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Assignment On Application of Plasma Technology in Textile

Undergraduate textile assignment

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32 views

Assignment On Application of Plasma Technology in Textile

Undergraduate textile assignment

Uploaded by

vateranspecs
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Table of Contents

Introduction ........................................................................................................................................................................ 3
Brief History…………………………………………………………………………………………………………………………..4
Principle of Plasma Technology……………………………………………………………………………………………4-5
Manufacturing Process………………………………………………………………………………………………………..6-7
Application Filed……………………………………………………………………………………………………………….8-10
Advantages……………………………………………………………………………………………………………………..10-11
Disadvantages……………………………………………………………………………………………………………………...11
Conclusion……………………………………………………………………………………………………………………...11-12
References ..................................................................................................................................................................13-14

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Plasma Technology in Textile
Introduction
In recent years, plasma technology has become important in all existing textile surface
modification processes. It is a dry, eco-friendly and worker-friendly method of achieving surface
weathering without altering the overall properties of different materials.(1) Due to increased
competition, textile materials cannot be limited to garments, linen, table cloths, and curtains
anymore, but must also be considered as high-tech products that, in addition to the
typical various technological applications in the apparel business sectors such as construction,
agriculture, automobile, and aerospace and medicine. Plasma technology has been used in this
area among all available textiles surface modification procedures. The particular physical and
chemical traits of the plasma surroundings make it appealing for textile processing. (3) A plasma
is an ionized gas, i.e. it consists of electrons, ions and neutral atoms and/or molecules. However,
now no longer all the ionized gases utilized in textile processing will showcase the properties
related to plasmas, particularly due to they have got low rate state densities as compared to the
impartial gas density or are produced with the aid of using transient phenomena. (2) The most
common plasma classification separates plasmas into two categories: hot plasma (when species
are in thermal equilibrium) and cold plasma (when species are not in thermal equilibrium).
Because most fiber-based materials are heat-sensitive polymers, cold plasma, also known as non-
thermal plasma, is ideal for textile surface modification and processing.(1) Textile materials have
long been utilized in the production of clothing, home furnishings, and everyday items. The
advancement of textile
industries and technology
provides the opportunity to
combine polymers, fabrics, and
other materials to improve the
performance attributes of
textiles for a wide range of
applications ranging from Fig : Plasma application in textile processing
geotextiles to sanitary and health
care textiles to electronic textiles. Textile material functions are connected with phenomena like
as wetting, biocompatibility, adsorption, and electrical conductivity in these applications. The
surface is where wetting, biocompatibility, adhesion, and many other performance qualities
begin. Textile surface and interface qualities are important in material processing and application
technologies. Surface modification of textile materials by plasma treatment has opened up new
opportunities in this industry in recent years. (4) Since the early 1980s, extensive research has
been conducted in numerous laboratories around the world dealing with low temperature
plasma treatments of a range of fibrous materials, with highly promising findings in terms of
improvements in different functional qualities of plasma-treated textiles. Growing environmental
and energy-saving considerations will also lead to the progressive replacement of many old wet
chemistry-based textile processing procedures, which use enormous quantities of water, energy,
and effluents, with different types of low-liquor and dry-finishing processes. When developed to
a commercially feasible level, plasma technology has the potential to offer an appealing technique
to accomplish novel functions in textiles. The goal of this study is to provide a thorough overview
and analysis of the science and technology surrounding plasmas, with a focus on their possible
applications in the textile industry. (4)

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Plasma Technology in Textile
Brief History
The fourth state of matter, plasma, is not such an odd phenomenon; I. Langmuir initially
introduced the plasma notion in 1926, and M. Faraday first produced plasma in the 1880s. An
ionized gas called plasma exists across a very wide range of temperature and pressure and has
an equal density of positive and negative charges.(5) In order to discover a means to significantly
increase the lifetime of the filament, Langmuir and his colleague Lewi Tonks were researching
the physics and chemistry of tungsten-filament lightbulbs. He created the hypothesis of plasma
sheaths, the boundary layers that form between ionized plasmas and solid surfaces, in the
process. Additionally, he observed that specific areas of a plasma discharge tube show periodic
fluctuations in the electron density, known now as Langmuir waves. During the 1920s and 1930s,
a small group of independent researchers started studying what is now known as plasma
physics.(6) Since their discovery, plasmas have sparked a lot of interest in both fundamental
study as well as in various applications of science and technology. One of its uses is plasma
treatment, which, depending on the treatment's settings, may alter the surface of a variety of
materials, including polymers, metals, textiles, and ceramics. Significant research work in the
textile field has been ongoing since the early 1980s in many laboratories around the world dealing
with low temperature plasma treatments of a variety of fibrous materials, with very promising
results in terms of improvements in various functional properties in plasma-treated textiles. (4)

Principle of plasma technology


Plasma technologies provide a diverse range of material treatment options. Plasma technology
for industrial operations primarily employs two forms of plasma: the first, known as "thermal
plasma," is generated at high pressure (>10kPa) using direct or alternating current (dc-ac) or
radio-frequency (RF) or microwave sources. These instruments create plasmas that have very
low gas ionization and electron and ion temperatures of the order of 1-2 eV. Thermal plasma may
be used to create anti-corrosion, thermal barriers, anti-wear coatings, and more. It can also be
used to eliminate solid, liquid, and gaseous poisonous, halogenated, and dangerous compounds.
The second form of plasma, known as cold or non-equilibrium plasma, is distinguished by having
an electron temperature higher than an ion temperature; it is created in a vacuum using low
power rf, microwave, or dc sources. Cold plasmas may be utilized for surface alternations ranging
from minor topological changes to the generation of fundamentally new surface chemistries and
coatings from the bulk
material.(7) Any
application of textile
processing will include
interaction between
the ionized gas and a solid
object. With addition
to the textile material,
the plasma may come into
contact with metal or
electrodes covered in
dielectric as well as the
chamber walls. Fig: Schematic process of different plasma process Potential structures
will be formed if the ionized gas fits the abovementioned conditions and may be classified as a

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Plasma Technology in Textile
plasma.(2) Because electrons are substantially less inactive than ions, the high-frequency
electromagnetic transmitters that are frequently utilized for the formation of a technological
plasma predominantly give their energy up to them. This indicates that the electrons are "heated,"
and as a result, their temperature and average kinetic energy both rise. When electrons and ions
collide, the electrons transfer their energy to the ions. This transfer of energy is relatively slight
because of the significant mass difference. To balance the temperatures of the ions and the
electrons, many collisions are required. It
depends on the pressure how many collisions
a particle experiences. Because there are
more collisions under high pressure, the
average energy of the electrons and ions
quickly equalizes. On the other hand,
thermalization across particle types is
ineffective in low density plasmas, leading to
the formation of a system with hot electrons
and cool ions. (8) Collisions, in
addition to thermal equalization, play a
Fig: Principle of Plasma Technology
function in the preservation of
charge carriers. When ions and electron mixtures are combined, neutral atoms are more likely to
result. The term "recombination" refers to this process. The plasma loses some of its conductivity
as a result of this recombination, which turns the two free charge carriers (ions and electrons)
into neutral atoms. An ionized gas is transformed into a normal gas by a process called
recombination. A balance between charged particle creation and annihilation is necessary for the
steady burning of ignited plasma. This source is made up of the previously described collisions of
electrons with atoms or ions. When a heated electron strikes an atom, it can knock out a trapped
electron (ionization). While initially there was only one free carrier, after the collision there were
three. If recombination and ionization are in equilibrium, the plasma will burn in a steady way.
Moreover, an electron impact can cause other processes in addition to the ionization of an atom.
To ionize an atom, an electron must transmit the ionization energy to the atom during the
collision. The impacted atom is stimulated if the amount of energy transferred after impact is less
than the energy required
for ionization. The excited
states of such an atom are
often unstable, and it
returns to its basic state
while emitting light. This is
the reason why plasmas
appear to be lighted. (9)

Fig : Plasma operation explained

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Plasma Technology in Textile
Manufacturing Process
In terms of electron temperature against electron density, plasma processes may be divided into
two basic categories: low-density and high-density. The temperatures of the electrons and heavy
particles are not identical in low-density, direct-current, and radio-frequency glow discharges.
Hot electrons, cold ions, and neutrals coexist in low-density plasmas. Low-temperature neutrals
are ionized and split apart when energetic electrons hit with them, producing free radicals and
ions that are extremely reactive.(2)
In most cases, well-known plasma types that are used in surface treatment processing procedures
are created by partly ionizing a gas at a pressure that is significantly lower than atmospheric
pressure. With an ionization percentage ranging from 10-5 to 10-1, these plasmas are typically
weakly ionized. At high power, electron cyclotron resonance (ECR) plasmas can have more
ionization. Due to the low pressures used in these systems, vacuum chambers and pumps are
required to develop and contain these plasma processes. Using a variety of inert and reactive
gases, the atmospheric plasma system can generate uniform and homogeneous high-density
plasma at atmospheric pressure and low temperatures. On a wide variety of materials, the
atmospheric plasma treatment process (ATP) treatments and functionalizes material surfaces in
the same way as the vacuum plasma treatment process does, and it offers distinct benefits over
the currently employed corona, flame, and priming treatment methods. Testing of APT
production equipment for the treatment of a variety of materials, including oriented PP film, PE
film, PE terephthalate (PET) film, and polytetrafluoroethylene film, has been done successfully.
These materials include PP fiber, PP and polyethylene (PE) nonwovens, polyester fiber, nylon,
wool, and textile yarn. The wettability, printability, and adhesive characteristics of the treated
materials were improved as a result of the treated materials' significantly enhanced surface
energies (without any backside treatment). (8)

Fig : Steps involved in plasma treatment

The grafting of a substance onto the fiber or surface modification by discharges are the two
primary approaches that may be taken into consideration in the prospect of chemical finishing
employing plasma. Plasma treatment changes the top atomic layers of a material's surface while
leaving the bulk properties unchanged. Surface alterations like as surface etching, surface
activation, cross linking, chain scission, decrystallization, and oxidation may emerge from this
treatment of textiles. The choice of working gas, as well as plasma density and energy, affect the
course of treatment. Plasma medium can be air, oxygen, argon, fluorine, helium, carbon dioxide,
or their mixes. The kind of gas utilized affects the process outcome. even if the gas is the same,
the outcome will change if the type of fiber is different. Textiles can be treated between two
electrodes (in fact in the plasma) or near the plasma region. (10)

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Plasma Technology in Textile
The feed gas is converted plasma-chemically, resulting in chemically active particles that, when
they come into contact with textile surface molecules, can change those molecules through
chemical processes. It is necessary to provide the radicals produced inside the plasma zone a
chance to migrate to the reaction site on the surface of the fabric strand. The radicals produced
inside the plasma zone must be allowed to migrate to the reaction site at the textile fiber surface.
It is necessary to provide the radicals produced inside the plasma zone a chance to migrate to the
reaction site on the surface of the fabric strand. As a result, the path of radicals between the sites
of production and reaction is constrained by the gas density, or the average distance between gas
particles, as well as by two factors: the distance between single fibers on the one hand, and the
gas density on the other. Assuming radicals react or recombine after several impacts with gas
particles and at surface sites on fibers there is a relationship between penetration depth of the
plasma effect inside the textile structure and process pressure as well as the textile structure
itself.(7)
Plasma spraying process: The surface being coated is sprayed with droplets in the same manner
as color spraying is. Unlike color spraying, plasma spraying requires the film material to be
melted by a high-energy heat source before being sprayed onto the cold surface of the fabric or
three-dimensional body. Due to heat transmission from the droplets to the underlying material,
they flatten and instantly cool off as they contact the surface (substrate). The particles shrink and
solidify. The films stick together principally as a result of mechanical adhesion and locally as a
result of various chemical bonding forces. The cleaned surfaces are sandblasted to provide a
rough surface in order to produce a high film adhesion. Due to the particles' ability to penetrate
surface roughness and
condense onto peak surfaces, this
results in strong adhesion. An electric
arc in a nozzle warms up a flow of gas
(typically argon, nitrogen, or helium) to
extremely high temperatures in
plasma spraying. Excessive gas
temperatures arise, resulting in the
splitting of molecular gases and
partial ionization of atoms. The high
temperatures cause a significant rise
in the volume of the gas (plasma),
which flows out of the nozzle at high
speed (Fig); in plasma spraying
facilities, the flow speed of the plasma jet may approach several times the speed of sound. A
carrier gas is Fig : Plasma spray process: (1) cathode (2) powder supply (3) used to feed the
powder particles (4) melted powder particles (5) splat (6)
powdered film substrata (7) fuel gas supply (8) anode (9) plasma arc (10) flame material into the high
intensity plasma with melted powder particles. jet. The particles are
melted and shot onto a prepared base material. However, the particle speed is less than the speed
of sound. Plasma spraying can produce high-quality coatings from almost any material that melts
without degrading and can be made in a sufficient grain size. Typically, aluminum oxide or
chromium oxide coatings are used in plasma spray applications. Plasma spraying can also be used
to apply pure tungsten coatings and tungsten carbide cobalt coatings. (8)

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Plasma Technology in Textile
Application Field
More than 15 years ago, a range of batch/in-line low-pressure plasma commercial devices, the
most of which are prototypes, have been available. Because they have so many benefits over
traditional wet processing methods, plasma treatments are becoming more and more popular in
the textile industry. The bulk property is unaffected by the plasma treatment. Plasma surface
treatments have special benefits since they may affect the surface characteristics of inert
materials, often using environmentally benign technologies. The use of "Plasma Technology" in
textile chemical processing is one of the most revolutionary techniques to improve textile wet
processing from pretreatment to finishing. The use of plasma technology in the pretreatment and
finishing of textiles is described in some detail below.(4)
Improvement of the Antimicrobial Property of Fabric:
Nowadays, a lot of textile surface modification methods including plasma treatment are employed
to create long-lasting antimicrobial fabrics. Sontara®, a nonwoven fabric used to make surgical
gowns, has been given a fluorocarbon plasma treatment and an antimicrobial finish to give it dual
functionality namely- blood and microbe repellency. Graft copolymerization with plasma
preprocesses was used to produce biocidal polypropylene. In order to make it easier to load
greater amounts of silver oxide and zinc oxide, cotton fabric has been preprocessed with plasma
to make the surface rougher. These oxides were utilized as a catalyst to enhance the reaction
between halogenated phenoxy chemicals and the binder microban, which resulted in the fabric
acquiring a biocidal characteristic. When in contact with an atmospheric pressure glow discharge
plasma, a 50/50 nylon cotton-blended military cloth develops a graft polymerized network.
Pentaerythritol tetraacrylate (PETA) with diallyldimethyl ammonium chloride monomer to
create a long-lasting antimicrobial network, use a cross-linking agent.(11)
Denim Fabric Decolorization:
Even though denim is one of the oldest textiles in existence, it never gets old. Blue jeans were
originally dyed with indigo to manufacture them, despite the fact that the term "jeans" referred
to a different, lighter cotton fabric. In the past, manufacturers of denim jeans have cleaned their
products using pumice stones to give them a soft handle and the desired worn appearance. Argon
Low Temperature Plasma has been researched as a method of decolorizing denim materials.
Denim samples from treated and untreated samples demonstrate certain benefits of the plasma
method over washing. Without weakening the fabric's strength, this technique leaves the denim
with an excellent varnish and smooth surface. Additionally, the technique takes significantly less
time (15 min) than stonewashing does (more than 90 min). Additionally, there is no requirement
for pricey pumice stones or specific enzymes, both of which are necessary for the stonewash
procedure.(12) A comparison was made between the outcomes of decolorized denim using
various gases, such as oxygen or argon, in a DC magnetron sputtering system. After being treated
for 15 minutes, the results reveal that Argon produces a superior decolored output than Oxygen.
However, the samples treated with O2 after washing the denims seem better than those treated
with Argon since all oxidized dyestuffs created during the plasma treatment were removed.
Increasing the dyeability of textiles:
By applying low temperature plasma treatment, Polypropylene Fabrics' dye-ability is increased.
Anionic dyes boost the dye-ability of PP textiles that have undergone LTP of N2, while the dye
exhaustion for cationic dyes rises considerably when OH and C=O groups are created on the
fabric's surface during LTP of O2. With cationic dyes, PP may readily be colored with O2 LTP
treatments. PP textiles also saw new applications as textile clothing evolved. The examples shown

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Plasma Technology in Textile
here demonstrate how plasma technology used at low pressure may result in a number of
techniques for modifying fiber or textile materials to meet extra, very desirable requirements. It
is believed that this technology, which has been around for a while and is already employed in a
variety of industrial sectors, will soon rule the textile industry as well. It was also investigated
whether plasma sputtering may replace mordant treatment in terms of how wool naturally dyes.
The findings demonstrate that sputtering has enhanced the natural dyeing capabilities of wool
fibers. It has also increased the resilience of wool to washing and light. The colored treated
materials have also developed excellent antibacterial characteristics.(14)
Improving the Hydrophilic Properties of Fabrics:
LTP treatment altered the physical and chemical properties of wool samples. The position of the
wool samples in the LTP reactor is critical. The wet and dye abilities of wool samples were
improved by placing them on the cathode and utilizing oxygen as a working gas.(4)
Improving Water Repellent Properties of Fabrics:
The interstices between the warp and weft yarn are blocked, preventing water from passing
through the treated textiles, thanks to the low temperature plasma coating of aluminum and
copper on the fabric's surface. The mechanical, aesthetic, and physical characteristics of the
materials remain unaltered after the treatment, allowing drips to freely fall on the surface.
Confirmation of LTP's inability to alter fabric strength comes from the crystallization structure of
textiles. (15) The characteristics of cotton treated with a thin coating of aluminum have been

Fig : Water proof coating using plasma technology

examined, particularly its water repellency. The procedure was carried out with a magnetron
sputtering apparatus in a low temperature plasma medium. Additionally, the effects of several
gases, including argon and oxygen, as the discharge medium on the characteristics of the
produced samples have been studied. Under the conditions of the experiment, the findings that
are time dependent reveal an excellent repellent property for 30 minutes of treatment in argon
medium. When O2 is introduced into the solution, however, the cotton property changes to
become hydrophilic, with the factor decreasing as the treatment duration increases.(4)
Anti Felting Properties of Wool:
When wool is treated with LTP, its surface might alter physically and chemically. The findings
demonstrate that the surface's chemical composition has also been altered in addition to its
topography. Additionally, the impact of exposing the samples when they are on the cathode or
anode, as well as their reaction to various gases including argon, oxygen, and nitrogen as the

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Plasma Technology in Textile
discharge medium, were examined. After LTP therapy, shrinkage has greatly diminished. The
results show that the position of the samples inside the plasma reactor and the kind of gas utilized
have a significant impact on the ability of the wool samples to resist shrinkage. We observed a
significant improvement in shrink resistance for Argon, O2 and N2-cathode plasma treated
samples, but not for O2 and N2-anode plasma treated samples. Under the right circumstances,
the wool's wetability and dyeability may both be improved. The disruption of the scale structure
caused by plasma etching on a wool surface and the introduction of additional polar groups such
carboxyl groups owing to plasma chemical alteration are the causes of the decreased water
absorption time and increased dye ability of wool samples. Furthermore, the LTP treatment may
impart considerable shrink-resistant and anti-felting properties to wool materials. (16)
Improving the Flame Retardant Properties of Fabric:
The effects of low temperature plasma pretreatment on the metal salt absorption by cotton
textiles and the flame retardant characteristics of the treated samples before and after dyeing
were examined. On cotton textiles, metallic salts of titanium dioxide (TiO2), zinc sulfate (ZnSO4),
lead(II) acetate (Pb(C2H3O2)2), aluminum sulfate (Al2(SO4)3), and silver nitrate (AgNo3) were
utilized. In order to assess the flame retardant properties of treated samples, several analyses,
including char production and LOI, has been studied. Greater LOI values of the plasma
pretreated/metal salt loaded textiles are a result of the enhanced char production. The findings
show that cotton textiles that have been prepared with plasma and inoculated had strong flame
retardant qualities. The LOI value increased from 18.6 to 23.3 after the inoculation in a Silver
Nitrate (AgNo3) 0.01 M solution. According to the findings, treated materials' flame retardant
qualities can endure dyeing, and coloring inoculation cotton fibers has no detrimental effects on
the fabric's ability to resist flame. According to the findings, treated materials' flame retardant
qualities can endure dyeing, and coloring inoculation cotton fibers has no detrimental effects on
the fabric's ability to resist flame.(17)

Advantages
 Woolen textiles' resilience to shrinking and anti-felting can be done by plasma treatment.
 Enhancement of hydrophilicity to increase wetting and coloring .
 Enhancement of hydrophilicity to promote adhesive bonding.
 Enhancement of materials that resist water and oil through hydrophobicity.
 Plasma treatment facilitates the removal of sizing agents.
 Removing surface hairiness from yarn.
 Antibacterial fabrics created via deposition of silver particles in the presence of plasma.
 Room-temperature sterilisation of medical textiles.
 Fabrics that have been plasma-treated have a high hydrophilic stability when kept in
alkaline medium.
 Graft polymerization of textiles and nonwovens with varied surface functional
characteristics on the front and back of the fabric using atmospheric plasma.
 A fabric with one side coated with a sizing agent that is inert to plasma and the other side
left hydrophobic or hydrophilic after size removal, resulting in a fabric with varied
functioning on its two sides.
 Flame retardant coating based on monomer vapour (halogen and/or phosphorus) in
conjunction with nitrogen and/or silicone.
 Silicone coating of airbag textiles using crosslinked silicone (polyorganosiloxanes).

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Plasma Technology in Textile
 Scouring cotton, rayon, and polyester textiles with a non-polymerisable gas (nitrogen,
argon, ammonia, or helium), followed by wet treatment to remove contaminants.
 Preventing natural occurring color fluctuation in fabrics.
 Durable antistatic properties using PU-resin and plasma processing
 Shrink resistance of animal hair textiles utilizing urethane-based resin and plasma
processing
 Textile yarns' ability to carry electricity through surface plasma deposition
 It is more cost effective than traditional wet processing due to lower chemical usage and
lower chemical and water expenses.
 Pore-free, uniform thin films with better qualities that traditional chemistry cannot
accomplish may be deposited on practically any substrate.
Numerous patents have been issued in the field of plasma treatment of fibers, polymeric textiles,
nonwovens, coated fabrics, filter media, composites, etc. for improving their functionalities and
performance. Hundreds of publications have been written on plasma technology.(2)

Disadvantages
 One of the plasma therapy's most significant drawbacks is system reliance. The same flow
rate, gas pressure, and power input may not result in the same amount of the required
reactive species, according to this.
 Although early expenses like buying pricey plasma equipment and high vacuum pumps
are thought to be limiting considerations and can be seen as a disadvantage.
 There may be technological difficulties when scaling up and changing a batch-based pilot
operation to a continuous process.
 Each process and piece of equipment must have optimal process parameters. However,
overcoming these obstacles is not difficult.
 The ability to treat thin surface layers without affecting the bulk may be advantageous in
some applications and disadvantageous in others, depending on whether it is desired to
maintain the bulk untreated or to treat only the thin surface layers.
 Yarns or fibers directly are used to create textile products. Even more so when they are
in high twist yarns, the fibers are overlapping in both cases. The darkened portions are
often shielded from plasma therapy as a result generating a shadow effect.
 It is more difficult to estimate the exact structural properties of the plasma treated region
for a more complicated chemical. This is because plasma causes the complicated
molecular structure to break into a plethora of coexisting active species that might react
or deposit on the surface.(18)

Conclusion
When compared to existing standard finishing procedures, plasmas offer the significant benefit
of using less chemicals, water, and energy. Integrating plasma technologies at various stages of
the manufacturing process (sliver, yarn level, or on fabric) has been researched for a wide variety
of materials and applications. Nevertheless, due to significant barriers that exist at many levels,
industrial use is still quite restricted.(19) Plasma technology is advancing in the industrial
revolution slowly but steadily. Although plasma treatment of textiles cannot completely replace
all wet methods, it can be a useful pretreatment process with several financial and environmental

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Plasma Technology in Textile
advantages. As a result, the textile sector should think about making larger capital investment in
equipment that will soon pay for itself through reduced environmental impact and increased
revenue from the sale of high-value added goods.(4)

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Plasma Technology in Textile
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Plasma Technology in Textile

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