Textile Processing Research Articles

Effect of Washing Process on the Release of Microplastics from Polyester Fabrics

Microplastics (MP), consisting of particles under 5 mm in size, and fibrous microplastics (FMPs), which originate from textiles and are shed during the washing process, are acknowledged as a new and expanding category of pollutants. This study aimed to conduct an analytical evaluation of the defragmentation process of polyester fabrics featuring a prominent tri-color pile surface. The evaluation involved washing the fabrics with detergent and water and employing various methods to assess the fabric, wastewater, and filter cake both prior to, and following, cryogenization. The specificity of a pile polyester fabric provided a baseline for evaluating the detergent and water system. Subjecting the polyester fabric to five cycles of washing in a detergent solution and water resulted in a measurable loss of mass. The pristine polyester fabric was analyzed microscopically and by FTIR, while the fabrics before and after washing were subjected to gravimetric analysis. The physico–chemical characteristics of the wastewater, such as the conductivity, turbidity, and chemical oxygen demand, were impacted by the composition of the washing bath. The application of pyrolysis, combined with gas chromatography and mass spectrometry (Py-GC/MS), on the filter cake demonstrated the value of using blank samples. The results indicated that both the detergent and the water significantly affected the release of FMPs during the washing process. Polyester fabric sample 1, which was washed in a detergent solution for five cycles, exhibited a mass loss of 1619 mg kg−1. In contrast, sample 2, consisting of a polyester fabric washed solely in water, showed a mass loss of 1707 mg kg−1 over the same number of cycles.

Global initiatives for industry 4.0 implementation and progress within the textile and apparel manufacturing sector: a comprehensive review

ABSTRACT A comprehensive picture on global initiatives to Industry 4.0 (I4.0), technological evolution within fibre-to-apparel manufacturing and its progression so far are reported here. Germany is the global progression leader while other developed countries; France, Italy, Spain, Portugal, and even the UK and USA have generic initiatives for upgraded manufacturing. Their initiatives are I4.0 strategies, funding, platforms, and model projects. Developing countries like Indonesia, Malaysia, Thailand, Brazil, Turkey, Vietnam, India, etc. have also taken I4.0 national initiatives. However, the apparel and textile manufacturing industry lags far behind other sectors, although applying I4.0 technologies in this sector has started. CPS, IOT, Cloud computing, Automatic bobbin changing, RFID, Blockchain, augmented reality, and digital twins, are found in the textile production and fashion retailing. Moreover, advanced machineries offer incorporated automation, remote maintenance and operability, cloud systems, self-optimization, and predictive maintenance facilities. The review identifies that technological gaps between concept and reality hinder commercial application. The readiness evaluation is predominantly grounded in academic literature, which requires field investigation from the start to the end of textile processing. Hence, case studies for empirical data, sustainability mapping for the upgraded technologies and integrated policy development are the future direction in this domain.

Microcontaminants and microplastics in water from the textile sector: a review and a database of physicochemical properties, use in the textile process, and ecotoxicity data for detected chemicals.

Microcontaminants (MCs) and microplastics (MPs) originating from the textile sector are today receiving a great deal of attention due to potential environmental concerns. Environmental pressures and impacts related to the textile system include not only the use of resources (e.g., water) but also the release of a wide variety of pollutants. This review's main objective is to highlight the presence of textile MCs and MPs in water, in their full path from textile factories (from raw materials to the final product) to wastewater treatment plants (WWTPs), and finally to the receiving surface waters. Their environmental fate and ecotoxicity were also addressed. Overall, more than 500 compounds were found, many of which are so called "contaminants of environmental concern" such as per- and polyfluoroalkyl substances (PFAS) and alkylphenol compounds. A database of physicochemical properties, ecotoxicity, and place of detection (specific textile process, WWTP, surface water or sediment) (classification by several international agencies) was compiled for the chemical detected. Preliminary risk assessment was conducted for those MCs for which the reported environmental concentrations exceeded the Predicted No Effect Concentration (PNEC). These chemicals were some nonylphenols, nonylphenol ethoxylates and organophosphate esters. Among MPs, polyester and nylon fibres were the most abundant. The highest concentration of MPs was reported in sludge (about 1.4 × 106 MPs per kg) compared to wastewater and surface water which showed MP concentrations at least two orders of magnitude lower. The role of transboundary contamination due to the release of chemicals from imported textile products was also assessed.

The Role of Ionic Liquids in Textile Processes: A Comprehensive Review.

Thanks to their unique physicochemical properties, ionic liquids (ILs) have moved from niche academic interest to critical components in various industrial applications. The textile industry, facing significant environmental and economic pressures, has begun to explore ILs as sustainable alternatives to traditional solvents and chemicals. This review summarizes research on the use of ILs in various textile processes, including dyeing, finishing, and fiber recycling, where their high thermal stability, tunable solubility, and low volatility are exploited to reduce resource consumption and environmental impact. The discussion also extends to the integration of ILs in textile waste recycling, highlighting innovative approaches to fiber dissolution and regeneration aimed at circular economy goals. Despite these advances, challenges such as high production costs and scalability remain barriers to the widespread adoption of ILs in the textile sector. Addressing these barriers through continued research and development is essential to fully realize the potential of ILs for sustainable transformation in textiles.

PEDOT/Polypyrrole Core-Sheath Fibers for Use as Conducting Polymer Artificial Muscles.

Electropolymerized polypyrrole (PPy) is considered as one of the promising polymers for use in ionic-electroactive or conducting polymer (CP) actuators. Its electromechanical properties surpass those of other prominent CPs such as poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT/PSS) or polyaniline. However, freestanding and linear contracting actuator fibers made solely of electropolymerized PPy are not available yet. This work therefore targets the development of all-CP-based actuator fibers: electromechanically active PPy is electropolymerized on the surface of wet-spun, also electromechanically active PEDOT/PSS fibers. The thickness of the PPy fiber sheath is varied by using different electropolymerization durations. Mechanical and actuation properties of the different PEDOT/PPy core-sheath actuator fibers are investigated via tensile tests and isotonic actuation strain and isometric actuation force measurements, respectively. The fiber actuators show high tensile stability in both dry and aqueous conditions, rendering them highly suitable for actuation in aqueous electrolyte media. Regarding linear, untwisted, and uncoiled CP fiber actuators, the presented actuation measurements demonstrate to the best of our knowledge the highest reported linear contractile actuation strains of up to 2.2% in electrolytes and remarkable tensile actuation stresses of 1.64 MPa, as well as a high long-term cyclic actuation stability using varying actuation durations. This renders the fibers as a highly promising material, particularly with regard to their further structural textile processing for use in actuating wearables or soft robots.

Membrane Treatment to Improve Water Recycling in an Italian Textile District.

The textile district of Prato (Italy) has developed a wastewater recycling system of considerable scale. The reclaimed wastewater is characterized by high levels of hardness (32 °F on average), which precludes its direct reuse in numerous wet textile processes (e.g., textile dyeing). Consequently, these companies utilize ion exchange resins for water softening. However, the regeneration of the resins results in an increased concentration of chlorides in the reclaimed wastewater that exceeds the limit set by Italian regulations for the reuse of water for irrigation purposes. The objective of this study is to investigate the potential of membrane filtration as an alternative method for removing hardness from water. Therefore, an industrial-scale ultrafiltration-nanofiltration (UF-NF) pilot plant was installed to test the rejection of hardness from the reclaimed wastewater. The experiment employed two types of NF membranes and three permeate fluxes (27, 35, and 38 L·m-2·h-1) for testing. The results demonstrated that the system could remove hardness with efficiencies exceeding 98% under all conditions tested. The experimental findings indicate that the UF-NF system has the potential to be employed as a post-treatment step to render the reclaimed wastewater suitable for all textile finishing processes and to expand the scope for reuse.

Evaluation of Sericin/Polyvinyl Alcohol Mixtures for Developing Porous and Stable Structures.

Fibrous by-products, including defective or double cocoons, are obtained during silk processing. These cocoons primarily contain fibroin and sericin (SS) proteins along with minor amounts of wax and mineral salts. In conventional textile processes, SS is removed in the production of smooth, lustrous silk threads, and is typically discarded. However, SS has garnered attention for its antioxidant, antibacterial, biocompatible, and anticancer properties as well as its excellent moisture absorption, making it a promising polymer for biomedical applications. Owing to its functional groups (carboxyl, amino, and hydroxyl), SS can blend and crosslink with other polymers, thereby improving the mechanical properties of sericin-based materials. This study explored the effects of different SS/polyvinyl alcohol (PVA) ratios on porous scaffolds fabricated via freeze-drying, focusing on the mechanical stability, water absorption, and protein release in phosphate-buffered saline (PBS). The scaffold morphology revealed reduced porosity with higher SS content, while increased PVA content led to material folding and layering. A greater PVA content enhanced water absorption, mechanical properties, and thermal stability, although SS release decreased. These results demonstrate that scaffold properties can be tailored by optimizing the SS/PVA ratio to suit specific biomedical applications.

Role and Application of Automation and Robotics in Spinning Section in Textile Industry

Modern technology transformation and the introduction of automatic machinery have changed the textile industries in numerous ways. There is development of advanced equipment and systems and they are being used in various manufacturing processes by manufacturing industries. The arrival of computer-controlled machinery has made it possible to complete industrial tasks more quickly, improving product quality and efficiency and lowering energy and production costs. Numerous aspects of the textile manufacturing process make extensive use of automation. Robotic applications are hugely used in yarn manufacturing technology among different textile automation divisions. The paper discusses various textile yarn spinning techniques and how automation has revolutionized these procedures. It provides comprehensive information on automation and robotic applications, from fiber opening in the blow room to yarn packaging in the winding in the spinning section.

Role of mordants in natural fabric dyeing and their environmental impacts.

The textile industry is undergoing a transformative shift towards sustainability, driven by mounting environmental concerns and consumer demand for eco-friendly products. This review article explores the use of mordants in textile dyeing processes, encompassing both traditional metal mordants and emerging bio-mordants. Metal mordants, commonly used in textile dyeing, present environmental challenges due to their toxic nature. In response, there is a growing interest in bio-mordants derived from natural sources such as plants and waste materials, offering a more environmentally friendly alternative. The review provides an overview of various mordants, including their sources, properties, and applications, highlighting their roles in enhancing fabric color fastness and functional properties. In addition to evaluating the environmental implications of metal and bio-mordants, the review identifies the key challenges involved in adopting bio-mordants on an industrial scale, such as availability, cost, and processing limitations. The potential benefits and limitations of both types of mordants are discussed in the context of sustainability, alongside recent technological advancements and innovative approaches to natural dyeing. By understanding and embracing mordants, particularly bio-mordants, the textile industry can progress towards sustainable coloration practices, meeting the demands of environmentally conscious consumers.

Surface modification of fabrics using dielectric barrier discharge plasma for improved antifouling performance

Surface modification of fabrics is an effective way to endow them with antifouling properties while still maintaining their key advantages such as comfort, softness and stretchability. Herein, an atmospheric pressure dielectric barrier discharge (DBD) plasma method is demonstrated for the processing of silk fabrics using 1H, 1H, 2H, 2H-perfluorodecyltriethoxysilane (PFDS) as the precursor. The results showed the successful grafting of PFDS groups onto the surface of silk fabrics without causing damage. Meanwhile, the gas temperature is rather low during the whole processing procedure, suggesting the non-equilibrium characteristics of DBD plasma. The influence on fabrics of the processing parameters (PFDS concentration, plasma treatment time and plasma discharge power) was systematically investigated. An optimum processing condition was determined to be a PFDS concentration of 8wt%, a plasma processing time of 40 s and a plasma power of 11.87 W. However, with prolonged plasma processing time or enhanced plasma power, the plasma-grafted PFDS films could be degraded. Further study revealed that plasma processing of silk fabrics with PFDS would lead to a change in their chemical composition and surface roughness. As a result, the surface energy of the fabrics was reduced, accompanied by improved water and oil repellency as well as enhanced antifouling performance. Besides, the plasma-grafted PFDS films also had good durability and stability. By extending the method to polyester and wool against different oil-/water-based stains, the DBD plasma surface modification technique demonstrated good versatility in improving the antifouling properties of fabrics. This work provides guidance for the surface modification of fabrics using DBD plasma to confer them with desirable functionalities.

Analysis of Identifying and Correcting the Digital Printing Defects in Pakistan's Textile Industry

This paper provides an in-depth examination of the issues hindering the adoption of digital textile printing in Pakistan. It presents background on commonly used printing techniques, and analyses industry data to identify major printing defects using quality tools such as Pareto charts and correlation analysis. The root causes of the main defects were determined through cause-effect diagrams and the 5 Whys approach. Preventive solutions are proposed in connection with fabric preparation, process controls, equipment maintenance, training, and sustainable practices. Instead of recommending broad strategies, the study focused on actionable solutions for addressing specific challenges in digital printing, including practical measures for improving operational efficiency in recycling. The analysis provides a comprehensive roadmap for Pakistan's textile industry to overcome current limitations and successfully transition to digital systems for improved productivity, innovation, profitability and global competitiveness.

Enhanced methylene blue removal from aqueous solution by electrocoagulation technique using combined iron and copper electrode

The rapid advancement in the industrial sector, particularly within the textile industry, necessitates the use of colorants for fabric processing, with methylene blue being a predominant choice. However, the improper disposal of methylene blue dyes can lead to significant environmental hazards, underscoring the need for effective treatment methods before release into ecosystems. This study explores electrocoagulation, an innovative treatment technique powered by electrical energy, as a potential solution for mitigating the environmental impact of methylene blue in textile wastewater. The research investigates the efficiency of the electrocoagulation process using iron (Fe) and copper (Cu) electrodes under various operational conditions, including electrode spacing (1, 1.5, and 2 cm), applied voltage (15, 20, and 24 volts), and electrode contact time (5, 10, 15, 20, 30, and 60 minutes). The findings reveal that the electrocoagulation method achieves an optimal methylene blue removal efficiency of 99% under specific conditions: an electrode distance of 1.5 cm, an applied voltage of 24 volts, and a contact duration of 30 minutes. This research underscores the potential of electrocoagulation as an efficient and environmentally friendly approach for the treatment of textile wastewater, contributing to the sustainable management of industrial effluents.

An innovative method for preparing durable flame-retardant cotton fabrics using tetrakis(hydroxymethyl)phosphonium sulfate without specialized equipment.

In this study, two phosphorus-based flame retardants diethylenetriamine trimethyl diphosphonate lysine (APTA) and a tetrakis(hydroxymethyl)phosphonium sulfate prepolymer with urea (DUPT) were synthesized. The structures of these compounds were characterized via nuclear magnetic resonance (NMR) and Fourier-transform infrared spectroscopy (FTIR). FTIR and scanning electron microscopy (SEM) analyses revealed that DUPT crosslinked APTA onto cellulose, which was pre-processed with diethylenetriamine dipropylene oxide (NAED) to introduce NH groups through PCN bonds. The APTA/DUPT-30 cotton exhibited a limiting oxygen index (LOI) of 36.4 % and a damaged length of 4.8 cm. After 50 washing cycles, the treated cotton maintained an LOI of 30.5 % and a damaged length of 5.4 cm. These results indicate the exceptional flame retardancy and washing resistance of the treated cotton fabrics. Moreover, the thermogravimetry (TG) curves indicated that APTA/DUPT altered the degradation process of the cotton fabrics. The TG-FTIR data and residue analysis from the vertical flame-retardant test confirmed that the treated cotton utilized a condensed-phase flame-retardant mechanism. Overall, this approach effectively imparts excellent durable flame retardancy to cotton fabrics through stable PCN bonds, eliminating the need for specialized equipment.

Innovative Application of Digital Printing Technology in “China Chic” Clothing

As the resurgence of Chinese traditional culture gains global attention, "China Chic" clothing design has become a prominent trend in modern fashion. Digital printing technology is an advanced textile printing process. It has become a core technology in "China Chic" clothing because of its high precision, full-color gamut, versatile design capabilities, and environmental benefits. This study explored the application effect of digital printing technology on fabrics of different materials through printing accuracy tests and printing color reducibility comparison tests of different fabric structures with case analysis, and verified its superior performance in traditional pattern reproduction and customization. The results indicated that digital printing technology can not only meet the complex design requirements of "China Chic" clothing but also significantly enhance the environmental sustainability of the production process. In the future, the development of digital printing technology should focus on improving production efficiency, reducing costs, and developing more environmentally friendly inks to expand its potential in the textile industry further. Finally, the study shows the outstanding performance of digital printing technology in application efficiency, vision and color, which can provide strong technical support for the innovative design of "China Chic" clothing

Sustainable Coloration Technologies

The textile industry is witnessing significant transformations in dyeing methods due to technological advancements. Innovations in dyeing techniques have not only revolutionized the way fabrics are colored but also paved the way for more sustainable and efficient practices. This article explores the innovations and advancements in dyeing methods brought about by technology, the impact of these advancements on the industry, and the implications for the future of textile dyeing processes. The successful substitution of hazardous chemicals with more sustainable alternatives like salt-free dyeing, urea replacement, use of natural dyes, and low-temperature soaping enhances efficiency, reduces waste, minimizes environmental impact, and promotes sustainable practices having eco-friendly solutions. These methods reduce water consumption and chemical waste, making them more sustainable alternatives to conventional dyeing processes.

A novel mass transfer effectiveness model incorporating water activity for moisture evaporation rate prediction from fabric clothes

Household clothes dryers (HCDs) are popular in modern society and account for a large portion of domestic energy consumption. Moisture evaporation from fabric is an essential phenomenon that must be considered in HCD control to improve energy efficiency and reduce drying time. This study aims to develop a novel mass transfer effectiveness model to predict the moisture evaporation rate (MER) by considering the thermophysical phenomena occurring during the drying process of fabrics. An experimental apparatus was constructed to measure the filling degree (FD) of fabrics in the dryer drum, leading to the development of a model predicting FD with a mean absolute percentage error (MAPE) of 10%. The FD correlation can be used to estimate the volume change of the fabric during the drying process. Simultaneously, experiments using a commercially available HCD were conducted to measure the moisture evaporation rate and associated parameters. Throughout the drying process, distinct changes in mass transfer effectiveness and water activity were identified. Subsequently, two empirical correlations for mass transfer effectiveness corresponding to each distinct drying regime were developed. These two correlations were integrated into a comprehensive model that aligns well with MER data from real-world HCDs, achieving a MAPE of approximately 11%.

UNISON framework with fuzzy decision tree for water conservation in the dynamic scheduling of the textile dyeing process

PurposeThis study aimed to optimize the dyeing scheduling process with uncertain job completion time to reduce resource consumption and wastewater generation, and while reconciling the conflicting objectives of minimizing the makespan and the need to limit the production on specific machines to minimize rework.Design/methodology/approachWe employed a UNISON framework that integrates fuzzy decision tree (FDT) to optimize dyeing machine scheduling by minimizing the makespan and water consumption, in which the critical attributes such as machine capacity and processing time can be incorporated into the scheduling model for smart production.FindingsAn empirical study of a high-tech textile company has shown the validity and effectiveness of the proposed approach in reducing the makespan and water consumption by over 8% while high product quality and efficiency being maintained.Originality/valueHigh-tech textile industry is facing the challenges in reducing the environmental impact of the dyeing process while maintaining product quality and efficiency for smart production. Conventional scheduling approaches have not addressed the relationship between machine groups and reworking, resulting in difficulty in controlling the makespan and water consumption and increasing costs and environmental issues. The proposed approach has addressed uncertain job completion via integrating FDT into the scheduling process to effectively reduce makespan and wastewater. The results have shown practical viability of the developed solution in real settings.

Synthesis, fabrication and tribo-mechanical studies of microcapsules filled and Al2O3/glass fibre reinforced UHMWPE based self-lubricating and self-healing composites

Development of composites containing both self-lubricating and self-healing (SLSH) characteristics is a nascent area of research for applications where direct lubrication is discouraged such as marine, textile, and food processing industries. For instance, SLSH composites may enhance the longevity of propeller shafts, bearings, and other dynamic components in such applications. The present work focuses on the synthesis of microcapsules with molybdenum disulfide (MoS2) as a core and polysulfone as a shell material, using the solvent evaporation method. The composites were fabricated by blending synthesized microcapsules in ultra-high molecular weight polyethylene (UHMWPE) matrix via injection moulding technique. Aluminum oxide (Al2O3) nanoparticles (3–12 wt.%) and glass fibres (10 wt.%) were also used as reinforcements. Flexural and tensile tests of the fabricated composites were conducted to evaluate their mechanical properties. Tribological behaviour was also investigated using a pin-on-disc tribometer. The polymer composites with a constant dose of 10 wt.% glass fibre and 5 wt.% microcapsules along with 6 wt.% Al2O3 exhibit the best performance. The maximum reductions in wear rate and coefficient of friction (COF) are 45.28% and 54.47%, respectively, as compared to the base matrix. Moreover, flexural and tensile strength increased by 43.55% and 39.77%, respectively. The worn surfaces exhibited fractured microcapsules which acted as SLSH agents, due to the high thermal stability of the polysulfone shell and release of the solid core. Various analytical tools, including optical microscopy, scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), Fourier-transform infrared spectroscopy (FTIR), and thermogravimetric analysis (TGA), are employed in this study.

Physicochemical Investigations of Textile Wastewater and Process Parameter Optimization for Bio-decolorization of Congo Red Dye by Pseudomonas aeruginosa MT-2 Strain

Pollution caused by dyes is a major environmental threat, posing adverse impacts on humans, animals, and plants. Therefore, the remediation of such pollutants is essential to protect the environment. This study aimed to conduct physicochemical and bacteriological analyses of textile wastewater to isolate and identify potential native bacterial strains for the decolorization of Congo red dye. Physical and nutritional process parameters were optimized to achieve maximum decolorization. The biological and chemical oxygen demands of the analyzed textile waste water were found to be above the recommended limits. In this study, 19 Congo red -decolorizing bacteria were isolated, with one bacterial culture capable of growing at a higher dye concentration of 300 mg/L. This bacterium was characterized biochemically and genetically (using 16S rRNA sequencing) and identified as the Pseudomonas aeruginosa MT-2 strain. A maximum decolorization of 94.0% was achieved at an initial dye concentration of 150 mg/L, 35°C, and pH 8.0 under static conditions. The bacterial culture also showed resistance to heavy metals such as arsenic, lead, and chromium. The biodegradation of Congo red dye was confirmed through UV-vis spectral analysis and Fourier transform infrared spectrophotometry. The findings of this study demonstrate the high remediation potential of the MT-2 strain, making it suitable for possible use in dye biodecolorization at contaminated sites.

Physico-Chemical Analysis of Textile Effluents from Bagru, Jaipur (Rajasthan, India): Implications for Environmental Impact and Treatment Needs

The textile industry is one of the largest water polluters worldwide. The coloured and bad odour effluent discharged from such industries pollutes not only the water bodies but also affects groundwater quality. In the present study, thirty-five water samples were collected from different dyeing units of the Bagru textile area (Rajasthan, India) famous for using natural dyes for textile processing. The physico-chemical analysis of these water samples shows that all parameters exceeded the permitted range recommended by the Central Pollution Control Board (CPCB) and World Health Organization (WHO). The analysis revealed the use of synthetic dyes in Bagru's textile industry for dyeing and printing. Based on the estimated characteristics, these textile effluents must be properly treated before releasing into the environment as the discharge of untreated effluents into local water bodies leads to significant water pollution, adversely affecting aquatic ecosystems and biodiversity. Additionally, contaminants can permeate the soil, compromising agricultural productivity and food safety. The air quality is also compromised due to the release of volatile organic compounds (VOCs) during the dyeing process, posing respiratory risks to nearby communities. This research underscores the urgent need for improved waste management practices and regulatory measures to mitigate the adverse environmental effects associated with synthetic dyes in Bagru's textile industry.