Effect of Acid Cellulase at Different Concentration & Parameters on Wet Processing of Knitted Fabric

Last Updated on 11/04/2021

Effect of Acid Cellulase at Different Concentration & Parameters on Wet Processing of Knitted Fabric

Md Ali Kaium, Diponkar Tarafdar, Bulbul Ahmed, Durjoy Das,
H A M Ehsanul Haque, Protik Chakma, Akter Hossain,
Tanvir Khan, Azmi Aktar & Rifat Jarin
Textile Engineering College, Noakhali

Abstract:
Cellulase enzymes are nontoxic and environmentally friendly biocatalysts. They are capable of significantly improving the hand and appearance properties of cellulosic materials. As biotechnology makes rapid progress concerning the availability of these enzymes and their application conditions, this finishing process has reached enormous industrial importance over the past few years. Celluloses perform best at a specific pH range and a temperature around 40-55°C, and both tolerable temperature and pH have become much more flexible. As biocatalysts, very small amounts are sufficient to accelerate a specific reaction. The enzymes are not consumed during this reaction. Their deactivation is performed by a simple shift in temperature or pH. For this project commercially available acid cellulase enzyme systems were used. The treatments were carried out on 100% cotton knitted fabric. Try to show effect of acid cellulase at different concentration in this study and also try to show some effect on the color fastness properties of the cotton knitted fabric.

Introduction

REVIEW:
Textile processing has benefited greatly in both environmental impact and product quality through the use of enzymes. From the 7000 enzymes known, only about 75 are commonly used in textile industry processes (Quandt & Kuhl 2001). The principal enzymes applied in textile industry are hydrolases and oxidoreductases. The group of hydrolases includes amylases, cellulases, proteases, pectinases and lipases/esterases. Amylases were the only enzymes applied in textile processing until the 1980s. These enzymes are still used to remove starch-based sizes from fabrics after weaving. Cellulases have been employed to enzymatically remove fibrils and fuzz fibers, and have also successfully been introduced to the cotton textile industry. Further applications have been found for these enzymes to produce the aged look of denim and other garments

BASIC DEFINITION:

• ENZYMES – Greek word “ENZYMOS” Meaning – in the cell / from the cell.
• Enzymes – Proteins composed of amino acids produced by all living organisms.
• Responsible for number of reaction & biological activities.
• Molecular weight is high & they are specific in their action. Effectiveness depends on their environment: pH, temperature, time, presence of electrolyte.
• Major functions- hydrolysis, oxidative, reduction coagulation & decomposition.

USES OF ENZYMES IN TEXTILE:

• Amylase → (desizing) → Used for cotton fabric to remove starch
• Cellulase→ (Washing) →Bio-finishing cellulosric fabric & garments.
• Pectinase → (Scouring) →pH: 8-9, Temp: 65^oC (BIO-SCOURING)
• Catalase Hydrogen per oxide killer.
• Laccase Used for oxidation of dyes such as indigo.
• Protease Used for protein fiber, wool, silk degumming

ACCORDING TO THE BIOLOGICAL SOURCE ENZYMES ARE TWO TYPES:

1) Animal / pancreatic: Degamma, Novofermosol, trypsin.

• Temperature: 50-55^oC
• PH: 7-7.5
• Concentration: 1-5 g/l

2) Vegetable: It has also two types

a) Malt extract: Maltoferment, Diastase, Deglatol.

• Temperature: 55-60^oC
• PH: 5.5-6.5
• Concentration: 3-20 g/l

b) Bacterial: Acry, Biolase, Rapidase.

• Temperature: 65-70^oC
• PH: 5.5-7.5
• Concentration: 0.5-3 g/l

CHARACTERISTICS OF ENZYMES:

• Used during the process & can be recovered at the end.
• Requires low activation energy – reaction conditions are close to the ambient.
• Sharp control over process conditions. Very sensitive to pH & temperature variations.
• Eco-friendly & accomplish their work quickly and efficiently without leaving any pollutions behind.

ENZYME & THEIR ATTACKING ZONE:

THE CHEMISTRY OF ENZYMES:
Enzymes are naturally-occuring proteins capable of catalysing specific chemical reactions and being catalysts, facilitate the reaction without being consumed. After catalysing the chemical reaction, therefore the enzyme is released and is able to catalyse another reaction-and so on. Enzymes have a protein like structure with primary, secondary, tertiary and quaternary structures and are susceptible to denaturing (degradation due to temperature, ionising radiation, light, acids, alkalies and biological effect factors). The textile and clothing sector are now a major user of enzymes during manufacturing and after-care. Table-1 summerises some of the already important established enzymes. Cellulases are widely used in textile application. Cellulases are high molecular colloidal protein catalysts in metabolic form and are commonly produced by soil-dwelling fungi and bacteria.

Industrial cellulases are complexes of a number of cellulases, cellobiase and related enzymes in non-uniform composition, with molecular weight ranging from 10,000 to 4,00,000. Cellulases comprise a multicomponent enzyme system, including endoglucalases (EGs) that hydrolyse cellulose chains randomly, cellobiohydrolases (CBHS) that split cellobiose from cellulose ends, and cellobiases that hydrolyse cellobiose to glucose. EG or EG-rich preparations are best for aging and defibrillation of fibre surfaces, while complete cellulase systems are best for cleaning and depilling effects. In general, there are two major commercial classifications of cellulase enzymes based on optimum ranges _9 ‘acid cellulases’ exhibit the most activity within the pH range 4.5- 5.5, at a temperature of 45-55~ ; while ‘neutral cellulases’, are more effective in the 5.5-8.0 pH range at 50-60~. Currently, acid cellulases and neutral cellulases are more commonly used. With alkaline cellulases, there is a possibility of applying the enzymes in combination with reactive dyes from a dye bath.

MECHANISM OF ENZYME ACTION ON COTTON TEXTILES
Enzyme’ s effect mechanism, i.e. enzyme catalysis, operates first of all to form an enzyme substrate complex. Direct physical contact of enzyme and substrate is required to obtain the complex. The current proposed mechanism of cellulase action is illustrated in Figure-1.

However, the mechanism of enzymatic hydrolysis of cellulosic materials is complicated and not yet fully understood. Enzymes contain true activity centre in the form of three-dimensional structures like fissures, holes, pockets, cavities or hollows. Endoglucanases or endocellulases hydrolyse cellulose polymers randomly along the chains, preferably attacking non-crystalline region. Cellobiohydrolases or exo-cellulases, attack the polymer chain ends and produce cellobiose. Coupled with the binding domains associated with the enzyme, exo-cellulases may assist in degradation of cellulose by disrupting the local crystalline cellulose structure, which makes the region more susceptible to subsequent hydrolysis by endo-cellulases. Fig-2 shows the reducing and non-reducing end groups by the action of cellulase on 1,4-[3-glycoside bond lase on 1,4-[3-glycoside bond of the cellulose molecule. [3-glucosidases hydrolysc small chain oligomers, such as cellobiose into glucose.

The three types of cellulase component act synergistically in degrading cellulose to glucose. Synergism of different components in the cellulase complex and inhibition mechanisms further complicate the reaction. Enzyme diffusion plays a much more decisive role in the heterogeneous system of soluble enzyme and solid substrate. The kinetics of reaction therefore depend on the diffusion of enzyme to and into the solid phase of the substrate and the diffusion of the reaction products out of the solid phase into the liquor. For cotton, the restriction of the enzyme to the fiber surface is easily achieved because cellulose is a highly crystalline material and possesses only small amorphous areas, making the diffusion of enzymes into the interior of the fiber nearly impossible. Thus, by regulating enzyme dosage and choosing the right type of enzyme, the catalytic action of the enzyme can be confined to the surface of cotton and to the amorphous regions, leaving the fibers, as a whole, intact.

OBJECTS:

1. To know the effect of acid enzyme (low & high conc.) on knitted fabric.
2. To know the effect on wash fastness properties of fabric due to use acid enzyme.
3. To know the effect on rubbing fastness properties of fabric due to use acid enzyme.
4. To know the effect on perspiration fastness properties of fabric due to use acid enzyme.
5. To know the whiteness (Reflectance) properties of both treated & untreated fabric by using data color.

MATERIAL & METHOD:

1. Material specification:

• Fabric type: single jersey
• GSM: 160
• Sample wt.: 10gm

2. About acid cellulase:

• Brand name: Lerzyme 2000
• Country: china

Processing method:

1. Enzyme treatment recipe: Acid cellulase (Bio-polish enzyme)

• Lerzyme 2000: High conc.- 0.1-0.4%, Low conc.- 0.4-0.8%
• PH: 5
• M: L = 1:10
• Temp: 50-60ºC
• Time: 1hr

2. Dyeing recipe: Scouring & Bleaching

• NaOH = 5gm/l
• H₂O₂ = 5gm/l
• Wetting agent = 2gm/l
• Sequestering agent = 2gm/l
• Stabilizer = 2gm/l
• M: L = 1:15
• Temp. = 105°C
• Time = 50min
• Sample = 5gm
• Dyes = according to shade

DYEING SEQUENCE:

M/C load
↓
Detergent & other chemical
↓
70ºC X 10ʹ
↓
DRAIN
↓
NORMAL WACH
↓5-10ʹ
WATER FULL
↓
SCOURING CHEMICAL(INJECT)
↓
CAUSTIC(DOSING) 50-60ºC
↓
H2O2 @ 70ºC
↓
98ºC 50ʹ
↓
DRAIN
↓
RINSE
↓
ACID
↓
PH CHECK
↓
ENZYME
↓55ºC X 1hr
SAMLPE CHECK
↓
70ºC X 5ʹ
↓
DRAIN
↓
RINSE
↓
LEVELLING & OTHER CHEMICAL
↓
SALT DOSING
↓
COLOR (DOSING)
↓10ʹ
SODA DOSING
↓
STEAM (60ºCX 60ʹ)
↓
COOLING
↓
SAMPLE CHECK
↓
DRAIN
↓
RINSE
↓
NORMAL HOT 70ºCX10ʹ
↓
ACID
↓
DRAIN
↓
ACID SAMPLE CHECK
↓
DRAIN
↓
RINSE
↓
SOFTENER
↓ 10ʹ
FINAL SAMPLE CHECK
↓
UNLOAD

TESTING METHOD:

Color Fastness: 
The resistance of a material to change in any of its color characteristics, to transfer its colorant to adjacent material or both as a result of exposure of the material to any environment that might be encountered during the processing, testing, storage or use of the material.

Types of color fastness:

• Wash fastness to hot water as per ISO method
• Wash fastness to cool water as per ISO method
• Rubbing fastness (dry & wet)
• Light fastness
• Perspiration fastness
• Dry cleaning fastness
• Chlorinated or sea water fastness

Factors affecting color fastness:

• Dye size or molecular structure of a dye
• Types of bonding (i.e., ionic, co-valent, H-bond etc.)
• Amount of dye present in fibre
• Chemical nature of fibre or compatibility of dye with fiber
• Presence of other chemicals like binder
• The actual condition prevailing during exposure and after treatment

Reasons of color loss:

• Due to decomposition of dye molecules
• Due to removal of external media
• Due to reaction of dye molecules with acid, alkali, or perspiration
• Due to friction with other surface

Washing fastness (ISO 105):

Recipe:

1) Anhydrous sodium carbonate = 2gm/l
2) ISO standard soap = 5gm/l

• M: L = 1:50
• Sample size: 10cm×4cm
• Adjacent fabric: 5cm×4cm
• Temperature: 60 oC
• Time: 30 min

Assessment:

Rubbing fastness (ISO 105):

Two type:
a) Dry rubbing,
b) Wet rubbing

• Sample size: 20cm×5cm
• Crock fabric (WHITR): 5cm×5cm
• No. of rotation: 10
• Time: 10 sec
• Load: 9N±5%

Assessment:

Perspiration fastness:

Recipe:

• Di sodium hydrogen orthophosphate di-hydrate NaHPO4 = 2.5 g/l
• L-histidine hydrochloride mono hydrate = 0.5gm/l
• Sodium chloride NaCl = 5g/l
• Time = 4hr
• Temp = 37°C

Grey scale for assessing change in shade:

EN ISO 105-A03 / IUF 132 / VESLIC C 1211
This Grey Scale is for assessing the degree of change in shade caused to a dyed Textile fabric / yarn in color fastness tests. For example, the change of shade of wool and cotton fabrics in the wash fastness, perspiration fastness etc. The scale consists of nine pairs of gray color chips each representing a visual difference and contrast.

The fastness rating goes step-wise from:
Note 5 = no visual change (best rating) to Note 1 = a large visual change (worst rating).

The gray scale has the 9 possible values:
5, 4-5, 4, 3-4, 3, 2-3, 2, 1-2, 1.

It is now quite common to measure the Grey Scale change in color instrumentally. This is made using a suitable reflectance spectrophotometer according to the test method procedure, EN ISO 105-A05.

Grey scale for assessing staining:

EN ISO 105-A03 / IUF 132 / VESLIC C 1211
This Grey Scale is for assessing the degree of staining caused by a dyed Textile / yarn in color fastness tests. For example, the staining of wool and cotton fabrics in the wash fastness, perspiration fastness, etc. The scale consists of nine pairs of gray color chips each representing a visual difference and contrast.

The fastness rating goes step-wise from:
Note 5 = no visual change (best rating) to Note 1 = a large visual change (worst rating).

The grey scale has the 9 possible values:
5, 4-5, 4, 3-4, 3, 2-3, 2, 1-2, 1.

It is now quite common to measure the Grey Scale for assessing staining instrumentally. This is made using a suitable reflectance spectrophotometer according to the test method procedure, EN ISO 105-A04.

MACHINE USE IN THIS PROJECT WORK:

1) DATA COLOR:

2) GYROWASH (FOR WASH FASTNESS TEST)

3) CROCKMETER (FOR RUBBING FASTNESS):

4) LIGHT BOX:

5) Perspiration meter:

MACHINE SPECIFICATION:

1) Spectrophotometer (data color):

• Data color spectrum
• Designed in USA

2) Washing & Dry-Cleaning Color Fastness tester:

• Model: 41518
• Brand: James H. Heal
• Origin: UK

3) Crockmaster:

• Brand: James H. Heal
• Origin: ENGLAND

4) Light box:

• Model: CAC-60
• Brand: Verivide
• Origin: UK

5) Perspiration meter:
Phenolic yellowing tester

• Model: HX30
• Brand: James H. Heal
• Origin: UK

Effect of Bio-polishing:

RESULT & DISCUSSION:

WEIGHT LOSS OBSERVATION:

FASTNESS PROPERTIES OBSERVATION:

1) WASH FASTNESS RATING (DEGREE OF STAINING)

2) WASH FASTNESS RATING (DEGREE OF COLOR CHANGE)

3) PERSPIRATION FASTNESS RATING:

4) RUBBING FASTNESS:

WHITENESS INDEX:

ACID CELLULASE= LOW CONC. [0.4%, 0.6%, 0.8%], & HIGH CONC. [0.1%, 0.2% ,0.4%]

CIE L* a* b* DATA OBSERVATION:

DISCUSSION:

1. If concentration of acid cellulase increase then brightness also increases.
2. If concentration of acid cellulase increase then whiteness also increases.
3. If concentration of acid cellulase increase then yellowness decrease.

CONCLUSION:
Thus the “Enzyme” replaces traditional method with more advantage such as-

1. Replace harmful chemical.
2. Require less effluent treatment
3. Low cost and less energy consumption.
4. No damages to material.

LIMITATIONS:

1. We have less time to complete the work so we could not narrate our research deeply.
2. More shortage of raw material & chemical.
3. We does not got proper help for the Industries so we could not implement our research practically.
4. Economic bound us within great limitation

You may also like:

1. Application of Enzymes in Textile Processing
2. List of Garment Washing Chemicals and Their Functions

Mazharul Islam Kiron

Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. He is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.

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