Textile Chemical Processing – I

A Presentation by Subham Pal

Stream – Textile Technology Year – 2nd semester – 4th

University Roll Number – 11101419038 Reg. No. - 013487
Government College of Engineering & Textile Technology, Berhampore
 Singeing is a process, where
loose hairy fibers are protruded
from the surface of the cloth,
fabric, and the yarn is removed
The verb ‘singe’ literally means to burn superficially. by burning.

Technically, singeing refers to the burning-off of:

• Loose fibers not firmly bound into the yarn and/or fabric structure;
• Loose yarns not firmly bound into the fabric structure;
• Protruding fiber ends sticking out of the textile yarns and/or fabrics.
Lose fibers protruding on the surface of textile products are chanted to remove
them in the textile industry. This results in higher wet ability, better dyeing
properties, enhanced reflection, no "frosty" appearance, a softer surface, good
printing clarity, increased visibility of the fabric structure, less pilling and reduced
contamination by removing fluff and lint.

Usually, the mechanism is to pass one or both sides of fabric over a gas flame to
burn off the protruding fibers. Other methods include infrared or heat for
thermoplastic fibers. The singeing of yarns is called "gassing." It's usually the first
step after weaving or knitting.
 A Yarn A Yarn
Before After
Singeing Singeing
Fabric Before Singeing Fabric After Singeing
▪ To remove the short fibers from the textile materials (yarn and fabric).

▪ To make the textile materials smooth, even and clean looking.

▪ To develop maximum luster in the textile materials.

▪ To make the textile materials suitable for subsequent next process.

▪ Singeing of a fabric is done in order to obtain a clean fabric surface which allows the structure
of the fabric to be clearly seen.
▪ Fabrics, which have been singed, soil less easily than un-singed fabrics.

▪ The risk of pilling, especially with synthetics and their blends, is reduced in case of singed
fabrics.
▪ Singed fabrics allow printing of fine intricate patterns with high clarity and detail.
▪ Extra loose fiber can be removed

▪ Smooth and even surface of fiber and fabric can be achieved.

▪ In the case of singed fabrics, risk of pilling, especially with synthetics and their
blends, is reduced.
▪ The singed fabric allows more luster and details of the dyeing and printing
color.
▪ It gives very clean and shiny looks in the fabric.
▪ Once the fabric is dyed, the uneven singeing effect may cause streaks, or bubbles when the fabric is
finished.

▪ Singeing is done on a gray cloth in the cotton system, but for blended fabrics containing synthetic fibers,
it is not advisable to singe gray as small globules of melted synthetic fibers preferably absorb the dye,
giving the cloth a skewed appearance.

▪ Thermal damage to temperature-sensitive fibers, such as polyester, may occur.

▪ Heat can cause color loss from the polyester portion of the blend due to dye sublimation when singeing
is done after dyeing.

▪ The tear strength may be reduced due to over-singeing of the fabric.

❑ Plate Singeing
Machine

❑ Rotary - Cylinder
Singeing Machine

❑ Gas Singeing
Machine
▪ In the process of plate singeing, the plates are heated with the help of certain fuels
(combination of air and gas), when heated, it turns reddish.

▪ Then the fabric is passed over two heated curved copper plates at a fixed speed (135-
225 meters per minute).

▪ The thickness of these plates is 1-2 inches.

▪ However, in this process, one side of the fabric is completed. To do the singeing on
the other side, again in the same way the other side of the fabric has to be passed over
the heated plate.
▪ Uniform singeing.

▪ Good for Velvet and Pile fabrics.

▪ A certain amount of luster is produced due to friction.

▪ Easy to handle and Maintenance cost is very low.

▪ In this type of singeing back filling in finishing process is possible.

▪ It is difficult to control the temperature of the plate.

▪ Only one side of the fabric is singed at the same time.

▪ It takes more time.

▪ Uniform singeing is not done in the stitch part.

▪ when thousands of meters of cloth are run through the machine, minute grooves are produced on
the surface of the metal which makes uniform contact with the hot surface difficult and thus gives
uneven singeing.

▪ Further, as the surface of the cloth alone comes in contact with the hot metallic plate, the fiber
ends present in the interstices of warp and weft are, not singed since the intense heat does' not
reach them.
▪ In this type of singeing machine, the cloth passes over and in contact with a heated
rotary cylinder made of copper or cast iron. The rotary cylinder has internal firing and
revolves slowly so that constantly a fresh surface of the roller comes in contact with
the cloth. The direction of rotation of the cylinder is opposite to the direction of the
fabric so that the protruding fibers or nap of the fabric is raised.

▪ This type of machine is particularly suitable for the singeing of velvets and other pile
fabrics.

▪ If the singeing of both sides of the fabric is required, then two cylinder are employed,
one for each side of the fabric.
▪ More luster is produced than Plate Singeing Machine.
▪ Cylinder rotates in a direction opposite to that of the fabric which
raises the nap of the cloth making it particularly suited to the
singeing of velvet and, piled fabrics.
▪ It is possible to singe both sides, of the cloth in one operation by
using two cylinders.
▪ In roller singeing, the temperature of the cylinder is more uniform
at all places than in the case of plate singeing; hence there is less
uneven singeing.
▪ It also produces minute grooves when thousand of meters
of cloth is passed over the cylinder giving rise to uneven
singeing.
▪ The fiber ends present in the interstices of warp and weft
are not singed since the intense heat does not reach
them.
▪ In this method, gas burners are used to singe one or both sides of the fabric during a single passage of the cloth over the
flames. The machine consists of two or more burners supplied with a suitable mixture of gas and air under pressure. The
width of the sets of burners can be adjusted to suit the width of the fabric: the length of the flame and hence the intensity of
heat can also be adjusted. The cloth in open width is drawn over the flame at high speed at 90 meters per minute, so as to
burn the protruding fibers without damaging the cloth. The burn: used is normally a simple iron pipe with suitable
perforations along its is length. In the case of slot burner, the width of the slot is adjustable. The mixture of gas and air may
be prepared separately and compressed or it may be formed by allowing compressed gas ado and air to mix immediately
before the entrance of the slot the chamber.

▪ While singeing. The cloth is allowed to run through the machine and then burners are ignited. While stopping the machine,
the flames are first extinguished and then the machine stopped. The high temperature (300 to 500C) met with in the singeing
does not damages the cloth because the time of contact is only fraction of a second. The singeing room is separated from
other departments in the mill. The singed cloth is quenched by passing. It through a mangle revolving in a water box to
extinguish sparks and to reduce the risk of fire to the minimum.

▪ Synthetic fiber fabrics can also be singed, During singeing such fabrics, the protruding fibers melt and recede from the flame
forming minute beads. These absorb the dye faster than. The rest of the fabric giving specky dyeing. In order to avoid this.
Defect, singeing is carried out after dyeing. In the case of tricot fabrics, singeing controls pilling.
Pyrolysis
Pyrolysis refers to transformation of a substance by the action of heat. At temperature of pyrolysis
(Tp), both thermoplastic and non-thermoplastic fibers decompose (pyrolyze) into lower molecular
weight fragments. The chemical change, which begins at temperature of pyrolysis, continues through
the temperature of combustion (Tc).
▪ At the start, the fabric passes through a tension unit with guide rollers and bars, which ensure crease-
free entry of the fabric into the machine. Then, there are (optional) pre-drying cylinders which even out
any variations in the fabric moisture-content and temperature.
▪ Next, the fabric passes through pre-brushing unit which, in addition to removing dirt/dust, lint and loose
fibers from the fabric, causes the fibers sticking to the fabric surface to stand out for easy subsequent
burning. A dust collection system, provided just below the brush rollers, is connected to a powerful
suction unit.
▪ After pre-brushing, the fabric enters into the singeing chamber, where it passes over the burning flames,
which are positioned on both sides of the fabric. The cloth can be threaded so as to allow singeing of
either one or both sides of the fabric. Burner body is specially designed to provide gas flow at uniform
pressure/velocity throughout the fabric width. Burner is termed as the heart of singeing and should
generate homogenous, stable, uniform and highly concentrated flame rich in energy by ideal
combustion of the gas : air mixture. Good singeing machines offer adjustable flame intensity, flame
width and distance between the flame and the fabric.
▪ Gas outlet section of the burner is provided with water jacket to keep the burner cool.
Adjustable water-cooled rollers are used to obtain different fabric/flame positions, which
permit desired degree of singeing effect on different quality of fabrics by adjusting the guide
roller position with respect to the flame. A Carburetor or air/gas mixer allows automatic
mixing of gas with air to control the intensity of the singeing flame.

▪ After passing over the flames, the fabric passes through (optional) steam quenching unit to
put off any sparks and/or through post-brushing section for clean-up/removal of burnt fibers.
The after-brushing keeps the subsequent impregnation-liquor cleaner and reduces the
amount of dust entering in the following process steps. Then, the fabric passes though a
saturator, which contains the desizing agent along with the auxiliary chemicals. After
saturation with the desizing liquor, the fabric is squeezed by squeezing mangles and is wound
on a batcher.
 Important GAS singeing parameters :

➢Flame intensity
➢Fabric speed
➢Singeing position
➢Distance between flame burner and fabric
➢Flame Width
 Flame Intensity

Together with the supply and control units for gas-air mixture, burners comprise the most important part
of any singeing machine. The flame intensity of the singeing burners is based on the amount and the
outlet speed of the gas-air mixture leaving the burner slots. Besides having high thermal energy, flame also
has considerable mechanical energy. All the thermal and mechanical energy of the flame is directed onto
the fabric during singeing. The temperature of the flame at the mouth of the burner is in the range of
1250 to 1300C. The speed of the flame at the burner outlet may be between 15 and 35 meter per second.
The flame intensity usually lies between 5 and 20 m/s.
 Fabric Speed

The fabric speed in the singeing machine is usually in the range of

50-160 m/min depending on fabric (gram per square meter) weight
and fiber blend. For heavier fabrics, the speed is kept slower as
compared to lighter weight fabrics.
 Singeing Position

I) Singeing onto free-guided fabric

II) Singeing onto water-cooled roller

III) Tangential Singeing

I) Singeing onto free-guided fabric
This is the most intensive singeing
position with highest efficiency. In this
position, the flame bounces onto the
free-guided fabric at right angles. This
position is usually recommended for
singeing of fabrics with all natural
fibers (e.g. cotton), regenerated fibers
and blended fabrics, which have been
tightly woven and have weights over
125 g/m^2.
II) Singeing onto water-cooled roller
In this position, the flame bounces at right
angles onto the fabric while the fabric passes
onto water-cooled guide roller. This position
avoids the penetration of the flame into the
fabric. The flame does not pass through the
fabric, and because of the fabric passing onto
water-cooled roller, any thermal damage of
temperature-sensitive synthetic fabrics is
avoided. This position is usually recommended
for all blended and synthetic fabrics as well as
for fabrics having weights less than 125 g/m^2
and fabrics with open structure.
III) Tangential Singeing
In this position, the singeing flame falls
on the fabric tangentially. The flame
touches only the protruding fibers
without having any significant contact
with the main fabric body. This
position is usually recommended for
very light weight and sensitive fabrics
as well as fabrics with broken
filaments.
 Distance between Flame Burner and Fabric

As the energy content of the flame is lower the farther it is from the burner, the singeing
efficiency is consequently decreased by increasing the burner-fabric distance. The distance
between the burner and the fabric is usually in the range of 6-8mm but it can be adjusted in a
range from 6-20 mm.

Flame Width

All good singeing machines come with a provision of flame width adjustment according to
the width of the fabric. This is essential to optimize the gas economy.
▪ A flame with high mechanical & thermal energy to quickly burn
thermoplastic protruding fibers (e.g. polyester) without any molten
beads formation.

▪ A homogeneous flame with uniform mechanical & thermal energy

to result in uniform singeing.

▪ An optimal flame/fabric contact time to neither result in

incomplete not over-singeing.
▪ An indicator of the singeing effect is the fabric temperature just after its passing over the
singeing flame. The fabric temperature can be continuously monitored by a radiation
pyrometer and indicated by a thermometer. Hence, the fabric temperature may take over the
singeing control and regulating function. When the fabric temperature increases to a pre-set
value, the machine intensity would automatically reduce, while when the fabric temperature
goes down, the flame intensity would automatically increase.
▪ Hairiness Tester provides another possibility to control the singeing effect objectively. The
fabric surface is monitored by means of a laser beam and the hairiness of the fabric is
displayed on a computer screen. The measured information can be used as a set value for the
control of the singer in order to achieve the programmed effect.
▪ Make sure that the flame is more bluish (less yellowish) to give the maximum temperature.

▪ Control and maintain the recommended flame length and angle of contact, depending on the fabric
construction, thickness, weight, heat sensitivity, etc.

▪ Regulate the fabric speed according to the fabric construction/thickness/weight etc.

▪ Make sure that all the burner nozzles are free from choking. Choking of nozzles may result in the appearance
of haziness, patchy appearance or faint lines, which become apparent after dyeing.

▪ Make sure that the machine is threaded through the machine correctly. Rubbing marks may show up if the
fabric is threaded wrongly over defective stationery bars and/or if the fabric rubs against the burners. (As the
guide rollers are very close to the burners, any problems due to loose brackets supporting the rollers will guide
the fabric to touch the burner block/nozzle). Invariably such defects only show up after dyeing or finishing, at
which stage it is difficult to attribute the cause to the singeing machine operation.
▪ Make sure that the threading is as per specification drawing so that both sides of the fabric are singed.
Singeing on only one side of the fabric may result in face to back shade variation after dyeing.

▪ Make sure that the width of the flame is set to cover just a little more than the fabric width. This will
ensure conservation of energy.

▪ Make sure that the exhaust blowers over the burners are in proper operation. If not, it can lead to re-
deposition of the burnt out fibers on the fabric causing black specks.

▪ Ensure appropriate quenching into water/desize bath after singeing. Otherwise, the entrapped
smouldering particles may lead to fabric getting burnt (holes).

▪ Guide rolls next to the flames or the guide rollers on which flame is directed in case of heat-sensitive
fabrics should be cooled, generally by cold water circulating through the guide rollers. Otherwise they
could become red hot and scorch the fabric.

▪ Interlinking of stop button/flame switch-off mechanism/ quenching system should be effective to avoid
burning of the fabric and any incident of fire.
▪ This process is very fast.
▪ The fiber ends present in the interstices of warp and weft are
singed in this process.
▪ It is possible to singe both sides of the cloth in one operation by
using two burners.
▪ It is possible to control the flame intensity as per our
requirements.
▪ It is possible to control unwanted luster on the fabric in this
process.
▪ If the fabric incoming for singeing has too much moisture in it, a significant amount of thermal energy
will be used up in evaporating the fabric moisture rather than burning the protruding fibers, resulting in
incomplete singeing.
▪ Sometime Uneven Singeing happen across the Fabric Width for –
I. Uneven distance between the burner and the fabric
II. This may be due to misalignment or improper setting of the guide rollers
III. Uneven smoke evacuation over the burners
▪ Sometime Uneven Singeing happen along the Fabric Length for –

I. Variation in gas-air mixture supply

II. Increasing or decreasing thermal energy of the flames during production
III. Change in fabric speed during singeing
▪ Fabric can caught fire after passing the burner because of the unutilized spark on the fabric.
▪ Maintenance Cost is very high & well trained workers are needed for this process.
▪ Sometime Horizontal Singeing Stripes Happen for –
I. Rollers with an un-centered rolling action
II. Sudden fabric tension increase
▪ Sometime Vertical Singeing Stripes Happen for Total or partial blockage of flame
outlet.
▪ Sometime over-singeing or thermal damage of the fabric Happen for –

I. Too high flame intensity

II. Too slow fabric speed or too long contact time between fabric and flame
III. Too close distance between the fabric and the burner or too deep
penetration of the singeing flame into the fabric

▪ Formation of Small Beads of Molten Material could be happen due to Insufficient

energy supply, when the thermal energy is not supplied quickly enough to be able to
ignite the thermoplastic fiber rather than melting it.