Dr N.N.Mahapatra

   C.Col FSDC ( UK),C Text FTI ( Manchester )

    FRSC ( UK),FAIC ( USA)

  Business Head ( Dyes )

  SHREE PUSHKAR CHEMICALS & FERTILISERS LTD.

     301-302, 3rd Floor, Atlanta Centre, Near Udyog Bhawan,

         Sonawala Road, Goregaon (E), Mumbai – 400 063, India.

        Tel.: + 91 22 4270 2525

        Mail: [email protected] find us @ www.shreepushkar.com

There are two opportunities for biobased products to penetrate the textiles market. First, biobased fibres derived from either agricultural crops or forestry waste can be processed and developed to replace or blended with existing natural fibres. On the other hand, biobased chemicals can be used to manufacture polymeric materials that, depending on their characteristics, can be spun into fibre for use in textiles.

Biobased chemicals such as diols, diamines, diacids, etc. all have the potential to be used for manufacture of polyesters and nylons. This is the technology behind Dupont’s Sorona fibre technology, which produces propanediol that can be used to make polyester. A new bio-based material for the 21st century.The properties of polyesters based on propanediol have been well documented for many years, but until the last several years, an economical source of propanediol was not available. As other biobased chemicals that can be polymerized become available at competitive pricing, it can be expected that…
DuPont discovered Sorona® in the 1940s but did not commercialize it at the time because of the high cost of the key ingredient propanediol (PDO). A seven-year research program that began in 1993 concluded with the development of a process to make Bio-PDO™ from corn sugar. In 2004, a joint venture between DuPont and Tate & Lyle was formed to build, manufacture and sell this new renewably sourced monomer. The world’s first Bio-PDO™ plant in Loudon, Tenn., began commercial production in November 2006. The process to make Bio-PDO™ consumes 40 percent less total energy and reduces greenhouse gas emissions by 20 percent versus petroleum-based propanediol. Production of 100 million pounds of Bio-PDO™ through the DuPont Tate & Lyle Bio Products joint venture will save the equivalent of 13.5 million gallons of gasoline per year, or enough to fuel 24,000 cars annually. DuPont™ Sorona® is the first bio-based, renewably sourced polymer from DuPont. It contains 37 percent renewably sourced materials derived from corn. A breakthrough in polymer science, DuPont scientists developed a way to make Bio-PDO™, the key Sorona® ingredient, from corn using a new biological process. Whether it’s textile fibers and fabrics for home interiors and apparel, carpeting or a variety of packaging applications such as films, sealants, foams, rigid containers, Sorona® imparts distinctive, value-added characteristics.

DuPont™ Sorona® polymer provides a unique combination of benefits to a wide variety of applicatons.  This advanced, value-added polymer represents a major new mix-enrichment offering, with the potential for growing into a significant market over the next ten to twenty years.

. Sorona is a world leader in the textile industry – DuPont has introduced a new generation of one of the most innovative textile materials for clothing and bring a unique combination of performance advantages. Application of the Tianzi Sorona the performance of textile materials in yoga clothes and underwear on innovative design reflects its original ecological concept, but also a vivid interpretation of the Sorona “outstanding performance, from natural” claim, set off a fitness and underwear low-carbon fashion style. 

Manufacturing ; A unique molecular structure

DuPont™ Sorona® polymer is a unique polymer based on 1,3 propanediol (PDO).  Its beneficial properties are derived from a unique, semi-crystalline molecular structure featuring a pronounced “kink”, as shown in this image.

Sorona® polymer is a fiber-grade, which means it has a uniform micro-structure and a high molecular weight that enhances processing. It can be spun into fiber or made into fabric in many existing facilities that now process PET.  Because Sorona® polymer is manufactured in a continuous process, the variation of polymer properties is limited.  As a result, processing problems and waste generation are minimized, leading to increased productivity.

Sorona polymer (scientific name: polyethylene terephthalate, or PTT) is a DuPont the company’s new “intelligent” spinning raw materials, some from natural renewable resources – Preparation of bio-based PDO. The basic raw material production of Sorona polymer there are two: 1,3 – propanediol (PDO) and terephthalic acid (TPA). Than half a century ago, DuPont has found 1,3 – propanediol (PDO), the production of key raw materials Sorona polymer. However, PDO’s production costs are too high, has not been able to achieve industrial production. To the early 90s of last century, DuPont, together with strategic partners finally succeeded in developing bio-PDO process route preparation, and finally officially introduced to the market this innovative new materials revolutionary low-carbon environment.
PDO in the total proportion of raw materials accounted for 37% of PDO’s Sorona based on biological products is a sustainable development of the product.

Sorona® polymer is produced with renewable bio-based PDO through a fermentation process from corn sugar, which adds a brilliant point of environmental protection concept.

Following are the steps for manufacturing ;

  1. Harvesting the corn .
  2. Getting sugar from the corn.
  3. The Fermenter ; Turning sugar into a monomer.
  4. Turning monomers  into

Fibres and fabrics are created.

  • Properties  Of Sorona fibre ;

DuPontTM Sorona® polymer is the latest , the most advanced and eco-friendly macromolecule polymer developed by DuPontTM currently whose main material is from bio-based 1,3-Propanediol (PDO). As one of the licensees of DuPontTM located in China mainland, Shaoxing Global Chemical Fiber Co., Ltd is authorized to use DuPont’s technology to develop, produce and sell SovireTM filament yarn, its fabrics and garments made with Sorona® polymer.

Sorona® is called “smart” polymer by the industry because it combines the properties of polyester and nylon, provides designers and consumers with various merits as follows:

  • Super softness & bulkiness

Fabrics made with Sorona® are softer, with a more natural feel and a more cotton-like hand,  than any other existing synthetic yarns. It also has good draping property.

  • Excellent stretch-recovery

Fabrics made with Sorona® give with ease, then springs right back into shape, combing relaxed comfort with great fit.

  • Vibrant color

From one color to Technicolor, fabrics made with Sorona® hold deep rich colors and sharp, vivid prints. They are easy to dye — requiring no additional heat, pressure or carriers. And best of all, colors are washfast so they won’t fade with repeated washings.

  • UV & Chlorine resistance

For today’s active lifestyles, fabrics made with Sorona® keep their colorful good looks even when exposed to UV & Chlorine, thus suitable for swimsuit and active wear.

  • Stain resistance and ease care 

Fabrics made with Sorona® have stain-resistant, anti-static, fast–dry and wrinkle-free properties, they allow designers and manufacturers to create the carefree clothing that consumers value — clothing that transits from work space to play space.

Sorona polymer chain was visible ring structure, and its base group of three more to make the combination of carbon fiber with PET or PBT and nylon with different characteristics. Because of its low Young’s modulus, Sorona fiber is 3 times the normal PET fiber soft hand; and spring-like molecular structure gives a comfortable back elastic and perfect performance.

These features give designers a broad design brings tremendous freedom. Sorona fiber can be used alone, but also with other natural and synthetic woven or blended; Sorona fabric made of flexible, from underwear to coats, from sports to suits, from the shape memory to fashion jeans, Sorona everywhere, has been gradually penetrate into people’s daily life.

Leader in high-performance carbon fabric trend Tianzi brand is the swimsuit / fitness brand, one of the leaders, began in 2008 with Sorona, to develop yoga clothing line, and in 2009 achieved excellent sales results. This year, Tianzi in yoga clothing based on the further development of Sorona fabric made by the new underwear.

USES  OF  SORONA FIBRE  

Yoga clothes made with Sorona has fine silky touch, flow-like vertical sense of tremendous freedom to exercise comfort; and underwear made with Sorona not only has the “second skin” and silky touch, and The perfect fabric for underwear in the back performance after repeated washing can maintain beautiful appearance. Meanwhile, the fabric can stretch comfort and complete recovery without deformation, to wear a great movement to bring “freedom.” In addition, its excellent drying and not fade after washing, excellent chemical resistance, resistance to chlorine / UV, anti-wrinkle, stain and so is the nature of consumers favor; garment fabric, high-performance and durability are given Sorona the core value of various types of clothing. These are so beautiful clothes with a long look and wearing comfort. A new collection of laptop bags has been designed making use of DuPont’s bio-based Sorona polymer which is made from renewable corn-based feedstock.

Not only that, Sorona more numerous environmentalists pursue environmental value: Sorona production of a key raw material used (PDO) from renewable resources can be sustainable, rather than the traditional petrochemical raw materials, thus reducing the chemical fiber industry revolutionary dependence on oil resources. Meanwhile, the same output compared to nylon 6 polymers, Sorona polymer process can not only reduce 63% carbon dioxide (the greenhouse gas) emissions, but also consumes 30% less energy. Because it is a thermoplastic polymer, so easy to recycle. DuPont’s Sorona polymer is currently used in fiber materials for the ceiling surface skin, sun visor and pillar garnish of Japan-based Toyota’s new Sai model, launched in December 2009. The biopolymer is a polytrimethylene terephthalate resin, made from a copolymerization of terephthalic acid and DuPont’s corn-based 1,3 propanediol.

Tianzi International (HK) Ltd general manager Zhang Xiangyang confidently told reporters: “We brand the fabric of performance and quality requirements are high, Sorona is the ideal material for compliance with our requirements. Not only that, Sorona environmental value of further help us meet the strong demand for environmentally conscious customers.

Casual/outdoor wear, Jeans, Active/sports wear: swimwear, golf-wear, gym-wear, etc, Women’s & men’s formal wear, Knitwear, Intimate wear

Home textile products such as blankets, carpets; automotive inner decorative fabrics etc.