Production processes polyester fibers

Production processes for manufacturing polyester fibers and yarns, as explained in the following: 

Production of ester building unit

In this process a chemical reaction is carried out between monoethylene glycol and dimethyl terephthalate to produce diglycol terephthalate.

Polymerization

In this process (for fiber production) polymerization occurs to diglycol terephtalate to produce polyester polymer. 

Spinning

In this process, molten polyester polymer is pumped to the spinnerettes and the filaments come out to meet a stream of cold air and get solidified. The resulting filament tows collected

Manufacturing process of nylon fibers and nylon yarns

Manufacturing nylon fibers and nylon yarns, as explained in the following: 

Polycondensation

This is a chemical process to produce the nylon polymer using caprolactum and acetic acid.

Chipping

The nylon rope produced from the polymerization process is cut into chips.

Melting

In this stage nylon chips are melted to reach the viscosity suitable for pumping to the spinning process. 

Spinning

In this process, molten nylon is pumped to spinnerettes, and the polymer streams coming out are cooled by blown air that let the polymer solidifies and form continuous nylon filament.

Drawing and twisting

The nylon yarn produced in the previous process is subjected to stretch, is given twist and is

production processes for viscose fibers and filament yarns,

Soaking in caustic soda

In this process the wood pulp is soaked in sodium hydroxide to produce soda cellulose which is squeezed to remove the extra caustic soda solution .

Shredding

The crumbs of soda cellulose are shredded to produce small flakes.

Ageing

In this process, the shredded soda cellulose is aged for a certain time to adjust the molecular structure. 

Xanthating

The aged cellulose is mixed with carbon disulphide to produce by chemical reaction xanthate 

Dissolving

The xanthat is dissolved in sodium hydroxide to produce xanthate solution for spinning. 

De-aeration and filtration

In this process, the xanthate solution is stored in tanks under vacuum to remove any air bubbles, and is passed through multi stage filters to remove any trash particles, and when

Production processes for transforming woven or knitted fabrics into garments

Fabric laying

In this process the fabric is laid on a long table in multilayer arrangement, using a special machine with reciprocating carriage. This process is applied for the main garment fabric, and also the lining fabric. 

Placing patterns

After collecting the number of fabric layers, the patterns of the garment are placed on top of the layers, and fixed by special pins. 

Cutting

The multilayers are cut according to the patterns by using electric cutter which moves around the patterns to produce garment parts and, similarly lining parts and interlining parts 

Sewing

In this process, the garment parts are assembled together by stitching on sewing machines. Also, the lining

Production processes for finishing woven cotton fabrics and woven synthetic fabrics.

Singeing

This process (cotton only) is considered one of the processes for finishing preparation, and is only concerned with cotton woven fabrics. In this process the greige fabric surface on both sides is subjected to a gas flame which burns the protruding fibers and results in a smooth surface.

Desizing

In this process the size materials on the warp threads of the fabric are removed, by passing the fabric in a bath of sulpheric acid or by using enzymes, soap or hot water depending on the sizing material. This process is also considered one of the preparation processes for finishing. 

Scouring

In this process, the desized fabric is passed through a cleaning bath, using alkaline or solvent solutions to dissolve any impurities or soiling on the fabric. Desizing and scouring could be

Technology of tufted carpet

In the technology of tufted carpet , the tufting machine is fed with a large number of threads, and a spun-bonded nonwoven fabric, as the ground of the carpet. The needles of the tufting machine make tracks of parallel stitches through the ground fabric, creating a terry surface. The formed carpet is back coated with adhesive resin to bind the carpet pile to the ground fabric and the adhesive is covered with jute fabric as a back. Then, the carpet surface is sheared to improve the appearance and regulate it.  

Production processes for weaving yarns

The production processes for weaving yarns into fabric starts with a large number of parallel threads are arranged with the required length, wound on a beam, strengthened and smoothed by sizing, and interlaced with weft threads on the loom to produce a woven fabric, which is wound on another beam (cloth beam).  

Steps in wool spinning

In wool spinning, wool fibers from bales are scoured to be cleaned from grease, carbonized to remove the plant matter, carded, combed then drafted to a thin thread and twisted to produce woolen or worsted yarns. The produced yarn is wound on large package as final product for weaving or knitting, or for carpet production. 

The same line may be used to process man-made fibers of the type similar to wool, or blends of wool and man-made fibers. 

Cotton and synthetic knitted hose: Production Process

Cotton gin and production process flow sheet

Flowchart of cotton spinning

 

 

Flowchart of cotton spinning

In cotton spinning, cotton from bales is cleaned from dust, trashes and foreign matters, opened, mixed, carded, then drafted to a thin thread and twisted to produce the yarn. 

This line could also be used for spinning man-made fibers with characteristics similar to cotton, or blends of cotton and man-made fibers. The produced yarn is wound on large packages with conical shape on winding machines producing cone packages.

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Cotton gin and production process flow sheet
Cotton and synthetic knitted hose: Production Process

Production process of ammonia aluminium sulphate(amonia alum)

Ammonium alum((NH₄)Al(SO₄)₂·12H₂O.) is an extremely useful and profitable mineral salt. It is used as laboratory reagent, water purification, in vegetable glues, in porcelain cements, in deodorants and in tanning, dyeing and in fireproofing textiles.

Manufacturing process

The first step of the manufacturing process is as follows,

Leaching of ammonia and Aluminium trihydroxide (Al(OH)3) by Sulfuric acid (H2SO4) 

               Ammonia + Sulfuric Acid --> Ammonium Sulfate

               Aluminium trihydroxide + Sulfuric Acid -->Aluminum Sulfate

In the second step, the products Ammonium Sulfate and Aluminum Sulfate are combined using hydrometallurgy process,

Ammonium Sulfate + Aluminum Sulfate --> Ammonium Aluminum Sulfate (Ammonium Alum)

Renewable gasoline making flow chart

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Sustainable Integrated Jatropha seed processing flow chart

Integrated Jatropha seed processing flow chart shows how the seed is processed to make Jatropha oil, soap, biodegradable plastics, proteins for animal feed and bio oil.

Flow sheet of Jatropha fruit processing

Flow chart shows Jatropha processing routes leading to the production of oil, bio-oil and gasoline fuel along with use of Jatropha shell in generating process heat.

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Flow sheet of particle board making process

Process description of particle board making with video

How to make Labels and Badges from Textile

The main raw material inputs for the manufacturing of labels & badges are Embroidery thread, Silk yarn and fabric. 

A sheet of fine-line twill is hoped along with an iron-on non-woven substrate as a backing material. The label and badge design requires some special techniques, similar in approach to appliqué. The design should first be digitized with a running stitch (die line), indicating the cut line around the boarder of the label & badge. A machine stop is programmed at this point. The rest of the design is then digitized with in that boundary. (Tip: use the largest hoop you have and fit in as many label/badges as possible.) After the stitching is complete on all of the runs of the order, the sheet of material and backing is removed from the backing must now be bonded to the twill. This can be achieved with a heat transfer press. The temperature and dwell time should be set for the iron-on, non-woven.

Aluminum production process-Bayer & Hall-Héroult

Mostly aluminum is produced in two ways.

1.         Primarily Production Process

1. By refining aluminum from grinding and extracting from bauxite ore - Bayer process

2. By using reduction process for crystalline alumina - Hall-Héroult process

2.         Secondary Production Process

1. By doing pre-treatment of scraps such as cleaning and sorting  

2. By process of smelting, refining or alloying of aluminum

Bayer process: Refining Bauxite

In this process, the bauxite ore is dried, crushed and ground into a powder. It is then mixed with preheated spent solution. Lime is added to increase the solubility of alumina and the resulting mixture is pumped to digesters along with a solution of caustic soda to extract the alumina. The operation proceeds at elevated temperatures (using high temperature steam) and pressures in

Self-Adhesive tape production process

The major raw materials required for adhesive tape preparation are textile fabric (cloth) and acrylic adhesive mass. Auxiliary materials required for adhesive tape production include plastic spools, wrapping material, cartons and labels.

PVC cables production process

Basically the process of making PVC cable involves the coating of the copper wire with PVC plastic. And the process of coating or covering the wire takes the following stages. A wire tensioning and pay off unit carrying the base wire drums releases the wire under proper tension to the cross head mounted on the extruder. The extruder melts and delivers the required quantity of PVC compound to the cross head carrying suitable size nipples and dies in which the actual coating takes place. 

MEG regeneration process with flow chart

Glycol injection is provided by the injection pumps with the minimum to maximum flow rates of each pump ranging 0.19 – 0.69 m3/hr according to design. The rich glycol is separated from the condensate in the Cold Separators, about 35-120 minutes retention time dependent on the EG circulation rate, this is provided for the glycol to ensure proper separation of the glycol and condensate. The glycol exits the Cold Separators, under level control and flows to the reflux coils above the packing in the still columns of the EG Re boilers where self refluxing occurs. 

                                   

                  Flow sheet of MEG regeneration process in natural gas processing

The rich glycol is then passed through integral lean/rich glycol coils in the surge tank section of the M.E.G Re-boilers. After being preheated by the lean M.E.G. in the accumulator the rich glycol stream flows to the

Wood cement board, How it is made?

Wood cement board commonly known as panel board agglomerated with cement has been developed as building element for prefabricated houses, particularly suitable for the implementation of low cost housing programs. Major raw materials are wooden frame, sand, cement, wood flakes or fiber(wood waste) , water and a foaming agent. 

Clutch mechanism making with video

A Clutch is a mechanism for transmitting rotation, which can be engaged and disengaged. Clutches are useful in devices that have two rotating shafts. In these devices, one shaft is typically driven by a motor or pulley, and the other shaft drives another device. In a drill for instance, one shaft is driven by a motor and the other drives a drill chuck. The clutch connects the two shafts so that they can either be locked together and spin at the same speed (engaged), or be decoupled and spin at different speeds (disengaged).

There are many different vehicle cultch designs but most are based on one or more friction

Inner fabrics production process

The required raw material for the manufacturing of inner fabrics is cotton yarn.Knitting is done on a flat knitting machine. The knitted fabric passes down ward through the space between the upper edges of the plate, called the throat. In the knitting process, the needles are pushed up and down by the cam attached to a carriage with a yarn guide, which moves over the length of the machine. The width of the fabric can be altered by increasing or decreasing the number of active needles, allowing production of shaped fabrics.

The inner fabrics are produced through knitting of cotton yarn and doesn’t have finishing section, which uses various chemicals unless treatment plant is installed will cause adverse environmental impact.

Mango leather production process

Fruit leathers are dried sheets of fruit pulp which have a soft, rubbery texture and a sweet taste. They can be made from most fruits, although mango, apricot, banana and tamarind leathers are amongst the most popular.They may be eaten as snack foods as a healthy alternative to boiled sweets and also used as

Lithographic plate making process flow sheet

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Particle board making process description

Particle boards are substitute of solid and ply wood. Due to the growing deforestation, the natural wood is becoming more and more scarce. This calls for development of an alternative material such as Particle Board. It is made from eucalyptus tree, wood chips, saw dust etc and bonded by resins.  

Raw materials

The basic raw materials in the production of particle board are eucalyptus tree, waste woods, wood chips, saw dust, phenol Formaldehyde/Urea, Formaldehyde resins, veneers and sunmica coverings. Moreover,