Escolar Documentos
Profissional Documentos
Cultura Documentos
A Project
on
Application of cellulase enzyme on textile Processing
Submitted by:
Name ID
Arup Chandra Roy 072-178-041
Md. Iqbal Shaikh 072-223-041
Mehedi Hasan Khan 072-224-041
Abu Sayed 072-226-041
Gm. Mortuza 073-050-741
Md. Asadul Islam 081-028-741
Md. Sharif Miah 081-118-041
Sufal Chandra Sutradhar 081-272-041
Md.Abdus Sobahan 081-279-041
Supervisor:
Md. Mahbub Hasan
Sr. Lecturer , department of textile Engineering
Primeasia University
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Adessertation submmited on:
Submitted by:
Name ID
Arup Chandra Roy 072-178-041
Md. Iqbal Shaikh 072-223-041
Mehedi Hasan Khan 072-224-041
Abu Sayed 072-226-041
Gm. Mortuza 073-050-741
Md. Asadul Islam 081-028-741
Md. Sharif Miah 081-118-041
Sufal Chandra Sutradhar 081-272-041
Md.Abdus Sobahan 081-279-041
Supervisor:
Md. Mahbub Hasan
Primeasia University
3
“Application of Cellulase enzyme on textile processing”
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By the name of Allmighty ALLAH;
The most gracious;
The most merciful;
The lord of all creation.
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To our Parents
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Acknowledgement
We would like to express our gratitude to all those who gave us the
possibility to complete this project.
At last all the credits go to Almighty Allah, who enabled us to complete the
project.
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Abstract
Now a day’s the whole universe is concern about the hygiene and they are
looking for eco-friendly processes every where. Textile processing is one of the
most pollutants responsible for polluting the environment at a large degree. Use of
Cellulase enzyme for denim washing & Bio-polishing of knit fabric is a standard
eco-friendly technique to achieve desired appearance and washing of denim and
also the desired appearance of the knit fabric. Applications of enzymes to replace
harsh chemicals and other difficulties for process industries have been practiced for
decades. In this study we have tried to observe the washing effect of denim fabric
and the bio-polishing effect of knit fabric with Cellulase enzyme under different
conditions.
This work also evaluates the effect of cellulase finishing of dyed cotton fabrics.
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Objectives of the Project:
The technology which is used to modify the appearance, out
look, comfortability & fashion of the garments is called garment
washing.
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Scope:
Enzyme wash is suitable for all cotton/ denim garments,
cellulosic woven or knitted and regenerated cellulosic like
tencel and modal etc.
Permanent faded, soft hand effect can be produced on the
treated material.
It facilitates the removal of dead / immature cotton and
reduction of any fibre hairs on the surface (fewer
tendencies to pilling).
Faded look or wash-down look can be produced on treated
material.
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Limitations:
Possibility of producing same effect is difficult.
Possibility of fabric damages during washing.
Application of cellulase enzyme in the textile processing
often results in a certain amount of loss of tensile strength
along with the desired performance.
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METHODOLOGY:
PRIMARY STAGES:
SECONDARY STAGES:
Books, internet
Visiting industries
Magazine
Seminar
And Completed
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content
Chapter -1
Chapter-2
Chapter-3
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Cellulase wash ----------------------------------------------------------------- 32-34
Chapter-4
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Cellulase enzyme offers the following benefits ---------------------- 69
Conclusion ---------------------------------------------------------------- 71
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Chapter-1
GARMENTS WASHING:
The technology which is used to modify the appearance, out look, comfortability
& fashion of the garments is called garment washing.
Chemical action.
When these soft garments are touched then it seems to best touch of
garments.
Any dirt, spot or germ if added in the garments during manufacturing is also
removed due to washing.
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TYPES OF WASHING:
Enzyme wash (Bio Polish wash & enzyme wash)
Stone wash
Bleach wash
Sand Blasting
Permanent wrinkle
Pigment wash
Caustic wash
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Chapter-2
Enzyme:
Enzymes are proteins produced by living organisms. All organisms produce a wide
range of enzymes to accomplish necessary biological tasks. Some enzymes can
also be replicated in the lab, or engineered to perform in a particular way. One of
the reasons that enzyme washing is so ecologically friendly is the natural origins of
enzymes, which biodegrade, rather than lingering in the water supply. Enzyme
washing products are also much more potent than other laundry products, requiring
people to use far less, in terms of volume.
Enzymes, like other proteins, consist of long chains of amino acids held together
by peptide bonds. They are present in all living cells, where they perform a vital
function by controlling the metabolic processes, whereby nutrients are converted
into energy and new cells.
Enzymes are biocatalyst, and by their mere presence, and without being consumed
in the process, enzymes can speed up chemical processes that would otherwise run
very slowly. After the reaction is complete, the enzyme is released again, ready to
start another reaction. In principle, this could go on forever, but in practically most
catalysts have a limited stability, and over a period of time they lose, their activity
and are not usable again. Generally, most enzymes are used only once and
discarded after; they have done their job.
Different types of enzymes are suitable for different stains. In all cases, the enzyme
washing process breaks the stain down into smaller molecules which can be
removed with water or conventional soap. Amylases will remove starch based
laundry stains, while proteases break down protein chains, making them suitable
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for protein stains. Lipases work very well on grease and oil, and cellulases are
excellent general cleaners. Enzyme washing also yields a softer, more supple
garment.
We have worked only with cellulose enzyme. We tried to know the effect of
cellulose enzyme on garments washing.
For delicate garments, enzyme washing can be an excellent way to get clothing
fresh and clean. Enzymes also work at very low temperatures, making them
suitable for cold wash only things ranging from silk to wet suits. Many natural
detergent products mix enzymes into their formulas, to ensure that they are
effective at all temperatures and on all stains.
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Etymology and history:
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Enzymes are specific and work in mild conditions:
Industrial enzymes can be produced in an ecologically sound way where the waste
sludge is recycled as fertilizer.
There are a lot of enzymes like amylases, cellulases, catalase, pectinase and
protease for various textile wet-processing applications like desizing, bio-
polishing, denim finishing, bleach clean-up, bio-scouring and de-wooling.
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Sources of Enzymes:
Enzymes are the products of living cells and like proteins; no enzyme has as
yet been successfully synthesized. Among many sources these are the most
common: animal tissues, organs and fluids such as muscle, liver and saliva; animal
products, such as milk and eggs; vegetable materials and a variety of seeds as
reported in Encyclopedia Americana (1967). Pancreatic enzymes are prepared
from slaughter house waste such as pancrease, clotted blood, liver etc.
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Different type of Enzymes:
Proteases:
Proteases are the most widely used enzymes in the detergent industry.
Proteases hydrolyze proteins and break them down into more soluble polypeptides
or free amino acids. As a result of the combined effect of surfactants and enzymes,
stubborn stains can be removed from fibres.
Lipases:
Though enzymes can easily digest protein stains, oily and fatty stains have
always been troublesome to remove. The trend towards lower washing
temperatures has made the removal of grease spots an even bigger problem. This
applies particularly to materials made up of a blend of cotton and polyester. The
lipase is capable of removing fatty stains such as fats, butter, salad oil, sauces and
the tough stains on collars and cuffs.
Amylases:
Amylases are used to remove residues of starch-based foods like potatoes,
spaghetti, custards, gravies and chocolate. This type of enzyme can be used in
laundry detergents as well as in dishwashing detergents.
Cellulases:
The development of detergent enzymes has mainly focused on enzymes
capable of removing stains. However, a cellulase enzyme has properties enabling it
to modify the structure of cellulose fibre on cotton and cotton blends. When it is
added to a detergent, it results into the following effects:
Soil removal- Some dirt particles are trapped in the network of microfibrils and
are released when the microfibrils are removed by the cellulase enzyme.
Structure:
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Stability and storage:
The activity of cellulase preparations has been found to be completely
destroyed after 10-15 minutes at 80 °C. Solutions of cellulase at pH 5-7 are stable
for 24 hours at 4 °C. These products should be stored at 4 °C, in a dry place in
tightly closed containers. If stored in this manner, lyophilized preparation is stable
for several months without significant loss of activity.
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Sample washing Machine (Horizontal):
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Washing Machine (Front loading):
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Hydro extractor Machine:
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Dryer Machine (Gas):
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Boiler:
Generator:
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Compressor:
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CELLULASE WASH:
Cellulase enzymes are natural proteins which are used in denim garment
processing to get stone wash look on to the denim garments without using stones
or by reducing the use of pumice stone. Cellulase attacks primarily on the surface
of the cellulose fibre, leaving the interior of the fibre as it is, by removing the
indigo present in the surface layer of fibre. These enzymes are different from the
alpha amylase enzymes used for starch removal in that they are selective only to the
cellulose and will not degrade starch. Under certain conditions, their ability to react
with cellulose (cotton) will result in surface fiber removal (weight loss). This will give
the garments a washed appearance and soft hand.
There are different forms and types of cellulase enzymes used in Bangladesh.
– Production high
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Neutral stable Enzyme:
– Found in powder form.
SL ENZYME:
– SL enzyme is liquid form.
– PH range is 6 to 7.
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Denim fabric is constructed of indigo dyed cotton warp yarns and natural
undyed cotton filling yarns. The warp yarns are dyed by a special process that
deposits the dye on the surface of the yarn, facilitating easy removal of the dye for
a wash down appearance.
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CELLULASE ENZYME PROCESSING:
A number of factors impact cellulase activity during processing, and these factors
can be classified as mechanical or chemical:
MECHANICAL CHEMICAL
Equipment Type Cellulase Type
Equipment Design Cellulase Amount
Process Time Process Time
Garments wt. Process Temperature
Liquor Ratio Process PH
Machine Speed Auxiliary Chemicals
Auxiliary Products Pre-treatments
Process times for cellulase treatment typically range from 0.5-2.0 hours. Delicate,
lightweight fabrics/garments are processed for shorter time periods.
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When carefully controlled, the desired surface modifications can be
achieved within 30 minutes, without excessive strength loss. Heavier fabrics, such
as denim, normally require longer processing times at specific cellulase
concentrations to achieve the standard washdown of color reduction, seam
abrasion, and softness. Back staining of indigo denim is usually resolved by
switching from standard acid to modified acid or neutral cellulase.
Other options to reduce back staining include the use of anti-redeposition
agents, balancing enzyme amount/time factors, or reducing the load size.
Temperature control throughout the cellulase enzyme cycle is important for both
quality control and reproducibility.
First Step :
DESIZING:
Second Step :
Enzyme Wash:
Third Step :
SOFTENING:
– Temperature : Room.
– Time : 10 to 15 mins.
Fourth Step :
Hydro-extractor Machine:
– After unloading garments from the washing machine then they are
sent to hydro-extractor machine to remove excess water from the
washed garments
Fifth Step:
Drying Machine:
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– Temperature set at 75°c to 85°c.
– Sixth Step:
Samples:
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Raw Denim Enzyme washed
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Raw Denim Enzyme Washed
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Raw Denim Enzyme Washed denim (Dark shade)
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Raw Denim Enzyme washed Denim
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Raw Denim Enzyme Washed
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Raw Denim Washed denim (Medium Shade)
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Medium shade Garments
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ENZYME WASH PROCESS (For Light Shade):
The enzyme washing process of a batch of 60 kgs denim men's long pant
(Trouser) are described below:
First Step :
Desizing :
Second Step :
Enzyme Wash
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Third Step :
Bleaching:
Fourth Step :
Neutralization -1
– Temperature : 50°c.
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Fifth Step :
Second bleach:
– Temperature : 60°c.
– Time : 10 mins.
Sixth Step :
Softening:
– Temperature : Cold.
– Time : 10 to 15 mins.
Eighth Step :
Drying Machine:
Ninth Step :
After dryer garments are sent to quality section for quality checking and then
garments are ready for delivery
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STONE ENZYME WASH:
Now in Bangladesh most of the Denim garment is required STONE
ENZYME WASH effect. It is most popular wash for Buyer. A process of stone
enzyme wash of 60 kg batch of Denim Long Pant as mentioned below :
First Step :
Pre-treatment:
Desizing
– Batch Weight : 60 kg
– Temperature : 60°c
– Time : 15 to 25 mins.
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Second Step :
Hot wash:
– Temperature : 60°c.
– Time : 5 mins
Third Step:
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Fourth Step :
Bleaching:
– Machine running.
– Temperature : 60°c
Fifth Step :
Neutralization:
– Temperature : 40°c
– Time : 10- 12 m
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Sixth Step :
Softening:
– Time : 5 mins.
Hydro-extraction of the garments are done to remove excess water from the
washed garments.
Eighth Step :
Drying :
– Load 40 kg garments
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Enzyme Inactivation:
To prevent any damage of the fabric after the finishing operation it is very essential
that the reaction be terminated at the end of treatment by enzyme inactivation . If
the enzyme is not inactivated entirely then at the end of the reaction fibres get
damaged and even extreme cases total destruction of the material may result. The
enzyme inactivation is therefore of great importance from the technical point of
view.
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Advantage of enzyme washing:
1. Soft handle and attractive clean appearance is obtained without severe
damage to the surface of yarn.
2. Inexpensive, low-grade fabric quality can be finished to a top quality
product by the removal of hairiness fluff and pills, etc.
3. Simple process handling and minimum effluent problem.
4. Better feel to touch and increased gloss or luster.
5. Prevents tendency of pilling after relatively short period of wear.
6. Can be applied on cellulose and its blend.
7. Due to mild condition of treatment process is less corrosive.
8. Fancy colour-flenced surface can be obtained without or a partial use of
stone.
9. More reproducible effect can be obtained.
10.It allows more loading of the garment into machines.
11.Environmental friendly treatment.
12.Less damage to seam edges and badges.
13.Wear and tear of equipment is minimum due to absence of stone.
14.Use of softener can be avoided or minimised.
15.Easy handling of floor and severs as messy sludge of stones does not
interfere.
16.Due to absence of stone, labour intensive operation of stone removal is not
required.
17.Homogenous abrasion of the garments.
18.Puckering effect can also be obtained.
19.Problem of pumice powder contamination on garment is not there.
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Bio-polishing of Knit Fabric:
Cotton and other natural and man-made cellulosic fibers develop pills or
protruding fibers during spinning, weaving and wet processing operations, due to
abrasions. These pills make the appearance of the yarn or fabric to be dull and
hazy. In order to improve the appearance it is necessary to either remove the
protruding fibers or to cement it to the surface properly by the application of some
over coating.
Cotton and other natural and man-made cellulosic fibers can be improved by
an enzymatic treatment called Bio-Polishing. The main advantage of Bio-Polishing
is the prevention of pilling.
After Bio-Polishing, the fabric shows a much lower pilling tendency. Other
benefits of removing fuzz are a softer, smoother feel and superior brightness of the
dyed shade or white. Unlike conventional softeners, which tend to be washed out
and often result in a greasy feel, the softness-enhancing effects of Bio-Polishing
are wash proof and non-greasy.
For cotton fabrics, the use of Bio-Polishing is optional for upgrading the fabric.
However, Bio-Polishing is almost essential for the new polynosic fiber lyocell.
Lyocell is made from wood pulp and is characterized by a tendency to fibrillate
easily when wet. In simple terms, fibrils on the surface of the fiber peel up. If they
are not removed, finished garments made with lyocell will end up covered in pills.
This is the reason why lyocell fabric is treated with cellulases during finishing.
Cellulases also enhance the attractive, silky appearance of lyocell.
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Bio-Polishing has a lasting effect on knitted as well as woven fabrics, giving
improved resistance to pilling, a clearer, lint-free and fuzzless surface structure,
and improved drapability and softness.
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Mechanism of Biofinishing:
Understanding the behavior of the cellulolytic enzymes towards the cotton
fiber is essential to minimize the related negative effect on the strength of the
cotton fabric. Cellulose is made up of highly ordered crystalline region and less
structured amorphous region. The degree of departure from crystallinity is variable
to form the less structured purely amorphous region with all degrees of order in
between. The amorphous region is generally responsible to form the fuzz and
pilling in cotton fabric. Hence, a single type of cellulose preferentially
endoglucanase may probably be sufficient for degradation of amorphous cellulose
with minimum weight loss.
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Bio-Polishing of knit fabric with Cellulase Enzyme:
In the recent years enzymes have found a variety of uses in textile
applications. Popular uses are stone washing of denims and surface modification of
cellulosic fabrics to improve their appearance and handle. The process of treating
with cellulases is termed as bio-polishing. In case of denims one can get stone-
wash effect without using pumice stones by using enzymes. Another advantage of
using enzymes is that, these are environment friendly, since they are readily
biodegradable.
Besides, they will not leave chemical residue on the processed materials and the
colour changes on the dyed goods are very less.
Knitted goods treated with enzymes are free from surface hairiness and neps with
much improved handle and flexibility. The fabric surface becomes smoother and
more lustrous. There is also a lower tendency to further pilling possibly due to the
fact that there are less protruding fibre ends from the yarns after the enzyme
application.
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Favorable conditions of enzyme for Bio-finishing:
More than with other chemical reactions, the enzyme catalysed hydrolysis of
cellulose is strongly influenced by factors such as pH, temperature, time and
agitation. The optimal pH for a particular cellulase depends upon its origin.
Enzymes are more effective at pH 6 - 6.5. The reaction temperature is also
critical since at low temperatures, the reaction rate is slower than desired, but very
high temperature can deactivate the enzyme by providing enough energy to alter its
molecular alignments and thereby destroy its catalystic ability.
Since enzymes are true catalysts and are not consumed during the chemical
reaction, the hydrolysis reaction will continue until either the reaction conditions
change or the cellulose is physically removed from the reaction mixture.
Because the enzyme’s catalytic action is not reduced during the reaction,
effective methods of ending the hydrolysis must be employed to prevent excessive
fibre loss.
Since the molecule’s physical alignments are crucial to its catalytic ability,
procedures that alter the cellulase molecule’s internal structure can be used to
deactivate the catalysis and halt the hydrolysis. High temperatures (> 700C or
1600F for at least 20 min or short drying at 1200C or 2480F), high PH (>10) and
high electrolyte content as well as enzyme poisons can serve to terminate the
reaction by distorting the enzyme’s molecular shape.
PH - 5-6.5
Time - 1 hour
Temperature - 55◦C
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Procedure of bio-polishing of Knit Fabric:
• Load the fabric or garment in the machine • Fill the machine with water
• Add nonionic wetting agents (0.2 to 0.3 gpl)
• Adjust pH 4.5 to 5.5 with acetic acid
• Add 2 gpl lubricant (non-ionic)
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Process sequences of Bio-finishing:
Neutralization
Enzyme process
Dyeing
After Treatment
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Samples:
Recipe:
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Raw sample Bio-Polished sample (50 minutes)
Recipe:
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Raw Fabric Polished Fabric(1%)
Recipe:
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Advantages of using enzymes for bio-polishing are:
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Cellulase enzyme offers the following benefits:
Specific action on protruding fibers only.
Improves texture, softness and appearance of fabric.
Wide variety of application processes.
Eco-friendly & Biodegradable.
No damage to strength of fabric.
• Loss in weight
• Loss in strength
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Testing & Analysis:
The following tests can be carried out to assess the properties of bio-polished
cotton knitted fabric.
i) Wash fastness , ii) Abrasion resistance, iii) Weight loss, iv) Pilling.
– To achieve the high low abrasion (stone effect) on garment and seam
abrasion in sewing area.
– Enzyme attacks more the surface of the fabrics and gives a very
smooth surface
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Conclusion:
The most attractive feature of denim fabric is its washing effect. This is
produced by mechanical and chemical processing. The entire processes gives rise
to the wastage hence effluent and environment is polluting at a large scale. Enzyme
technology provides an environment friendly process to obtain the desired effect.
The bio-polishing of knit fabric can also be done with cellulase enzyme which
removes the protruding fibres of the fabric and gives a smoother, softer, Brighter
and cleaner fabric. The activity of the Enzyme can be controlled easily by
maintaining the PH, Temperature, Concentration and time.
The enzyme washing and Bio-polishing provides a better and uniform effect
over the conventional processes. Though the enzymes are costly but it is energy
and time saving over the conventional processes. The limitation of Enzyme
washing is that when localized washing effect is needed it is difficult to produce it.
In the future, enzyme technology will continue in importance as biochemists and
textile chemists strive to create new product and processing innovations to further
revolutionize textile processing.
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