Process Developments

Process Developments Towards Cost Saving

Spinning Area

  • Tandem Carding - for improved cleaning efficiency and significant improvements in yarn appearance and imperfection level.
  • Incorporating Modifications with Respect to Roller Stand Slide, Nose Bars, Cradles, Spacers, etc. - gives 30% reduction in thick and thin places and a substantial improvement in U%
  • Certain modifications to drafting system have been carried out to improve the regularity and imperfection level in the yarn. These modifications include nose bar, soft cots and offsetting of back top roller. Combining the three modifications brings down imperfections by 38 to 49%.

Weaving Area

  • BTRA has developed a number of attachments/systems (electromagnetic linkages) to eliminate imperfect mechanical linkages of pirn change automatic looms to reduce fabric defects. All the systems are maintenance free and assessment of functioning of all the motions can be made merely through visual observations and without stopping the loom.
  • Opto-electronic sensors for retrofitting on stop motion bars of warping machine with V-creel.
  • Electronic let-off motion for conventional automatic pirn changing loom to enhance fabric quality meant for export.

Chemical Processing Area

  • Single Stage Bleaching Process in Kier for Cotton Fabrics - saves time, labour, water and steam.
  • Single Stage Bleaching Process in Jigger for Polyester/Cotton Blends - 50% saving in time with no increase in chemical cost.
  • Rapid Bleach Process for Cottons (Open-width) - loom-state to bleached in 15-20 minutes.
  • Novel Electrolytic Process to Reduce Consumption of Sodium Hydrosulphite in Vat Dyeing - 15-40% saving without substitute chemical.
  • Process for the Complete Substitution of Rongalite in printing - import substitution with saving in cost.
  • Fast Acting Catalyst System for Pigment Printing - saving in power or doubling of production.
  • Mono-step Sizing-cum-dyeing Process for Denims - import substitution.
  • Process to Improve Uptake of Reactive Dyes in Cotton - 25% saving in dyestuff consumption.
  • Novel Technique of Printing `Broken Effects' on Textiles - non-repeatable `batik' type effects.
  • Novel Technique for Polychromatic Printing on Textiles - varying multi-colour effects within printed design.
  • Durable FR Finishing - for all types of textiles including all cotton apparel and industrial fabrics, polyester/cotton blends and flannelettes.
  • Solvent Scouring - for reducing the incidence of oil stains in fabrics.
  • Curing/Thermosoling - colouration of textiles with indigenous rapidogen dyes.
  • A Novel Technique Using X-ray and IR Methods - for assessing the difference in the degree of mercerisation between two sides of foam mercerised sample, which was hitherto not possible to quantify.
  • Replica Technique - for studying different types of spinneret (both old and new) without destroying the ring.
  • Fabric Hand Evaluation System - can be fitted to a tensile testing system.
  • Electrolytic Reduction Clearing System - for obtaining dazzling tint-free grounds in carbonised polyester sorts.
  • Process for Deweighting both the Components of Polyester/Cotton Fabrics - enhances fabric aesthetics.
  • Modification of Existing Mercerising Process - for shortening the preparatory wet processing sequences for reduced consumption of energy, caustic soda and other utilities.
  • Biogas from Willow Dust
  • ATR-IR Spectroscopy - Simple and Quick Method - to estimate the proportion of PVA and starch in size mixture.
  • A Novel Kiering Technique - enables scouring/bleaching with considerable reduction in kiering time. Applicable to cotton and P/C blends.
  • Cleaning and Recycling of Used Gear Oil for Textile Mills
  • An Oxidative Treatment for Stripping of Disperse Dyes from Dyed Fabrics - enables satisfactory stripping at temperature below boil in the presence of a carrier.
  • A Rapid Processing Technique (RPT) - combines the process of scouring and bleaching. Suitable for dyeing cotton and blended fabrics.
  • All-in-method of Dyeing at Ambient Temperature Using Mixed Alkali System.
  • Integrated Control System to Eliminate Process Variation in Wet-on-wet Application in Textile Processing Incorporating Various Modifications.
  • Cost Efficient and Effective System - for cleaning of used oil in textile mills.
  • Replacement of Costly and Toxic Sodium Hypophosphite (SHP) with Non-toxic and Cheaper Tri-sodium Citrate in Formaldehyde-free Finishing of Cotton Fabrics Dyed with Various Classes of Dyes.
  • Replacement of BTCA Resin with Non-toxic Citric Acid Cross-linking Agent.
  • Microwave Radiation as a Suitable Alternative and Cost Effective Approach for Setting of Fibres.
  • BTRA has given practical suggestions to enable mills to save over 40 % in wash water through counter-current flow washing techniques and also recovery and recycling of chemicals.