of tanks filled with water. The passage of material over perforated cylinders immersed in water and side way passing of air at regulated pressure, results in effective residues removal from substrate. Unlike water jet washing the air jet is capable of performing fluid impact function. This specific technique reduces drastically water consumption, followed by vacuum suction for both faces of fabric and similar treatment in various tanks removes totally any residues from substrate. Counter current washing have been implemented with this system. Finally the fabric is vacuum suctioned, hot flue or steam cylinders dried and taken to further process. Benefits? BRIEF DESCRIPTION OF DRAWINGS & ILLUSTRATIONS

Figure in sheet (1) illustrates the total configuration of COMBINED CONFIGURATION OF FLASH PROCESS AND SPECIAL WASHING UNIT. The passage of material through various units is illustrated.

NAMES OF COMPONENTS (Main Units)

A. FABRIC FEEDING UNIT

B. CHEMICAL IMPREGNATION UNIT

C. FLASH PROCESS REACTION UNIT

D. PRE-CLEANINGUNIT

E. SPECIALWASHINGUNIT

F. DRIER

NAMES OF COMPONENTS OF INDIVIDUAL UNITS

A. FABRIC FEEDING UNIT

S - Fabric

A₁ . Fabric Batch roll

A₂ . Tension Bars

B. CHEMICAL IMPREGNATION UNIT

B₁₉ B₂ - Pad Liquor Troughs B₃ - Padding mangle.

C. FLASH PROCESS REACTION UNIT

C₁, C₂ ^"Hot Air Blower fans

C₃, C₄ ^'Heat Exchanger Radiators

D. PRE-CLEANING UNIT

D₁ - Water Sprinklers D₂, D₃ - Vacuum Suction

E. SPECIAL WASHING UNIT

E₁, E₂ - Immersion rolls

E₃ - Air nozzles

E₄, E₅, - Vacuum Suction

E₆ - Squeezing rolls

F. DRIER

Fi to Fi2 - Steam Heated Drying Cylinders

F₁₃ - Fabric Plaiter

F₁₄ - Fabric Collection Trolley DETAILED DESCRIPTION

The configuration of overall system is presented in sheet 1. The presented system is one of the feasible configurations (linear) with alternate face flash heater units. The total system is composed of the following units.

A. Fabric Feeding Unit

B. Chemical Impregnation Unit

C. Flash process reaction unit

D. Pre-cleaning Unit

E. Special washing unit

F. Drier.

Function of each unit:

A. Fabric Feeding Unit:- The fabric to be processed is fed to the machine in a crease free, open width form from fabric batch roll to unit B

B. Chemical Impregnation Unit:- The fabric is impregnated with the process chemical mixture ( depending on type of process e.g. desizing or scouring or bleaching or combined ) and squeezed to remove excess pad liquor

C. Flash Process reaction chamber:- The chemical padded wet fabric is subjected to heat energy to the required time to activate chemical reaction with substrate.

D. Pre-cleaning Unit:- The reaction residues on fabric are given a soaking (wetting) treatment for solubllisation and are partially removed by vacuum suction.

E. Special washing Unit:- Further residues on fabric is removed by washing in series of tanks ( Cold wash, Hot wash, Soaping etc. )

F. Drier:- The washed fabric is dried to make it free of moisture to proceed for further processing.

DETAILED DESCRIPTION OF EACH COMPONENT OF THE SYSTEM:

A. Fabric Feeding Unit :-

The fabric to be processed is taken in batch rolls. Through contact drive roll, the fabric is drawn over series of supporting rolls, Tension bars using selvedge guiders to the chemical impregnation unit B.

Number of supporting rolls and tension bars, type of guiders depends on fabric type. Multi-layers of fabrics in layers can also be fed to increase heat utility and productivity. The infeed speed is proportional to the flash process time and speed.

Electrical and mechanical drive elements, control panel, operation keys and switches, indicators can be suitably designed and installed.

B. Chemical Impregnation Unit:-

This unit comprise of bottom trough / troughs to hold chemical pad liquor to be impregnated on to fabric. The recipe and composition, varies according to the type of process to be under taken, ie., desizing or scouring or bleaching or combined process. The principle is discussed later on flash process principle. Rubber mangles in pressure contact with each other or with ebonite / steel mangles are used for this purpose. The fabric from feed unit enters through the impregnation trough, absorbs pad chemical liquor and is squeezed to the required pick up ( 60 -100 % )and leaves to the flash reaction chamber.

• The hardness of rubber mangles, numbers (1/1, 2/1, 1/1/1) can be adopted suitably.

• The squeezing pressure can be pneumatic or hydraulic or mechanical.

• The squeezing pressure depends on pad chemical liquor pick up requirement.

• Proper dosing arrangements for chemical pad liquor infeed can be installed according to the speed of processing.

• Electrical and mechanical driving elements, mangle pressure control keys, washing/cleaning • arrangement and controls. C. Flash Process reaction chamber:-

This unit comprise of series of supporting rolls to carry fabric through the flash heat reaction chamber. On the moving wet fabric, heat energy ( hot air ) is forced through from heat exchanger unit damper slits or perforations. The heat energy source can be either one of 1) Electrical Heaters 2) Steam heaters 3) INFRARED Heaters or of 4) Radio frequency waves or 5) Micro waves. The temperature of hot air varies according to process ( 40° - 200⁰C or more ). The dwell time or reaction time' is decided by cloth speed and length of heater unit.

Principle of Flash Process:

1. By application of heat energy ( hot air ) directly on the chemical impregnated wet fabric, the reaction phase is speeded up. Specific heat application on substrate reduces total energy requirement. Time of process is drastically reduced. Material to liquor ratio (1:1) is kept at the lowest level.

2. Application of elevated temperature, reduces time and facilitates higher speed of reaction.

3. By incorporation of a fluid with higher boiling point than water ( e.g. glycol derivatives) in the chemical pad liquor, even if water evaporates, moist heat energy is retained on substrate. The boiling of water to vapour also contributes for flash reactivity. The higher boiling fluid under heat readily helps in diffusion of chemicals into fibre polymer system. The combined effect of temperature and higher boiling point fluid reduces reaction time to few seconds - compared to many hours or minutes by other process methods.

4. To prevent the degradation (strength loss) of fabric, padding recipe is modified by: a) Reduced dosage b) Milder chemicals or use of ammonium salts instead of direct acids as per process. c) Reduced time of process reaction d) Optimization of process temperature

5. The heating unit can be arranged in single face series or alternately top and bottom. The placement can be horizontal, vertical or both. The length of heater unit depends on production capacity and process time. In case of single face heaters, heat reflectors can be used at the opposite face of the heat ejection slits to reflect back heat on to substrate. This enables better heat utility.

6. The settings between substrates, heat ejection slit surface, reflector plates etc. can be tuned as per requirement

7. The overall flash heat unit can be insulated to prevent heat loss from entry to exit.

8. Suction / circulation fans, heat exchanger design can be engineered suitably.

9. The reaction vapours can be evacuated by exhaust unit.

10. The exhaust heat can be recovered for use in washing or drying units.

11. Shutter arrangements for heat release slit during width changes.

D. Pre-cleaning unit prior to washing:-

The fabric after leaving flash process reaction chamber enters the pre-cleaning unit. Series of nozzles sprinkle water (cold, warm or hot) to wet out the semi dry substrate and the reaction residues are solublized for easy removal. The dripping water from back face of fabric is collected by treys and released to drain. After getting sprinkled with water, the fabric enters vacuum suction unit by which the water, solublized residues ( organic & inorganics, hydrolised polymers etc. ) are suction cleared from substrate. In normal washing methods the residues or let into baths leading to suspended solids and TDS. The above pre- cleaning method removes maximum suspended solids and dissolved solids from substrate without being carried out to washing. This reduces pollution, water contamination and enables ease of effluent treatment. The speed of sprinkling, quantity of water, vacuum application mechanism, Vacuum pressure, contact slits etc. can be designed suitably. Single or both side vacuum suction can be installed. The numbers, spacings of series, sprinkler type etc., can be suitably designed based on width of unit. When width changes, shutter arrangement can be done.The feeble residues on substrate is washed off by special washing unit E. The vacuum suction air, after filter can be used for subsequent immersion air washing units.

E. Special Washing unit:-

The fibre residues from wet fabric are washed off by this process. This units consists of 3 - 4 or more individual tanks kept in series. Each tank consists of 2 cloth immersion rolls, ( Perforated or wire mesh covered) water inlet and outlet valves, vacuum suction unit, scroll rolls and squeezing mangles prior to passage into successive tanks. In normal washing systems, the fabric in first immersed and residues are transferred to water by soaking. In this system maximum impurities are directly removed by suction and by pre-cleaning unit. Further residues are removed efficiently by immersion in water and by air jets under water. This concept reduces water consumption and improves washing efficiency. The post suction operation at the end of each tank reduces further contamination to be carried to successive tanks. Depending on requirement 3 or 4 tanks or more can be arranged in serial. Each tank is kept at higher base level to ensure gravity flow of counter current washing. In counter current washing system, only the last tank is fed in with fresh water. The water from last tank flows backward to each preceeding washing unit. This is again a special feature of this washing system. By pass arrangement can also be done to divert over flow water from each washing unit.

The speciality of post washing unit developed in this report features the following.

1. Pre-cleaning of substrate prior to washing, having less contamination on substrate, requires minimum washing.

2. The mode of washing is fabric immersion into water bath over open mesh cylinders and impingement of air jets from serious of nozzles on to fabric. Literally instead of water , air is being used for forcing out impurities adhering onto fabric substrate.

3. These feature reduces water consumption and improves washing performance.

4. The vacuum suction before leaving each tank, removes directly residues from substrate interms of suspended and dissolved solids.

5. The wash water from the washing unit is less contaminated, reduced pollution load and ease of effluent water treatment and more reuse scope are enhanced.

Direct / indirect heating arrangements for heating water, washing chemicals dosing arrangements, Temperature control valves and indicators, surface speed synchronization between various elements, speed varion keys and switches, control panel boards, water / steam control valves, heat recovery from flash heat reaction chamber, capacity and type of compressors, air nozzles, pressure regulators, in feed and drain valves, bye-pass valves, electrical and mechanical drive element can be engineered suitably.

The diameter of immersion drums, types and shapes of perforations, capacity of tanks, number of tanks, nozzles design, pressure settings etc. can be suitably ascertained.

This technique is adaptable to existing washing units by modification and even to domestic washing machine

F. Drier Unit :

The wet fabric after final vacuum suction and squeezing is carried to drier unit. The drier unit can be of hot flue type or steam heated drying range. In case of hot cylinders. The number of cylinders accounts for efficiency, speed, temperature of drying. This decides the temperature and speed of drying. After drying the fabric is plaited on trolleys or batched as per convenience.

Pressure control valves, temperature indicators, keys and switches, rolls, expanders, mechanical and electrical drive elements can be suitably designed. GENERAL

1. Material of construction of various elements can be suitably ascertained.

2. Surface speed synchronization between individual drives from unit A to Unit F and inter unit speed synchronization

3. The width of the unit, cross section depends on width of fabric to be processed.

4. Parallel processing of multi web processing and washing can also be installed to save energy.

5. Mutual inter unit heat recovery and reuse is possible

6. Maintenance aspects of mechanical and electrical gadgets can be kept in view in the designing aspect.

7. Variable speed drive.

8. The foundation, level, support frames of individual units can be engineered as per requirement.

9. The overall width of entire unit depends on width of fabric, number of webs being processed.

10. Controls, indicators, regulatory valves for water, air, temperature and pressure can be suitably installed.

11. The placement of various units can be horizontal or vertical or folded to save space requirement.

12. Entry to intermediate and exit, suitable fabric guider systems can be introduced.

13. The overall speed of processing can be varied as per production requirement

14.Apart from preparation process, this washing unit can be used for washing of dyed or printed or other process goods in an efficient manner.

Trouble shootings foreseen:

1) Fabric degration or strength loss can be controlled by chemical concentration, flash heat temperature, time, fabric tension etc.

2) Abrasion - can be controlled by surface speed control and tension

3) Foam in washing unit due to air can be controlled by cleaning systems.

4) Emergency stops, fabric cut off or seam cut off detection sensors, heater unit temperature cut off, devices in case of stoppage etc. to be suitably installed.

5) Uniform heat transfer to ensure by way of hot air circulation dynamics design. APPLICATION SCOPE OF FLASH PROCESS AND SPECIAL AIR WASHING SYSTEM

1. Continuous desizing - Washing - Drying of 100% Cotton fabrics

2. Continuous scouring Washing - Drying of 100% Cotton fabrics

3. Continuous Bleaching - Washing - Drying of 100% Cotton fabrics

4. Combined desizing & scouring - Washing - Drying of 100% Cotton fabrics

5. Combined scouring & Bleaching - Washing - Drying of 100% Cotton fabrics

6. Combined desizing, Scouring, bleaching - Washing - Drying can also be made feasible

7. Scope for combined desizing & Scouring - Washing - Drying of synthetics or blends.

8. Scope for combined desizing, Scouring & Bleaching - Washing - Drying of synthetics or blends

9. Can be used for development of padded dye/ print by dry heat fixation & Washing - Drying Cotton fabrics.

10. Application scope to existing process / Washing unit by suitable modification.

11. Facility for multi layer fabric processing and parallel webs processing to achieve maximum productivity.

12. Saves energy, Water, Time, Pollution - increased speed, reduced, man power & cost of production. ADVANTAGES

1. Reduced water consumption (60-70% Savings)

2. Reduced energy consumption (90-99% Savings)

3. Reduced time of process and increased speeds

4. Scope for multi layer & Parallel webs processing for maximum productivity

5. Internal heat recovery and reuse scope.

6. Scope for preparation processes like desizing, scouring, bleaching - Washing - Drying by single stage or combined ( 2 in one or 3 in one etc) for 100% cotton, Synthetics & blends.

7. Scope for pad - dry - fixation - Washing for dye padded / printed fabrics.

8. Excellent process efficiency, washing & improved fastness.

9. Reduced pollution potential, Easeir effluent treatment & water reuse scope rendered.

10. Clean technology option.

11. The reduced water, energy, time, manpower & improved productivity, combined and continuous manner of processing and washing - results in reduced cost of production and pollution problems.

EXPERIMENTAL PROOF

METHODOLOGY ADOPTED

Since, the overall cost of engineering and final run of actual system, involve huge cost, the applicant had adopted the following procedures to derive experimental proof.

FLASH PROCESS, PRECLEANING AND IMMERSION AIR WASHING MATERIALS & TOOLS USED

1. 100% sized, woven, cotton fabric

2. Weighing balance, beakers, and requisite chemicals for recipe formulations.

3. Laboratory 2 bowl padding mangle as chemical impregnator unit.

4. 1000 W electrical room heater with blower /Electrical hair drier (for flash heat application)

5. Water sprayer (in place of pre-cleaning water sprinkler)

6. Domestic vacuum cleaner (for vacuum application)

7. Buckets filled with water (for immersion wash tanks)

8. Mini compressor with hose (As air impingement nozzle)

9. Steel wire mesh (As perforated immersion rolls) for fabric support during washing.

10. Domestic vacuum cleaner (For vacuum suction after air washing)

11. Laboratory padding mangle (As squeezing mangle)

12. Glass beakers, volume jars, test tubes for comparative assessment of wash, water.

13. Fabric Tensile strength Tester, TDS meter, crock meter, wash fastness Testing bath with heating arrangement.

Flash process experiments were conducted with suitable recipe formulations by studying various parameters based on (for designing, scouring, bleaching and combination processes for 100% cotton fabric) trails. Simultaneously normal bath based preparation processes for 100% cotton viz- designing, scouring, bleaching and various combination process were conducted. Comparative process efficiency tests were conducted and obtained results were recorded. After flash process, the pre cleaning vacuum suction experiments were done by water sprayer and domestic vacuum suction. Followed by this the immersion air washing was conducted by keeping pre cleaned sample on wire mesh support into bucket of water and air washing was done by compressor air hose under water. Wash bath continuation and next bath contamination after vacuum suction and squeezing were studied and recorded.

Comparative figures for consumption of energy, water and time were assessed & recorded.

COMPARATIVE RECTPE MODIFICATIONS

Normal desiring^* Flash desizing

Recipe Recipe

Biocon (Enzyme) - 0.5 - l gpl DEG - 10%

Sodium chloride - 5 - 10 gpl Ammonium chloride - 6% pH - 5.5 - 7.5 Non ionic wetting agent - 2%

Time - 4 - 6 hrs Non ionic soap - 1%

Temperature - 60 - 70⁰C Emulsifier - 3%

M:L ratio - 1 : 4 Water - 100 parts

Time - 60 sees

Temperature - dry heat pH - 6

M:L ratio - 1:1 SCOURING

Normal scouring Flash scouring

Recipe Recipe

Caustic soda -5% M:L ratio -1:1

Tri sodium phosphate - 1% DEG -5%

Soda ash - 1.5% Soda ash -2%

Soap - 0.5% Caustic -1%

Wetting agent - 0.75% Non- ionic wetting agent -1%

Water - 100 parts Sodium bisulphate - 0.5% pH -10 Water -100 parts

Temperature -9O⁰C Time - 60 sees.

Time -4hrs Temp - dry heat

M:L ratio -1:4 pH -9-10

BLEACHING

NORMAL FULL BLEACHING:

Recipe bleaching (desizing & scouring as mentioned earlier):

Wetting agent - 0.4%

Sequestering agent -1%

Stabilizer - 0.5%

Caustic soda -3%

Hydrogen peroxide -7%

Defoamer - 0.2%

Water - 100 parts

Time - 1-2 hours

Temperature -9O⁰C

MLR -1:4 pH -10-11

FLASH DESIZING, FLASH SCOURING WITH HYDROS & FLASH BLEACHING:

Recipe Desizing Recipe Scouring Recipe for Bleaching

DEG - 10% M: L ratio -1:1 M:L ratio -1:1

Ammonium chlorids ; -6% DEG -5% Sodium acetate -3%

Non ionic wetting Soda ash -2% H₂O₂ -3% gent -2% Caustic -1% DEG -5%

Non ionic soap -1% Non- ionic wetting Sodium silicate - 0.5%

Emulsifier -3% agent -1% Mercerizing wetting

Water - 100 parts Sodium bisulphate -0.5% agent -1%

Time - 60 sees Hydros - 0.5% Water -100 parts

Temperature - dry heat Water - 100 parts Temperature -dry heat pH -6 Time - 60 sees. Time - 60 sees.

M:L ratio -1:1 Temp - dry heat pH -10-11

PH -9-10 FLASH DESIZING CUM SCOURING AND FLASH BLEACHING:

Flash desizing cum scouring Normal desizing and scouring

Recipe Desizing Recipe

M:L ratio -1:1 Biocon (Enzyme) -0.5-1 gpl

DEG - 10% Sodium chloride -5-10gpl

Ammonium chloride -6% pH -5.5-7.5

Non ionic wetting agent -2% Time - 4 - 6 hrs

Non ionic soap -1% Temperature -60-70⁰C

Water -100 parts M:L ratio -1:4

Time -40 sees

Temp -dry heat Scouring Recipe pH -6 Caustic soda -5%

Tri sodium phosphate -1%

Soda ash - 1.5%

Soap -0.5%

Wetting agent -0.75%

Water - 100 parts pH -10

Temperature -9O⁰C

Time -4hrs

M:L ratio -1:4

Ih the same manner recipes for synthetics and blends can be formulated and set.

EXPERIMENTAL RESULTS

COMPARATIVE FIGURES ON SAVINGS OF WATER, TIME AND ENERGY 1 JIGGERDESIZING

3 KEER SCOURING

4 JIGGERBLEACHING

5) NORMAL CONTINUOUS SCOURING AND BLEACHING VS FLASH DESIZING CUM SCOURING WITH AND FLASH BLEACHING

6) NORMAL FULL BLEACHING VS FLASH DESIZING, FLASH SCOURING WITH HYDROS AND FLASH BLEACHING

7) NORMAL FULL BLEACHING VS FLASH DESIZING CUM SCOURING AND FLASH BLEACHING

8 NORMAL DESIZING AND SCOURING VS FLASH DESIZING CUM SCOURING

9) STRENGTH OF FABRICS AND PROCESS EFFICIENCY AND DYEABILITY a) DESIZING

b) SCOURING:

c) BLEACHING:

d) COMBINED PROCESS

DESIZING CUM SCOURING

• All the above test results shows that the flash process can be safely employed for efficient processes like desizing, scouring, desizing cum scouring, bleaching without fabric degradation.

RESULTS OF WATER IMMERSION AIR WASHING TECHNIQUE

1. The immersion air washed both showed more contamination and turbidity, stating that the washing was intense.

2. A vacuum suctioned sample from first wash showed less contamination and clarity in Second wash bath than just squeezed first wash sample with vacuum suction.

3. Suspended solids, TDS levels of wash water of immersion air was sample found lesser than normal was sample.

4. Fastners of Dyed and Printed washed goods by immersion air wash samples were better than normal washed Dyed and printed goods.

Claims

CLAIM1) I claim the invention of a NOVEL FLASH PROCESS AND WASHING TECHNIQUE OF WET PROCESSING OF TEXTILES FOR SAVING OF ENERGY, TIME AND WATER which is comprised of the following units.A. FEED UNIT - To feed fabric in open width formB. CHEMICAL IMPREGNATION UNIT - For application of chemicals as per process requirement by paddingC. FLASH HEAT APPLICATION UNIT - To supply required heat energy for process reactionD. PRE-CLEANING UNIT CONSISTING i) Water sprinkler Unit - To wet out process completed fabric ii) Vacuum suction unit - To remove reaction products from substrate by vacuum suctionE. WASHING UNIT - To totally remove reaction product residues from textile substrateF. DRYING UNIT - To dry the wet fabric after washing.A. FEED UNIT :2) The system as claimed in Claim-I : The number of supporting rolls and tension bars, type of guiders depends on fabric type. Multi-layers of fabrics in layers can also be fed to increase heat utility and productivity. The infeed speed is proportional to the flash process time and speed.Electrical and mechanical drive elements, control panel, operation keys and switches, indicators can be suitably designed and installed.B. CBOEmCAL IMPREGNATION UNIT:-3) The system as claimed in Claim-I : The recipe and composition, varies according to the type of process to be under taken, ie., desizing or scouring or bleaching or combined process. Rubber mangles in pressure contact with each other or with ebonite / steel mangles are used for this purpose. The fabric from feed unit enters through the impregnation trough, absorbs pad chemical liquor and is squeezed to the required pick up ( 60 -100 % )and leaves to the flash reaction chamber.• The hardness of rubber mangles, numbers (1/1, 2/1, 1/1/1) can be adopted suitably.• The squeezing pressure can be pneumatic or hydraulic or mechanical.• The squeezing pressure depends on pad chemical liquor pick up requirement.• Proper dosing arrangements for chemical pad liquor infeed can be installed according to the speed of processing.• Electrical and mechanical driving elements, mangle pressure control keys, indicators, washing/cleaning arrangement and controls.C. FLASH PROCESS REACTION CHAMBER:-4) The system as claimed in Claim-I : The heat energy source can be either one of 1) Electrical Heaters 2) Steam heaters 3) INFRARED Heaters or of 4) Radio frequency waves or 5) Micro waves. The temperature of hot air varies according to process ( 40° - 2000C or more ). The dwell time or reaction time is decided by cloth speed and length of heater unit.• Time of process is drastically reduced. Material to liquor ratio (1 : 1) is kept at the lowest level.• Application of elevated temperature, reduces time and facilitates higher speed of reaction.• By incorporation of a fluid with higher boiling point than water ( e.g. glycol derivatives) in the chemical pad liquor, even if water evaporates, moist heat energy is retained on substrate. The boiling of water to vapour also contributes for flash reactivity. The higher boiling fluid under heat readily helps in diffusion of chemicals into fibre polymer system. The combined effect of temperature and higher boiling point fluid reduces reaction time to few seconds - compared to many hours or minutes by other process methods.• To prevent the degradation (strength loss) of fabric, padding recipe is modified by: o Reduced dosage o Milder chemicals or use of ammonium salts instead of direct acids as per process. o Reduced time of process reaction o Optimization of process temperature ♦ The heating unit can be arranged in single face series or alternately top and bottom. The placement can be horizontal, vertical or both. The length of heater unit depends on production capacity and, process time. In case of single face heaters, heat reflectors can be used at the opposite face of the heat ejection slits to reflect back heat on to substrate. This enables better heat utility.♦ The settings between substrates, heat ejection slit surface, reflector plates etc. can be tuned as per requirement♦ The overall flash heat unit can be insulated to prevent heat loss from entry to exit.♦ Suction / circulation fans, heat exchanger design can be engineered suitably.♦ The reaction vapours can be evacuated by exhaust unit.♦ The exhaust heat can be recovered for use in washing or drying units.♦ Shutter arrangements for heat release slit during width changes.D. PRE-CLEANING UNIT :5) The system as claimed hi Claim-I : The speed of sprinkling, quantity of water, vacuum application mechanism, Vacuum pressure, contact slits etc. can be designed suitably. Single or both side vacuum suction can be installed. The numbers, spacings of series, sprinkler type etc., can be suitably designed based on width of unit. When width changes, shutter arrangement can be done.The feeble residues on substrate is washed off by special washing unit E. The vacuum suction air, after filter can be used for subsequent immersion air washing units.E. SPECIAL WASHING UNIT:-6) The system as claimed in Claim-I : This units consists of 3 - 4 or more individual tanks kept in series. Each tank consists of 2 cloth immersion rolls, ( Perforated or wire mesh covered) water inlet and outlet valves, vacuum suction unit, scroll rolls and squeezing mangles prior to passage into successive tanks. Depending on requirement 3 or 4 tanks or more can be arranged in serial. By pass arrangement can also be done to divert over flow water from each washing unit.The speciality of post washing unit developed in this report features the following.

3. These feature reduces water consumption and improves washing performance.

F. DRIER UNIT :

7) The system as claimed in Claim-I : The drier unit can be of hot flue type or steam heated drying range. In case of hot cylinders. The number of cylinders accounts for efficiency, speed, temperature of drying. This decides the temperature and speed of drying. After drying the fabric is plaited on trolleys or batched as per convenience.

8} The system as claimed in Claim-I :

♦ Material of construction of various elements can be suitably ascertained.

♦ Surface speed synchronization between individual drives from unit A to Unit F and inter unit speed synchronization

♦ The width of the unit, cross section depends on width of fabric to be processed.

♦ Parrallel processing of multi web processing and washing can also be installed to save energy.

♦ Mutual inter unit heat recovery and reuse is possible

♦ Maintenance aspects of mechanical and electrical gadgets can be kept in view in the designing aspect.

♦ Variable speed drive.

♦ The foundation, level, support frames of individual units can be engineered as per requirement.

♦ The overall width of entire unit depends on width of fabric, number of webs being processed.

♦ Controls, indicators, regulatory valves for water, air, temperature and pressure can be suitably installed.

♦ The placement of various units can be horizontal or vertical or folded to save space requirement.

♦ Entry to intermediate and exit, suitable fabric guider systems can be introduced.

♦ The overall speed of processing can be varied as per production requirement

♦ 14.Apart from preparation process, this washing unit can be used for washing of dyed or printed or other process goods in an efficient manner.

TROUBLE SHOOTINGS FORESEEN:

9) The system as claimed in Claim-I :

♦ Fabric degration or strength loss can be controlled by chemical concentration, flash heat temperature, time, fabric tension etc.

♦ Abrasion - can be controlled by surface speed control and tension

♦ Foam in washing unit due to air can be controlled by cleaning systems.

♦ Emergency stops, fabric cut off or seam cut off detection sensors, heater unit temperature cut off devices in case of stoppage etc. to be suitably installed.

♦ Uniform heat transfer to ensure by way of hot air circulation dynamics design.

APPLICATION SCOPE OF FLASH PROCESS AND SPECIAL AHl WASHING SYSTEM

10) The system as claimed in Claim-I :

♦ Continuous desizing - Washing - Drying of 100% Cotton fabrics

♦ Continuous scouring Washing - Drying of 100% Cotton fabrics

♦ Continuous Bleaching - Washing - Drying of 100% Cotton fabrics

♦ Combined desizing & scouring - Washing - Drying of 100% Cotton fabrics

♦ Combined scouring & Bleaching - Washing - Drying of 100% Cotton fabrics

♦ Combined desizing, Scouring, bleaching - Washing - Drying can also be made feasible

♦ Scope for combined desizing & Scouring - Washing - Drying of synthetics or blends.

♦ Scope for combined desizing, Scouring & Bleaching - Washing - Drying of synthetics or blends

♦ Can be used for development of padded dye/ print by dry heat fixation & Washing - Drying Cotton fabrics.

♦ Application scope to existing process / Washing unit by suitable modification.

♦ Facility for multi layer fabric processing and parallel webs processing to achieve maximum productivity.

♦ Saves energy, Water, Time, Pollution - increased speed, reduced, man power & cost of production.

Thus, while the invention has been particularly shown and described with respect to a preferred emboidment thereof, it will be understood by those skilled in the art that changes in form and details may be made therein without departing from the scope and spirit of the invention.