TASKOPARAN, Erdinc (Keresteciler Sitesi Fatih Cad, Selvi Sokak No:18 Merter, Istanbul, 34169, TR)
CLAIMS
1. A process for production of environment friendly fabric and textile products without use of chemicals and/or synthetic agents and without applying sizing / desizing process characterized in that it comprises the following steps: - mixing of organic cotton and/or colored cotton fibers formed by means of converting the previously treated, used yarns and/or fabrics into fiber by opening, at certain rates,
- paralleling homogenized fiber mixtures at draw-frame,
- cleaning for removal of dirt captured in fibers and removal of fibers shorter than required length and forming fiber bundle,
- production of yarn from the obtained bundles,
- folding the produced yarns and subjecting them to spinning process,
- alignment of yarns side by side in the width of the fabric to be woven and in the targeted frequency in the fabric to be woven, and rolling on the beam, - conversion of the yarns into fabric by means of weaving,
- subjecting the obtained fabric to finishing process only with water vapor without use of any chemicals,
- applying the sanforizing process to the fabric after finishing without use of any chemical agents in order to provide shrink proof / dimensional stabilization,
- optionally, subjecting the obtained fabric to cutting and sewing processes and production of desired textile products,
- subjecting the produced fabric and/or textile product to washing and cleaning process under O 3 pressure without use of any chemical agents, - quality control of produced fabric and/or textile product.
2. The process according to claim 1 characterized in that the homogenized fiber mixture comprises organic cotton of 80% - 100% in weight and colored cotton fiber of 0-20% in weight formed by means of converting the previously treated, used yarns and/or fabrics into fiber by opening.
3. The process according to claim 1 characterized in that the fibers of the said homogenized fiber mixture are subjected to carding and drawing to make them parallel.
4. The process according to claim 1 characterized in that the said yarns are produced in the range of Ne12/1 - Ne30/1 by means of open-end technique.
5. The process according to claim 1 characterized in that the said yarns are subjected to spinning in range of 150 - 550 cycle/m at spinning machine.
6. The process according to claim 1 characterized in that the said O 3 pressure is 0,1 - 0,2 bar. 7. The process according to claim 1 characterized in that the said washing process is applied for 15 to 60 minutes.
8. The process according to claim 1 characterized in that the said washing is performed at the temperature range of 15°C and 60 0 C. |
PROCESS FOR PRODUCTION OF ENVIRONMENT FRIENDLY FABRIC
AND/OR TEXTILE PRODUCTS
TECHNICAL FIELD The invention relates to a process regarding production of environment-friendly fabric and textile products without use of any chemicals and/or synthetic materials.
The invention particularly relates to a process comprising the steps of obtaining fabric from 80% - 100% organic cotton and 20-0% colored cotton fiber without use of any chemical and/or synthetic agent and sizing/deizing procedures, finishing of the fabrics with water steam again without use of any chemical and/or synthetic agents, production of textile products from finished fabrics and washing and cleaning the textile products by means of oxygen and environment-friendly ozone again without use of any chemical and/or synthetic agents.
PRIOR ART New measures for protection against the problems such as environmental pollution, air pollution and water pollution emerging together with developing technology have been have been thought in particularly the developed countries so as to both sustain industrialization and protect the environment, it is pursued to provide solutions for use of raw material at minimum level, decrease of energy utilization in processes or pursue of clean power sources, use of non-harmful packing materials and easy ways of elimination thereof. The results of them reflect into all industry branches in way of big waves and have also influenced the textile sector, the biggest and most important sector in Turkey. It is an inevitable requirement for textile industrialists exporting products to Western European countries, particularly Germany to produce the textile products ecologically.
Ecological textile or eco textile products are the products produced observing the environmental requirements at all process steps from fiber to finished product, not causing harm to the user during use and recyclable after use or convertible into products not damaging environment.
Textile industry is one of the industries consuming the most water, air, chemical agents and power. Various processes are applied to textile products from raw material until finished product. Various chemicals and dyeing agents are applied to the textile goods under different conditions particularly at finishing operations so as to provide the requirements of the customers (color, gluing etc.).
Satisfying one of the three basic needs of man, the textile products are the product groups which are mostly in contact with human body after food products. The clothes being as if like skin of people and textile products having close contact with human body should not harm people in any way either through skin contact, breathing or respiratory. With this point of view in mind, what has the most meaning in terms of users and consumers is human ecology.
Effects of Textile Products on Human Health:
Depending on specie of fiber, dermatitis may occur on the skin (contact dermatitis = skin inflammation). In conventional dermatitis cases, the veins close to skin reddens and inflames. If not recovered in due time, the color of skin gets darker and deep scars may occur. Particularly, synthetic fibers cause dermatologic problems such as allergy etc.
Chrome dyeing agents of too bright and of lower wet fastness are harmful to health and carcinogenic. Reactive agents frequently used in textile industry are also highly dangerous. Reactive dyeing agents of high fastness and bright colors can react with proteins and cause allergy.
The color of the dyeing agent is also important in respect to environment. Dyeing a product in dark colors mean use of more dyeing agent and more chemical agents and water, that is all of them are dangerous in respect to environment. Particularly a good favor would be made for the environment of use of black is avoided.
Formaldehyde resins are used in wrinkle resistant and water proof finishing processes of cotton fabrics. Formaldehyde provides chemical fixing processes of wool products and used for disinfection of clothes and elimination of fungus. Formaldehyde reacts with skin proteins and causes occurrence of haptenic effect. In case of irritation, gangrene of epidemic tissues occurs. Upon breathing formaldehyde vapors, eye, throat and nose secretion increases and bronchial
irritation, bronchitis, coughing, skin ulceration can be seen. For that reason, the formaldehyde concentration should not exceed 5 ppm in operations working with formaldehyde and protective clothes, gloves and masks should be worn.
Epoxy resins are used together with poly acrylic and polyamine compounds during felt-proof processes and permanent pressing processes of woolen products. They may react with amines of the skin in sensitive people and cause start of dermatitis.
Some chemicals used in textile finishing contain some heavy metals even though the quantity thereof is minor. Some of heavy metal ions can penetrate into textile products via various dyeing agents. Nickel, cobalt, copper and chrome ions can penetrate into human body by means of sudation.
In addition to them, textile products are treated with various base and acid agents during finishing process. The acid and acidic residual remaining on the textile products can irritate the skin in humid ambient. For that reason, pH value of textile products should be same as normal pH value of human skin (pH 5,5). In conclusion, in order to eliminate the disadvantages of the existing related art, it has been necessary to make a development in the related art due to need for clothing products obtained from fabrics produced without use of chemicals and/or synthetic materials and for production processes for them and inadequacy of the existing solutions. OBJECT OF THE INVENTION
From this state of the related art, the object of the invention is to develop a process for production of environment-friendly fabric and/or textile products without use of any chemical and/or synthetic agents.
Another object of the invention is to ensure saving in power consumption needed for sizing / desizing by means of elimination of this process, and to prevent use of chemical agents.
A further object of the invention is to eliminate dyeing process wherein the chemical agents and power is consumed most highly in all textile production chain and to provide production of fabric and/or textile products sensitive toward human health.
A further object of the invention is to provide realization of finishing process by use of only water vapors so as to avoid use of chemical agents, and to prevent production of those chemicals, application of them to textile products and also prevent occurrence of harms caused to the environment during discharge after process.
Another object of the invention is to ensure application of fabric centering process by use of only water vapor so as to prevent use of chemical agents.
In order to achieve the said objects, a process comprising the following steps has been developed; - mixing of organic cotton and/or colored cotton fibers formed by means of converting the previously treated, used yarns and/or fabrics into fiber by opening, at certain rates,
- combing the fibers of the fiber mixture of homogenous form and paralleling them at draw-frame, - cleaning for removal of dirt captured in fibers and removal of fibers shorter than required length and forming fiber bundle,
- production of yarn from the obtained bundles,
- folding the produced yarns and subjecting them to spinning process,
- alignment of yarns side by side in the width of the fabric to be woven and in the targeted frequency in the fabric to be woven, and rolling on the beam,
- conversion of the yarns into fabric by means of weaving,
- subjecting the obtained fabric to finishing process only with water vapor without use of any chemicals,
- applying the centering process to the fabric after finishing without use of any chemical agents in order to provide shrink proof / dimensional stabilization,
- subjecting the obtained fabric to cutting and sewing processes and production of desired textile products,
- subjecting the produced fabric and/or textile product to washing and cleaning process under O 3 pressure without use of any chemical agents,
- quality control of produced fabric and/or textile product.
In order to achieve the said objects, the homogenized fiber mixture comprises organic cotton of 80% - 100% in weight and colored cotton fiber of 0-20% in weight formed by means of converting the previously treated, used yarns and/or fabrics into fiber by opening.
In order to achieve the said objects, the yarns are produced in Ne12/1 - Ne30/1 range by means of open-end production technique. In order to achieve the said objects, the yarns are subjected to twisting at 150 - 550 cycle/m at twisting machine.
In order to achieve the said objects, O 3 pressure is in the range of 0,1 - 0,2 bar.
In order to achieve the said objects, washing process is applied for a period from 15 to 60 minutes. In order to achieve the said objects, washing is performed at the temperature range of 15°C and 6O 0 C.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to a process for production of environment friendly fabric and textile products without use of any chemical and/or synthetic agents. The process developed under the scope of the invention comprising the following steps:
Preparation of Raw material:
The fiber, raw material used in all textile products, is obtained by natural, artificial and synthetic ways in general. Since use of chemical agents in production of artificial and synthetic fibers is inevitable, organic cotton made of natural fibers is used under the invention. In regard to the animal originated fibers falling within natural fibers, for instance the animal producing wool, since absolute control of feeding is not likely, they are also excluded from the scope of the invention.
Under the invention, only international ecologic certificated cotton (organic cotton) of 80 - 100% produced in fully controlled areas and under controlled conditions without use of any chemicals and chemical drugs is used.
In addition, colored cotton fiber of 20 - 0% by weight of, which is obtained by means of re-opening of previously processed, used but not usable anymore or disposable in normal circumstances in normal conditions of clothing fiber from confection clipping or materials such as part fabrics, at fiber opening machines is used to satisfy tastes and expectations of different consumers.
Fiber Preparation and Mixing (Blending - handling): Organic cotton from stock of desired rates and certain rates of fiber opened from previously used and colored reste yarn and fabrics are mixed to prepare blending prescription and blend lots are prepared. The purpose here is to provide same quantity of the mixture in each unit of the yarn or fabric to be formed.
Paralleling Fibers (Comb draw:) For conversion of the fiber mixture homogenized with blending-handling process into yarn, the fibers are paralleled and dirt remaining in fiber is removed and short fibers are removed. The fiber mixture are subjected to carding and draw-frame process under normal conditions and paralleling is provided and upon cleaning, the fiber bundle, in other words, strip is formed. Yarn production:
In the process of producing yarn from fiber, although there are several production methods, open-end yarning is preferred for producing yarn from strips because of economical reasons and technological conformance. The yarns are produced in Ne12/1 - Ne30/1 but preferably in Ne18/1 by use of open-end production technique.
Twisting:
Two yarns selected from varying range from Ne12/1 to Ne30/1 provided from organic cotton and previously colored used textile products by means of open-end yarning technique through opening are firstly folded and subjected to spinning at spinning machine at 150-550 cycles/m depending on fabric type and demand.
Spinning process is made essentially only by weaving but sizing requiring use of high chemical agent and power is eliminated.
Weaving Preparation / Warp Preparation:
The warp is prepared at the same quality as normal production process. Warp process is the process of paralleling yarns in the targeted frequency in the fabric to be woven and rolling on the beam. It is essential to roll the warp yarns on beam at equal tightness so as to conduct weaving without problem.
Warp Strengthening / Sizing:
Since weaving is the process of putting weft yarns in perpendicular to waft yarns of parallel position, warp yarns are subjected to varying and high forces of too high frequency. In order to provide strength of yarns to such high variable and high frequency, the warp yarns are coated with chemical agents called sizing in conventional weaving process and so protection is provided. However, application of sizing agent, the chemical compound and removal afterward require power which makes it as not always desired process. Sizing is not conducted under this invention and therefore, sizing removal process is not applied either. The power needed by such process is saved.
Coloring / Dyeing:
The dyeing process which is the process of all textile production chain wherein the most intense chemical agents are and power is used is not applied to the yam or fabric under the invention.
Fabric formation / Weaving or Knitting:
Under the invention weaving is made at weaving performance values at warp and weft yarn breaking rates without problem and at acceptable rates at all weaving looms where conventional box loom, rapier or projectile weft, armored or jacquard looms in, 3/1 - 2/1 - 1/1 and similar pattern design/weaving and constructions and yarns are converted into fabrics.
Under the invention, the yarns are converted into fabrics such as denim, gabardine, velvet etc. by means of weft warp or warp knitting techniques in addition to warp weft system.
Finishing :
Conventionally almost all textile products are subjected to finishing processes to provide additional functions such as softening, visual and weaving improvements or water pushing, oil pushing, sweat absorption. The said processes are almost always conducted in wet ambient by means of chemical agents and wastes harmful to environment occur during both production of the chemical agents and application to the textile as well as dispose after process. Under the scope of the invention, fabric finishing is realized by use of only water vapor.
Dimensional Fixing and Stress Removal / Sanforizing: Since the fibers are mechanically twisted and spun during conversion from fiber to yarn and from yarn to fabric, power is accumulated on them. It is because of that accumulated power that when the fabric is in free form, it moves to gain minimum power level. Movement of fabric occurs in general as fabric rotation or fabric wrinkling-shrinking. Such changes are the events not desired. In order to eliminate such changes, under the invention the fabric is subjected to sanforizing by use of only water vapor without use of any chemical agent and shrink-proof and dimensional stabilization is provided at thet end of the process.
Production of Textile Products / Cutting and Sewing:
Cutting and sewing of fabric does not contain any chemical agent use as it is in confectionary production, cutting and sewing processes are applied for production of pants, shirts, t-shirts and similar textile products under the invention.
Rock washing / providing attraction:
In order to provide user attractiveness of the fabric andOor textile product produced under the invention, lastly the oxygen (O 2 ) is converted into environment-friendly O 3 without use of any chemical agents such as enzyme - wetting-softening agents - chloride etc. and washing and cleaning process is conducted. This process changes the appearance and brightness of the fabric and/or textile product as per user expectations.
During this process O 3 pressure of 0,1 - 0,2 bar is formed while the doors are in closed position in bath of 50 liters. The fabrics produced under the scope of the invention are wetted and centrifuged wet and then subjected to washing at
temperature of 15, 30, 45, or 6O 0 C at O 3 pressure of 0,1 - 0,2 bar for 15, 30, 45, 60 minutes as per desired color effect.
Final Quality Control
As in all textile products, the fabric and/or textile product produced under the scope of the invention are subjected to known visual quality control before delivery to the users.
The protection scope of this patent application has been specified under the claims and can never be limited to the descriptions provided for sampling. It is obvious that any person skilled in the related art may suggest the innovation claimed under this invention by use of similar embodiments and/or may apply this embodiment to other arts used for similar purposes in the related art. Therefore, it is obvious that such embodiments will lack innovation and particularly exceeding the background of the related art.
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