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Preparation process

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What is the Preparation Process?

What is the Preparartion Process?

It is a process to prepare for putting colors , colors with designs, or putting functional finishes such as providing soft hand or water absorbency.
Fibers have its own natural impurities like colorants, oils, or inorganics, as well as sizes or waxes as a external sources, when making wovens or knits. These impurities should be removed well due to their becoming potential obstacles when putting colors, color with designs or other functions.
There are many kind of preparation processes , such as scouring to remove sizes or oils, bleaching to decompose the colorants on natural fibers to be white, mercerizing to make the colors more brilliant, on cotton fiber, relaxing to make the fabric more , which determines the primary fabric hands, and presetting to stabilize the fabric dimentions with its density.

Processing method

Open Soaper

This machine is used for pretreatment of synthetic woven fabrics of taffeta or twill , which does not require relaxing process.
It is processed by open-width way, having tention toward warp direction. Low concern of causing creases and can be done in a short time having high production efficiency. The basic machine arrangement is to have few or several wash boxes , or steamer with several wash boxes. The important points are to select chemicals, having fast penetration power with anti-redepostion characteristics of removed impurities , and to control chemical concentration , amount of counter-flow solution, and alkali concentration in the bath.

Recommended Recipe:

NaOH(F)
1g/L
SUNMORL HS series 【scouring/penetratnt】
1g/L
NEOCRYSTAL series 【chelate/dispersiant】
0.5g/L
90~95°C×Xmin.

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Pre-wetter

It is used for scouring and relaxing on synthetic knitted fabrics.
The purposes are to remove external sourced impurities like knitting oils, to adjust yarn or structural or potential uneveness, and to get fiber shrinkage by hot water before pre-setting, followed by wet-setting.
Required chemicals are to provide silicone oil removal and the emulsification performance for high percentage of containing poly urethane fiber as the recent trends.

Recommended Recipe:

SUNMORL WX series 【scouring agent】
1g/L
60~80°C×Xmin.

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Relaxer

Relaxer

It is used for scouring and relaxing on synthertic woven fabric ,containing textured or conjugated yarns.
It is possible to get evenly shrunk fabric in a short period of time with well scouring by spraying the solution onto the fabric or by mechanical beating (relaxing) on continuous treatment.
However, the applicable fabrics are rather limited because of postentially leading to seam slippage or wrinkles by physical beatings.
It may create high foam, so selection of scouring agent with low foaming is the key.

Recommended Recipe:

NaOH(F)
1g/L
SUNMORL HS series 【scouring/penetrant】
1g/L
NEOCRYSTAL series 【chelate/dispersant】
0.5g/L
90~95°C×Xmin.

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Boil-Off

It is used for scouring and relaxing on synthertic woven fabric , containing textured or conjugated yarns.
It is treated for 5-10 min. in continuously in open width without tension during scouring process.
Due to having no tension, it is possible to achieve basic hand feel by its yarn shrinking characteristic.
On the other hand, it requires a huge amount of water (40 ton) with steam . Once this treatment is started, it will run for one week without changing the scouring bath. Paying attention to the chemical concentration level is important.

Recommended Recipe:

NaOH(F)
1g/L
SUNMORL HS series 【scouring/penetrant】
1g/L
NEOCRYSTAL series 【chelate/dispersant】
0.5g/L
90~95°C×Xmin.

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Continuous machine for cotton woven pre-treatment

It is used for continuous treatment for desizing, scouring, and bleaching process on cotton or cotton blended woven fabric.
There are 3 patterns. One is to desize, scour, and bleach by all separate in 3 stages. The sencond is to combine desizing and scouring as one stage and perform bleaching separately, while the third is to combine desize, scour, and bleach all in one bath.
It consists of saturator which has chemical solution for padding, steamer for acclerating reactions under high temerature, and rinse boxes to wash off residual chemicals or treated impurities. Steamers are called L-Box as the appearance, or Perble range. Chemicals require high alkali resistance as the usage of alkali is high.

Recommended Recipe:

NaOH(F)
50~70g/L
SUNMORL CS, UM series
【scouring agent】
2~4g/L
NEOCRYSTAL series 【chelate/dispersant】
2~4g/L
Oxidizing desizer
15~20g/L
95~102°C×20~40min.

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Pressurized jet dyeing machine

Pressurized jet dyeing machine

It is used for scouring on knitted fabrics and for relaxing on synthetic wovens.
Applicable for raising up temerature above 130C, with the device of rcirculating fabric by spraying power from the nozzle.
Scouring and dyeing are done in one bath normally on synthetic knits, requiring the chemicals of no interference on dyeing.
Also it is used for relaxing on synthetic wovens. It makes the base of fabric characteristics including hand feel by applying heat and physical beatings. The chemicals require emulsification property as this process makes extra scouring effect in addition to the previous continuous treatment. This helps pull out more impurities from the fabric and needs to have low foaming characteristic for treating both knitted and wovens.

Recommended Recipe:

SUNMORL WX series 【scouring agent】
1g/L
NEOCRYSTAL series 【chelate/dispersant】
0.5g/L
NaOH(F)
1g/L
100~130°C×20min.

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Winch

Winch

It is used for scouring and bleaching on cotton knitted fabric.
There are both atmospheric and pressurizing types and the latter is applicable for polyester fabric. The device is to use reel for circulating the fabric.
The fabric stays in the chemical bath rather long with less tension so the fabric hand feel is soft.

Recommended recipe for Cotton:

H2O2(35%)
5g/L
NaOH(F)
1g/L
SUNMORL BH series 【scouring agent】
1g/L
NEORATE PH series 【stabilizer】
1~2g/L
TEXPORT D series
【in-bath quality improver】
1g/L
90~95°C×30min.

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Package (Cone) dyeing machine

It is used for scouring and bleaching on yarns for making wovens or knitted fabric. The yarn, wound up to core bobbin, will be proceed to the dyeing stage in same condition as scouring and bleaching.
The solution with chemicals alternate the circulation from in-side to out-side and out-side to in-side. The most important key is to treat inner side, middle side and outer side of cone equally. The chemicals are required to provide penetration and eveness property.

Recommended recipe for Cotton:

H2O2(35%)
5g/L
NaOH(F)
1g/L
SUNMORL BH series
【scouring agent】
1g/L
NEORATE PH series 【stabilizer】
1~2g/L
TEXPORT C-100
【in-bath quality improver】
1g/L
90~120°C×30min.

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