Textile Manufacturing Research Articles

Untwisting Beycesultan Höyük: the earliest evidence for nålbinding and indigo-dyed textiles in Anatolia

Cuneiform tablets indicate the importance of textile manufacturing in the Bronze Age Old Assyrian Colony Period and Hittite Empire, yet the organic traces of this industry rarely survive. Two burnt textile fragments found at Beycesultan offer an unexpected insight into the Bronze Age textile industry in Anatolia. Here, the authors present the results of chromatographic and microscopic analyses that indicate one fragment was made from hemp using the nålbinding, or single-needle knitting, technique and was dyed with the woad or indigo plant, while the other was a natural tabby weave. Both add to our understanding of the diversity of textile production in the Bronze Age.

Into the Revolution of NanoFusion: Merging High Performance and Aesthetics by Nanomaterials in Textile Finishes

AbstractThe field of technical textiles has grown significantly during the last two decades, with a focus on functionality rather than aesthetics. However, the advancement of NanoFusion technology provides a novel potential to combine better functionality and aesthetic value in textile finishes. NanoFusion incorporates nanoparticles into textile treatments to improve waterproofing, stain resistance, durability, and breathability. This is performed without affecting the textile's visual appeal or aesthetics and may even improve them. This textile finishing revolution is expected to impact industries such as athletics, outdoor clothing, car upholstery, and luxury fashion. It offers cutting‐edge functionality while maintaining style and design integrity. Furthermore, the use of nanoparticle textile coatings opens up new opportunities for personalization and modification. Manufacturers and designers can now experiment with different color combinations, patterns, and textured finishes while maintaining performance characteristics. NanoFusion technology has the potential to transform the textile industry by providing hitherto unattainable levels of performance and aesthetics. This study reviews the current state of the art in nanofinishes for garment textiles, focusing on their many varieties, techniques, mechanisms, and applications. In addition, it addresses significant concerns such as sustainability and the environmental footprint, paving the way for a new era in textile manufacturing.

Modern-Day Green Strategies for the Removal of Chromium from Wastewater

Chromium is an essential element in various industrial processes, including stainless steel production, electroplating, metal finishing, leather tanning, photography, and textile manufacturing. However, it is also a well-documented contaminant of aquatic systems and agricultural land, posing significant economic and health challenges. The hexavalent form of chromium [Cr(VI)] is particularly toxic and carcinogenic, linked to severe health issues such as cancer, kidney disorders, liver failure, and environmental biomagnification. Due to the high risks associated with chromium contamination in potable water, researchers have focused on developing effective removal strategies. Among these strategies, biosorption has emerged as a promising, cost-effective, and energy-efficient method for eliminating toxic metals, especially chromium. This process utilizes agricultural waste, plants, algae, bacteria, fungi, and other biomass as adsorbents, demonstrating substantial potential for the remediation of heavy metals from contaminated environments at minimal cost. This review paper provides a comprehensive analysis of various strategies, materials, and mechanisms involved in the bioremediation of chromium, along with their commercial viability. It also highlights the advantages of biosorption over traditional chemical and physical methods, offering a thorough understanding of its applications and effectiveness.

Synthesis of Stearyl Alcohol/Polyethylene Glycol Hybrids as Water-Repellent Finishes for Cotton/Polyester Blended Fabric

AbstractNowadays, developing and innovation of new finishing agents that are cost effective, efficient, durable, and safe for the consumer as well as the environment are greatly required by the textile manufactures. In that concern, new stearyl alcohol/polyethylene glycol (SA/PEG) hybrids were synthesized, characterized, and applied as textile finishes to impart cotton/polyester fabric with water repellency. Such hybrids were synthesized by reaction of SA with PEG of molecular weight 1000 or 4000 Da in the presence of ammonium persulfate (APS) as initiator. The optimum conditions of the synthesis reaction are: APS/PEG, 20%; PEG/SA, 15%; reaction temperature, 80 °C and reaction time, 45 min. The synthesized hybrids are self-water dispersible that form oil-in-water stable emulsions. The results indicated that treating cotton/polyester fabric with easy-care finishing formulation containing 60 g/L of dimethyloldihydroxyethylene urea as a cross-linker, and 60 g/L of any of such hybrids emulsions imparts the treated fabric with water repellency, softness, and stiffness properties. Moreover, increasing the PEG molecular weight from 1000 to 4000 Da leads to a reduction in extents of softness and contact angle along with an enhancement in stiffness of treated fabric. Furthermore, the prepared hybrids emulsions-treated fabric samples are durable up to five washing cycles. The FTIR analysis confirmed the chemical structure of the synthesized SA/PEG1000 hybrid. The transmission electron microscope (TEM) revealed that the particles size of SA/PEG4000 hybrid emulsion is in the range of 34–70 nm and reaches to 185 nm in case of the SA/PEG4000 hybrid emulsion. The surface of SA/PEG1000 hybrid emulsion-treated fabric was characterized via scanning electron microscope (SEM).

Electrocoagulation treatment of wastewater collected from Haldia industrial region: Performance evaluation and comparison of process optimization

This study investigates the treatment of oil-contaminated wastewater with high levels of inorganic substances, suspended solids and turbidity, collected from the Haldia industrial region of India in February 2023. The wastewater, originating from industries such as chemical, petrochemical, textile, and battery manufacturing, presents a complex pollutant load that challenges traditional treatment methods. Electrocoagulation was employed as the treatment technique, with process optimization conducted using Box-Behnken design (BBD) and central composite design (CCD) for key parameters: pH, initial oil concentration, current density, and electrolysis time. The study comprehensively examined the effects of these parameters on turbidity removal. The optimal conditions were determined to be a pH of 7.5, an initial oil concentration of 275 mg/L, a current density of 17.5 mA/cm², and an electrolysis time of 20 min. Under these conditions, CCD outperformed BBD, achieving a desirability score of 93 % compared to 80 % for BBD. The process successfully reduced turbidity from 450 NTU to 56 NTU and total suspended solids (TSS) from 300 mg/L to 102 mg/L. The operation cost of the process was found to range from ₹0.904/m³ to ₹2.71/m³ as the electrolysis time increased from 0.17 to 0.5 h. The study presents a viable solution for industrial wastewater treatment in this region, aligning with the United Nations Sustainable Development Goal (UN SDG) 2030. Additionally, combining electrocoagulation with membrane filtration may enhance comprehensive pollutant removal.

Understanding and addressing the water footprint in the textile sector: A review

Abstract Textile industry has a significant water footprint (WF), leading to various sustainability challenges. This article discusses key findings on the WF and outlines potential solutions. The industry’s WF includes three types: green, blue, and grey. Textile manufacturing is water-intensive, with stages like pretreatment, dyeing, printing, and finishing. This can contribute to water scarcity in some regions. Water pollution is another critical challenge, as the industry generates considerable wastewater containing diverse pollutants which can harm ecosystems and pose risks to public health. Different treatments to reduce the pollutants in water are studied. We have grouped innovations into five major categories for water conservation efforts in the textile industry: To address these sustainability challenges, several solutions are proposed. Each category offers a pathway to reduce its environmental footprint through water conservation. The adoption of water-efficient technologies, such as low-water dyeing and wastewater recycling, can reduce water consumption. Stricter policies for pollution control, along with incentives for sustainable practices, can encourage industry-wide change. Collaboration among stakeholders, including industry, government, and environmental groups, is also crucial for promoting sustainability and reducing the industry’s environmental impact. These approaches can help the textile industry move toward a more sustainable future. Further research needed is suggested.

Made in South Asia: Centering Labor in Textile and Garment Manufacturing Work, 1970s to 2020s

Abstract Labor in the textile and garment industry is at the heart of a series of recent books on South Asia. Together these books document the different scales at which textile and garment work has been structured and restructured over the last century, and its implications for workers, their health as well as collective solidarity. Across the countries of Bangladesh, India, Nepal, and Sri Lanka, the industry developed and declined in vastly different temporalities and rhythms. Yet, as these works reveal, workers have often been confronted with similar challenges brought on by the boom-and-bust cycles of industrial development. In each case, textile and garment workers have been forced to navigate transitions to premature deindustrialization, closure, or national/transnational industrial policy changes. The books center workers and their long “post”-industrial or industrial “afterlives,” as they cope with the dramatic changes in the global manufacturing of textile and garment.

Revolutionizing Textile Manufacturing: Sustainable and Profitable Production by Integrating Industry 4.0, Activity-Based Costing, and the Theory of Constraints

The textile industry, a cornerstone of daily life and a highly globalized sector, faces significant environmental challenges due to its high water and energy consumption and extensive chemical usage. This study proposes a comprehensive green production planning and control model integrating Industry 4.0 concepts, activity-based costing (ABC), and the theory of constraints (TOC). The model utilizes mathematical programming to optimize product mix, maximize profitability, and minimize environmental impact. It leverages real-time sensing technologies and ERP systems to facilitate waste recovery, reduce carbon emissions, and achieve energy savings. Various carbon emission cost models, including continuous and discontinuous tax functions, are explored to balance corporate profitability with environmental sustainability. The findings demonstrate the model’s potential in optimizing resource utilization, reducing the environmental footprint, and enhancing profitability.

A novel human-centered methodology for assessing manual-to-collaborative safe conversion of workstations

The Industry 5.0 paradigm places workers’ well-being and safety at the core of the production processes. Despite its objectives, the current industry still faces several challenges. Examples of these challenges include global market pressures for customized products, along with the significant occurrence of Work-Related Musculoskeletal Disorders and the ageing workforce. These challenges underscore the persistent need for human-centered solutions, allowing adaptations that align with humans’ physical and cognitive constraints. Collaborative robots offer a promising solution, with the potential to enhance workers’ well-being, while maintaining safety, productivity, and production process flexibility. This study introduces a novel methodology designed to assess the feasibility of converting manual tasks into collaborative ones. During the development of the methodology, a focus group approach was used, comprising 6 experts in the field of Ergonomics & Human Factors and Robotics. The proposed methodology is suitable for the identification of tasks appropriate for joint execution by humans and robots, thereby augmenting the effectiveness of the robotic solution. This methodology incorporates a set of indicators (physical and cognitive ergonomics, health and safety, and operational efficiency) and technical requirements. The results of the focus group allowed the improvement of the suggested methodology. For its testing, we applied across 13 manual workstations in 5 companies from different manufacturing sectors (civil construction, cutlery, furniture, and automotive fabric manufacturing). Results show that it is possible to comprehensively identify manual workstations/tasks with good and high potential to convert into collaborative systems. This methodology seems to constitute a relevant approach to support the conceptualization of collaborative workstations.

Bioremediation of textile wastewater using Bacillus cereus isolated from refinery site: Comparative analysis of free and immobilized cells systems

The textile industries consume a considerable amount of freshwater and discharge untreated or semi-treated pollutants to the environment. Azo dyes, generally employed in textile manufacturing industries, have a hazardous impact on the ecosystem. Incomplete treatment of wastewater containing azo dyes discharges into the aquatic system, which has recalcitrant and toxic properties. Hence, the need for cost-effective and high-performing technologies is essential. In this direction, bacterial degradation is considered an economically viable and efficient technique for the treatment of Active blue (AB) dye. Polyurethane foam (PUF) is a low-cost and hydrophilic material with a microporous structure, which offers an excellent surface-to-volume ratio. Hence, PUF was preferred for the immobilization of isolated bacterial species. For this, a dye-degrading gram-positive bacteria namely Bacillus cereus GS2 IIT (BHU) was isolated from the petroleum sludge. A comparative analysis between free and immobilized cell systems was carried out by varying the process parameters, i.e., batch time, pH, temperature, glucose concentration, and initial AB dye concentration. The corresponding optimum conditions were found to be 6.0 days, 6.5, 30 °C, 1.0 g/L, and 50 mg/L, respectively. The immobilized cell system exceeds the dye removal efficiency (RE) by 10. 7 % compared to the free cell system. The packed bed bioreactor could be able to deliver 98.56 % of dye removal at an inlet loading rate of 30 mg/L d and 50 mg/L of initial dye concentration.

Industrial Pollution in Patna City : Physico-Chemical Analysis of Effluents and Their Effects on Water and Soil

Industrial pollution is a significant concern in Patna City, with rapid urbanization and industrial growth contributing to the degradation of natural resources. This study focuses on the physico-chemical analysis of industrial effluents and their effects on the water and soil quality in and around Patna. Effluents from various industries, including textile, sugar, rice mills, and small-scale manufacturing units, are released into nearby water bodies and soils, posing serious environmental risks. The research aims to assess the levels of pollutants by analysing key physico-chemical parameters such as pH, total dissolved solids (TDS), biochemical oxygen demand (BOD), chemical oxygen demand (COD), heavy metals (lead, chromium, cadmium), and organic contaminants in industrial effluents. Samples were collected from various locations near industrial zones and water bodies. The study also evaluated the impact of these pollutants on soil and groundwater quality. It was found that prolonged exposure to industrial effluents led to the accumulation of toxic metals in soil, reducing its fertility and altering its structure. Additionally, groundwater sources were contaminated with hazardous chemicals, making them unfit for drinking and irrigation purposes. The implementation of advanced treatment technologies and sustainable industrial practices is crucial for safeguarding the environment and public health in Patna City.

Harnessing Emotional Intelligence: Enhancing Employee Performance in Kerala’s Retail Textile Industry

This research explores the effects of EI (Emotional Intelligence) on employee performance in the retail textile industry in Kerala with specific reference to the moderating roles of organizational culture and leadership style. With the ever-growing demands of the retail sector, it is imperative to demonstrate the efficiency of EI in improving employee performance to support a sustained competitive advantage. This research adopts a descriptive research design, whereby both quantitative and qualitative data will be collected to capture the goals and objectives of the study. Structural equation Modelling (SEM) was used to determine the relationship between EI and the level of performance of employees, as well as the moderating role of organizational culture and leadership style. This study focuses on textile manufacturing employees of the selected retail outlets of Kerala, with a sample size of 250. The results are expected to help explain how EI can enhance performance, especially under conditions of leadership support and organizational culture. The implications of these findings should offer explicit counsel to managers in the retail textile industry to facilitate a work climate that boosts the emotional capabilities of workers, resulting in increased work efficiency and contentment. Apart from extending the body of knowledge on emotional intelligence and employee performance, the findings of this study provide an important guideline for the retail sector of Kerala with regard to emotional intelligence that must be developed to enhance performance and sustain business success in the future.

Efficient Fabric Classification and Object Detection Using YOLOv10

The YOLO (You Only Look Once) series is renowned for its real-time object detection capabilities in images and videos. It is highly relevant in industries like textiles, where speed and accuracy are critical. In the textile industry, accurate fabric type detection and classification are essential for improving quality control, optimizing inventory management, and enhancing customer satisfaction. This paper proposes a new approach using the YOLOv10 model, which offers enhanced detection accuracy, processing speed, and detection on the torn path of each type of fabric. We developed and utilized a specialized, annotated dataset featuring diverse textile samples, including cotton, hanbok, cotton yarn-dyed, and cotton blend plain fabrics, to detect the torn path in fabric. The YOLOv10 model was selected for its superior performance, leveraging advancements in deep learning architecture and applying data augmentation techniques to improve adaptability and generalization to the various textile patterns and textures. Through comprehensive experiments, we demonstrate the effectiveness of YOLOv10, which achieved an accuracy of 85.6% and outperformed previous YOLO variants in both precision and processing speed. Specifically, YOLOv10 showed a 2.4% improvement over YOLOv9, 1.8% over YOLOv8, 6.8% over YOLOv7, 5.6% over YOLOv6, and 6.2% over YOLOv5. These results underscore the significant potential of YOLOv10 in automating fabric detection processes, thereby enhancing operational efficiency and productivity in textile manufacturing and retail.

Fabric Defect Detection Using Transfer Learning

Transfer learning in fabric defect detection involves utilizing pre-trained deep learning models on a large dataset, typically from a different domain, and fine-tuning them on a smaller dataset that is specific to fabric defects. By leveraging transfer learning, the limitations of limited annotated data for fabric defect detection can be overcome by utilizing the knowledge gained from a more extensive and diverse dataset. The pre-trained model's learned features are adjusted to recognize specific fabric defect patterns, resulting in more accurate and efficient defect detection. This approach reduces the reliance on a massive labelled dataset for training, which is particularly beneficial in industrial applications where obtaining a vast amount of annotated fabric defect images may be challenging. Ultimately, transfer learning enhances the model's ability to generalize and detect fabric defects with higher precision, thereby contributing to improved quality control in textile manufacturing processes.

Enzymatic modification of cotton fibre polysaccharides as an enabler of sustainable laundry detergents

Cotton is the most common natural fibre used in textile manufacture, used alone or with other fibres to create a wide range of fashion clothing and household textiles. Most of these textiles are cleaned using detergents and domestic or commercial washing machines using processes that require many chemicals and large quantities of water and energy. Enzymes can reduce this environmental footprint by enabling effective detergency at reduced temperatures, mostly by directly attacking substrates present in the soils. In the present study, we report the contribution of a cleaning cellulase enzyme based on the family 44 glycoside hydrolase (GH) endo-beta-1,4-glucanase from Paenibacillus polymyxa. The action of this enzyme on textile fibres improves laundry detergent performance in several vectors including soil anti-redeposition, dye transfer inhibition and stain removal. Molecular probes are used to study how this enzyme is targeting both amorphous cellulose and xyloglucan on textile fibres and the relationship between textile surface effects and observed performance benefits.

Waste-based composites using post-industrial textile waste and packaging waste from the textile manufacturing industry for non-structural applications

The textile industry significantly contributes to environmental pollution, generating substantial amounts of waste. The prevailing linear model exacerbates this issue, accumulating a significant portion of the waste in landfills. This research aimed to tackle these challenges by developing value-added composites from post-industrial textile waste and packaging materials, for non-structural building applications. To achieve this, shredded polyester textile waste fibers served as the reinforcement, while waste packaging was used as the matrix. Varying fiber-matrix weight percentages seven composite types were developed. The physical, mechanical, and thermal properties of the composites were evaluated. The findings indicated that these composites exhibited properties comparable to those of commercial partition boards. Notably, composites with fiber weight percentages of 7.5 % and 10 % demonstrated the most favorable performance among the tested variations. Emphasizing the application of sustainable chemistry, this study highlights the potential of these composites to develop substitute materials for non-structural building applications. Moreover, it presents a promising solution to address the textile waste management challenge and value-added materials for the construction industry in a developing context.

Establishing an Incubator: Accelerating Sustainable Fashion SMMEs

The South African Clothing and Textile manufacturing industry has encountered substantial hurdles, notably job losses attributed to imports from regions with lower wage rates and inefficiencies within the value chain, exacerbated by the COVID-19 Pandemic. This situation underscores the potential for industry rejuvenation, particularly in light of escalating costs associated with importing clothing, encompassing labour and transportation expenses. A significant impediment to the industry's advancement is the absence of a robust design sector capable of generating innovative designs. The forthcoming research will delve into an exploration of literature pertaining to international fashion incubators, fashion districts, and fashion clusters. The insights gleaned will serve as the foundation for crafting a model aimed at expanding a clothing and fashion technopreneurship hub located in Cape Town, South Africa, with the specific aim of supporting graduates in the fields of clothing, textiles, or fashion. This strategic approach involves active engagement with emerging entrepreneurs to expedite their journey towards achieving pivotal economic objectives such as innovation and sustainability, thereby augmenting their competitive edge. Furthermore, this initiative aids these entrepreneurs in navigating the complexities associated with launching small businesses by facilitating access to pertinent best practices and customized technology support services tailored to their unique requirements.

Pretreatment and dyeability analysis of cotton and novel Bauhinia vahlii fiber

The textile industry is witnessing a paradigm shift towards sustainable materials, prompting the exploration of novel natural fibers as alternatives to synthetic fibers to meet environmental standards and address the growing demand for eco-friendly and sustainable products. Different natural fibers possess varied properties and are suitable for numerous applications in conventional and technical textiles. The coloration of these textile materials is an important aspect of conventional textiles, which starts with the pretreatment of the material. This study introduces a novel blend of cotton and Bauhinia vahlii fiber, a lesser-known natural cellulosic fiber with promising textile properties, and evaluates its pretreatment outcomes and dyeability characteristics. The study employs a systematic approach to pretreat the cotton and Bauhinia vahlii fiber blend (cotton: Bauhinia vahlii fiber 70:30) in a single bath using a conventional combined scouring bleaching process. The pretreatment process is carried out two times with varied sodium hydroxide (NaOH) and hydrogen peroxide (H2O2) concentrations for different processing times at 90 °C to assess the component fibers’ whiteness index, union bleaching balance, and weight loss percentage under diverse pretreatment conditions. Each time, 50% of the chemicals were used and continued for half of the processing time. The dyeability of the treated fibers is analyzed by dyeing the same in a single bath using amron bright red HF2R bifunctional reactive dye in varied shade depths (1%, 3%, and 5%) and fiber blend ratios (cotton: Bauhinia vahlii fiber 100:0, 90:10, 80:20, 70:30, and 0:100) to assess the color strength, union dyeing balance, and fastness properties. The maximum whiteness was achieved with 6 g per liter (gpl) of NaOH and H2O2 and at a processing time of 150 min with a whiteness index of 80.46 and 54.34 of cotton and Bauhinia vahlii fiber, respectively, with a union bleaching balance of 1.48. The dyed fibers’ colorimetric results confirm that Bauhinia vahlii fiber gives higher color strength than cotton fiber, irrespective of shade depth and blend ratio. The union dyeing balance of 1.2 was achieved at 5% shade depth with a 70:30 cotton Bauhinia vahlii fiber blend. This research contributes to the conventional textile field by introducing a sustainable fiber blend that reduces reliance on synthetic fiber and opens new avenues for utilizing Bauhinia vahlii fiber in conventional textile manufacturing.

The Influence of Compensation, Perceived Supervisor Support, and Career Development on Intention to Stay with Job Satisfaction as a Mediating Variable in XYZ Manufacturing Employees

This research aims to examine the company's efforts to retain competent employees in the textile industry. The research background shows that the textile industry in Indonesia has a significant contribution to the country's economy, but is faced with challenges in maintaining a competent workforce. The research was conducted at the company PT XYZ, one of the textile manufacturing companies in Tangerang. The method used is quantitative with the SEM-PLS analysis technique. Data was collected through questionnaires distributed to employees. This research aims to examine the influence of compensation, perceived supervisor support, and career development on intention to stay which is mediated by job satisfaction. The research results show that the work environment, superior behavior, career development and compensation are factors that influence employees' desire to continue working at the company. This research emphasizes the importance for organizations to create a conducive work environment, build good relationships between employees and superiors, and match the workload with the compensation received. These findings provide managerial implications for textile companies in managing human resources to maintain business sustainability and competitiveness.

A simulation model of thermal uniformity ratio applied in conductive thermal woven fabrics

Wearable technology based on conductive textiles generally focuses on the development of textile sensors and electric thermal textiles. The primary preparation methods currently used are coating and interweaving. Compared with the coating method, interweaving provides better deformability, durability, and a larger target functional range. Among them, woven conductive fabrics offer good stability, and by designing various jacquard patterns, multi-layer material structures can also be formed. Using woven conductive thermal textiles as a base, this paper established a thermal uniformity ratio simulation model through the design of fabric structure parameters and the analysis of thermal performance. This methodology provides possible design direction for such textiles, thereby enabling a reduction in production expenditure. Furthermore, it offers avenues for the realization of personalized adaptation and the transition towards the industrial-scale manufacturing of woven thermal textiles.