Dr N.N.Mahapatra
C.Col FSDC ( UK),CText FTI ( Manchester ), FRSC ( UK ),FAIC(USA)
Business Head(Dyes)
SHREE PUSHKAR CHEMICALS & FERTILISERS LTD.
(301-302, Atlanta Center, Near Udyog Bhawan,
Sonawala Road, Goregaon (East )
Mumbai 400063. India
Apart from the above major achievements, the industry progressively has seen major developments in the production of Technical & Industrial Textiles covering around 25 different fields of new applications. A huge variety of revolutionary products have been brought into the world market as a result of technological innovations in new fibres, yarns, fabrics, processing methods, dyeing and finishing. Unforeseen a few decades ago, these products have been successfully imagined and developed and now on the whole have brought dramatic positive changes in our environment and life-styles. The most exciting new markets for Technical and Industrial Textiles from a potential growth/value-added/profitability point of view involve the high technology or high performance applications. The forecast as to what will happen most likely in the technical and industrial textile world during the next decade is one of growth in spite of the current global financial situation.Global initiative has exploded in a big way in the recent years, creating an awareness of the impact our everyday life is creating in the environment. With an attempt to boost their sales, various sectors are enhancing their ecological credentials through the development of business strands, and through the manufacture of earth friendly products.
The need for truly sustainable options for 21st century life remains one of the most critical challenges facing the global community. As a society we need to find ways to encourage innovation in ways that drive energy and resource efficiency, reduce greenhouse gas emissions, develop a more sustainable infrastructure and encourage job creation.As a science company, DuPont has the experience and expertise to put our science to work in ways that can design in – at the early stages of product development – attributes that can deliver solutions that help protect or enhance human health, safety and the environment.Through our science, we will design products and processes that pass rigorous criteria for reducing the use of energy, water and materials and encourage the development of products based on the use of renewable resources. We believe this is a direct route to a successful, profitable business that add value to our customers, their customers, consumers, and the planet.
Through science, the world is safer, more efficient and more comfortable – a better place. It is science that has provided the foundation for every historic breakthrough at DuPont since its creation more than 200 years ago.Today, nothing has changed. It is still our unmatched ability to harness science to create new products, processes and applications that makes DuPont a leader. Nomex®, Teflon®, Tyvek®, Kevlar®… the list of DuPont breakthroughs is long and impressive indeed, and it is growing. Never satisfied to rest on its past accomplishments, DuPont laboratories are, right now, developing the next generation of scientific breakthroughs. DuPont manages its research process prudently, striving to maximize outcome and minimize risk.
PRODUCTION OF BIOPHYL FIBRE –
The only difference between Biophyl polyester and standard polyester is the raw material used . In normal polyester manufacturing Ethylene Glycol is used which is obtained from petroleum.But in case of Biophyl the ethylene glycol used is derived from corn sucrose known as Bio-PDO . Firstly the innovative polyester polymer ( PTT –Polytrimethyleneterephthalate ) also known as Sorono polymer is made then melt spinning takes place as usual . It is called ECO –Polyester fibre/yarns .It is manufactured by the European polyester producer with the brand name “Biophyl “ using DuPont’s Bio-PDO polymer .
The Biophyl fibre is made using polyethylene terephthalate ( PTT) ,a special polyester –like polymer,where the petroleum –based glycol is replaced with sucrose from corn.This resource is renewable and therefore reduces the dependability on petro-chemicals ,which is the classical raw material for polyester . This is an important step towards achieving sustainability for polyester textiles .Since producing the polymer consumes 30% less energy and reduces CO2 emissions by 63% in comparison to nylon 6, Biophyl also offers additional skin benefits such as fluid, silky and comfortable and it dries quickly.
Further energy reductions can be achieved during the dyeing and finishing of Biophyl fabrics as compared to regular polyester , these fabrics can be dyed at lower temperatures and in a shorter process time . BIOPHYL™ fabrics offer additional values to the user: They are easy to care for and have a unique soft hand together with excellent stretch and recovery.
These beneficial end-use properties derive from a unique, semi-crystalline molecular structure featuring a pronounced “kink” which gives special in-use properties superior to either nylon or standard polyester . “The use of yarns made with these polymers contributes to energy savings and a reduction of greenhouse gases,” said Advansa. “In comparison to fossil fuel-based nylon, the production of this polymer consumes 30-40 % less energy and results in 50-60% less greenhouse gas emissions,” it claimed. Using standard available dyes, ‘Biophyl’ fabrics can be dyed at lower temperatures than regular polyester, without requiring pressure or chemical carriers,” said Advansa, “The special polymer molecule enables the crystalline structure of the fibre to begin accepting the dye pigment at approximately 85ºC. Full depth of colour is achieved at 110°C, with outstanding wash fastness.”
With close to 300 thousand metric tons of fibre extrusion, ADVANSA is, by far, the largest manufacturer of polyester fibre products in its operating region of Europe, Middle East and Africa. ADVANSA produces polyester staple fibre and filament yarn, both POY and textured, serving customers in the main end use markets with an extensive range of products for all sectors. Production takes place at three different sites, based in two countries : Germany and Turkey. All sites are ISO registered with integrated quality management and customer support services. The company’s leadership position is reinforced by a strong portfolio of branded and speciality fibres, backed by significant ongoing investment in research and development and upstream integratio ADVANSA uses DMT (Di-Methyl Terephthalate) as a raw material in the production of its polyester fibres.
Produced at the Adana site, DMT is used in particular for end-products and semi-finished products such as synthetic fibres, films and other polymer materials and materials for the packaging industry. Polyester Polymer Solutions, which manufactures specialty products, is split in two: homo- and copolymers. These polyester polymers are used by manufacturers of POY yarns and films,
Properties of BIOPHYL™ fabrics
Fabrics made with Biophyl are said to be very soft. “Stress-strain tests demonstrate that flat yarns made with this polymer are softer than nylon at the same denier, because less effort is required to bend the fibres,” said the company referring to the unique molecular structure of the polymer. Research has also shown that a fully drawn flat yarn made with the Bio-PDO containing polymer recovers 100% from an approximately 120% strain. Textured yarns, offer up to 145% stretch with 100% recovery and are said to provide greater bulk and cover than nylon, using the same amount of fibre. Fibres that contain these polymers have a very soft hand-feel, comfort stretch and recovery, easy dyeability, natural stain resistance and easy-care characteristics.
Other qualities of Biophyl are thermostability ,UV/chlorine resistance ,ironability and certification according to the Oeko-Tex Standard 100 with the highest possible Class I, which also includes the category for babies.
Biophyl also combines the advantages of sustainability with the performance of polyester products .In addition ,it has the positive quality of absorbing less moisture than polyamide does; it dries very quickly ,repels dirt and is extremely durable .
1 .Softness
Both flat and textured yarns bring exceptional new level of softness to any fabric.
Stress-strain tests demonstrate that flat yarns made with this polymer are softer than nylon at the same denier, because less effort is required to bend the fibres.
2 .Stretch Recovery
Research shows that a fully drawn flat yarn made with this polymer containing Bio-PDO™ recovers 100% from an approximately 120% strain. Even at higher strain levels, fibres recover completely, returning to their initial form. Textured yarns, offer up to 145% stretch with 100% recovery. And provide greater bulk and cover than nylon, using the same amount of fibre. These characteristics are comparable to PBT yarns, another ADVANSA product that offers stretch recovery (widely used in the Denim industry).
3 .Easy dyeability
Using standard available dyes, BIOPHYL™ fabrics can be dyed at lower temperatures than regular polyester, without requiring pressure or chemical carriers. The special polymer molecule enables the crystalline structure of the fibre to begin accepting the dye pigment at approximately 85ºC. Full depth of colour is achieved at 110°C, with outstanding wash fastness.
4 .Heatsetability
For easy care, BIOPHYL™ fabrics are heat settable. Heat setting does not diminish the stretch and recovery capacity of BIOPHYL
