Ministry of Textiles, Government of India

MINISTRY OF TEXTILES, GOVERNMENT OF INDIA

DESIGN AND DEVELOPMENT OF GEOTEXTILE CREEP RUPTURE BEHAVIOUR

HIGHLIGHTS:

BTRA designed and developed a test instrument to evaluate the functional performance of the Geotextiles for creep and creep rupture behaviour that will be meet the requirements of ASTM standard test methods of ASTM D 5262 and ASTM D 6992.

Date of Start : 16/11/2010
Duration (months) : 24
Target Beneficiaries : Geotextiles
Grants Received (Rs. In Lakhs) : 25.52
Location : Mumbai
Status : Completed

STUDIES ON TEXTILES DOPED WITH CONDUCTING POLYMERS

HIGHLIGHTS:

Prototypes such as Heating Pad/blanket, Warm Jackets, Smart Mat, etc. are developed. Two patents are filled. Demonstration of Prototypes are shown at various textile exhibitions for the past 3 years.

Date of Start : 12/11/2009
Duration (months) : 36
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 40.40
Location : Mumbai
Status : Completed

DEVELOPMENT OF METHOD FOR TESTING AND ANALYZING THE FORMALDEHYDE CONTENT IN TEXTILE AUXILIARIES

Industrial Benefits & Feed Back

The project is mainly focused on the development of a test method for analyzing the formaldehyde content in textile auxiliaries. Since the formaldehyde is a hazardous substance and restricted its use in the textile industry and at present there is no scientific/ validated test method available to quantify the presence of formaldehyde in trace levels, hence the textile industry is facing lot of difficulty to control the formaldehyde in their finished product especially for export materials. The developed test method can be successfully used to quantify the formaldehyde content in the input raw materials as well as the final products like binder, resin, dye fixing agent, softener etc. This method can serve as preventive approach to avoid use of formaldehyde by the processors.

In order to disseminate the information and to put to practical use, a presentation based on the developed test method was made in the BIS TX-05 committee meeting. Based on the recommendation and feed back of the committee.

Further, as a part of method validation of the in house developed method as per the feed back by the Industry representatives, was validated by conducting the Inter Laboratory Comparison (ILC) testing. It may be noted that the BIS is represented by the stake holders (Industry representatives) who are either user of the test method or test results for their business prospects. The representatives of the industry realized the importance of the outcome of the work and gave feedback for ILC and making it as a national standard for testing.

The work was presented at the expert advisory committee meeting of BTRA on 21st March, 2012 which was appreciated by the members.

Date of Start : 01.01.2010
Duration (months) : 24
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 48.83
Location : Mumbai
Status : Completed

STUDIES ON FIRE RETARDANT FINISHING OF APPAREL AND HOME TEXTILES TOWARDS MEETING THE EXPORT REQUIREMENT

Industrial Feedback

The project was aimed at creating awareness about hazardous nature of various FR chemicals used by the industry and trade. As part of the project we have conducted awareness workshop/seminars at Mumbai, Bangalore, Kolkata, Ahmadabad and Bhilwara. Nearly 300 industry personnel have participated in the interaction. During these workshops, the participants were impressed upon the ill effects of various FR chemicals and their eco-friendly/ unfriendly properties. Further, the ways and means to characterize them to find out their presence in the finishing chemicals as well as finished products were given. Since the project address the Niche component of textile market i.e. FR products, the participants were interactive and took keen interest in the dissemination of workshop especially those who do business with EU and USA. It was noticed that the industry representatives by and large were not aware of the hazardous nature of FR chemicals like the azo dyes. During the interaction the participants were briefed about material safety data sheets (MSDS) and interpretation of the same as per international requirement was given. Hence it is informed that the dissemination of seminars have served the purpose of bringing awareness to the industry about the hazardous nature of the substances and the legislative requirements of EU and USA. Further the implication of usage of such chemicals in terms of poor business prospects of export of FR treated textile goods containing these types of finishes were discussed. Details of minutes of the interaction in each seminar are enclosed in the completion report of the project.

Aspects pertaining to commercialization of the project findings:

The positive list of the FR chemicals will be provided to Prospective industries.
Protocol has been developed for evaluation of the FR chemicals; this will be used for evaluating the FR chemicals submitted by the industry. The necessary feedback for its use as well as improvement will be given to the industry.

The work was presented at the expert advisory committee meeting of BTRA on 21st March, 2012 which was appreciated by the members.

Date of Start : 12.11.2009
Duration (months) : 24
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 30.00
Location : Mumbai
Status : Completed

PLASMA TECHNOLOGY FOR TEXTILE PROCESSING

Industry feedback/ response

The continuous endeavor to disseminate the project outcome by way of the presentations and publications resulted in interactions with industries from various textile segments. The units approached BTRA for exploring the potentials of atmospheric pressure plasma technology for their specific requirements. The names of industries and specification of work done for them are not mentioned because of confidentiality nature of work. However, some of the areas in which specific application addressed are as under:

Manufacturers of denim and cotton related products have approached to impart functional properties to cotton fabrics. Pilot scale trials were conducted on the atmospheric pressure plasma machine at BTRA. The initial trials have shown encouraging results for imparting functional properties to cotton fabrics. Investigation is going on at their end regarding the future collaboration for use of plasma technology.

Pilot scale trials were conducted for an industry manufacturing coated abrasives based polyester fabrics. The studies were performed for improvement in wettability and adhesion promotion of the treated fabrics.

Dialogue is going on with other players in the synthetic fibre manufacture in India to meet the specific targets using of plasma technology.

Commercialization aspects:

The interested industries will be provided know-how for plasma assisted desizing, plasma assisted dyeing and plasma assisted finishing. The necessary technical support in the adoption of new technology as well as conducting initial trials will be done by BTRA with use of pilot scale plasma machinery installed in the BTRA labs.

The work was presented at the expert advisory committee meeting of BTRA on 21st March, 2012 which was appreciated by the members.

Date of Start : 01.01.2009
Duration (months) : 36
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 50.00
Location : Mumbai
Status : Completed

DESIGN AND DEVELOPMENT OF REELING-CUM-TWISTING AND SPINNING MACHINES FOR NON-MULBERRY SILK

HIGHLIGHTS:

Achievements were made against the target by developing reasonably productive and quality oriented miniature silk fibre processing machinery in the non-mulberry sector by BTRA. The productivity turns around 20-25 % on higher level against the latest machinery available in this sector. The mechanical stability of the machines is so sound that the machine efficiency has gone up to an encouraging level. Hence the achievements made under the project have been commendable. With this development, there will be an end for all primitive and health hazardous practices presently adapted in silk yarn manufacturing of non-mulberry silk sector. The results need to be scaled up.

Date of Start : 01.09.2005
Duration (months) : 30
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 16.75
Location : Mumbai
Status : Completed

EXPLORATION OF NEW AVENUES IN APPLICATION OF BIOTECHNOLOGY IN TEXTILE PROCESSING WITH RESPECT TO QUALITY IMPROVEMENT AND SOURCE REDUCTION IN STREAM POLLUTION

HIGHLIGHTS:

Desizing of cotton fabrics(sized with starch-based composition) and weight reduction of polyester (to improve quality) in a process house lead to discharge of effluent stream with high pollutional load. Under this project, application of enzymes in these processes was studied for reduction in pollutional load of effluent stream as well as for changes in physical properties of fabric quality.

Date of Start : 01.01.2002
Duration (months) : 24
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 07.50
Location : Mumbai
Status : Completed

IMPROVISATION OF EXISTING HANK SIZING PROCESS AT DECENTRALIZED POWERLOOM SECTOR TO UPGRADE QUALITY AND FABRIC REALIZATION OF VALUE ADDED YARN DYED SORTS

HIGHLIGHTS:

A hank sizing machine was designed to overcome and eliminate the various shortcomings associated with the conventional hank sizing process. Based on the design, a prototype model of the machine was developed and sizing trials on the hanks were undertaken to study the efficacy of the machine. This machine is in operation in the Powerloom Service Centre at Malegaon.

Date of Start : 01.09.2001
Duration (months) : 12
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 09.39
Location : Mumbai
Status : Completed

DESIGN AND DEVELOPMENT OF COMPUTER BASED TRAINING MODULES FOR TOTAL QUALITY MANAGEMENT IN TEXTILE INDUSTRY

HIGHLIGHTS:

Design and development of computer-based training modules for Total Quality Management (TQM) in textiles is done. The CD-ROM prepared covers various aspects such as concepts of TQM (like ISO 9000 / TPM / 5S / Kaizen), case studies in mills, self-learning, etc. and it can be used interactively.

Date of Start : 16.07.2001
Duration (months) : 18
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 21.03
Location : Mumbai
Status : Completed

DEVELOPMENT OF TEST BENCH FOR TESTING AT VARIOUS PNEUMATIC COMPONENTS, CIRCUITS AND ASSEMBLIES, USED IN TEXTILE MANUFACTURE

HIGHLIGHTS:

To develop a test bench for testing pneumatic components, BTRA has assembled a pneumatic test bench and prepared a comprehensive training package to train technicians for understanding the basic functions as well as assembling different pneumatic components / electro-pneumatic circuits. The testing methods to test various pneumatic components are prepared.

Date of Start : 12.02.2001
Duration (months) : 24
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 35.36
Location : Mumbai
Status : Completed

ECO-FRIENDLY FINISHING TO NATURAL DYED FABRIC WITH SPECIAL REFERENCE TO DECENTRALIZED SECTOR

HIGHLIGHTS:

Dyed fabrics (dyed with several natural dyes) were treated with conventionally used cross-linking agent (DMDHEU), very low formaldehyde (VLF) and no formaldehyde polycarboxylic acids. These finished fabrics were then evaluated for changes in shade and different physical properties.

Date of Start : 12.02.2001
Duration (months) : 18
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 27.34
Location : Mumbai
Status : Completed

DEVELOPMENT OF INTEGRATED SYSTEM TO IMPROVE AND OPTIMIZE THE PERFORMANCE OF STENTERS IN PROCESSING THE TEXTILE FABRICS TO SAVE ENERGY AND IMPROVE QUALITY

HIGHLIGHTS:

Integrated system for stenters using microcontroller and peripheral IC is successfully designed and developed by BTRA. The system is designed in such a manner that it can be retrofitted on any existing stenter machine. The stand alone system has all the facilities such as key board, alphanumeric display, battery back up, data retrieval facility, etc. to enable the operator to know the current status of all machine parameters. The data is continuously monitored by the system which can be communicated to central PC for long term data storage, analysis and report generation. The field trial has proved the reliability and trouble free operation of the system in mill conditions. It has improved machine performance and fabric quality.

Date of Start : 12.02.2001
Duration (months) : 24
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 39.97
Location : Mumbai
Status : Completed

DEVELOPMENT OF SHADES ON CELLULOSIC YARNS AND FABRICS MEANT FOR VALUE ADDED PRODUCTS MANUFACTURED BY DECENTRALIZED POWERLOOM SECTOR USING TRICHROMATIC REACTIVE DYES

HIGHLIGHTS:

Using trichromatic reactive dyes, various shades are developed on cellulosic yarns and fabrics (woven/knitted) meant for value added products manufactured by decentralized powerloom sector. Also,a database on the same is built that is useful in giving shade matching services to textile units.

Date of Start : 12.02.2001
Duration (months) : 24
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 31.61
Location : Mumbai
Status : Completed

DEVELOPMENT OF SPECIAL ECO-FRIENDLY FRICTION REDUCING AGENT TO MINIMIZE RING YARN HAIRINESS TO ENHANCE TEXTILE EXPORTS

HIGHLIGHTS:

A low odour, unique eco-friendly ring lubricant has been developed which reduces co-efficient of friction between the ring and traveller and in turn hairiness. Shop-floor studies carried out showed 30 % reduction in hairiness in normal ring conditions without incurring much cost. Use of BTRA ring lubricant has brought about drastic reduction in hairiness, improved traveller life due to smooth running of the traveller and better fabric appearance. Many mills are successfully using this newly developed product.(Technology transferred to M/s. C & C Textiles Pvt.Ltd., Ahmedabad).

Date of Start : 01.10.1999
Duration (months) : 18
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 19.39
Location : Mumbai
Status : Completed

ASSESSING THE POTENTIAL AND FORMULATING / SUGGESTING MEASURES FOR FUEL SAVING IN DECENTRALIZED PROCESS HOUSE UNITS

HIGHLIGHTS:

The study has helped in generating awareness and effecting fuel savings in the process house units to a greater extent. Many of these units have acknowledged the fuel savings achieved through BTRA’s assistance.

Date of Start : 01.10.1999
Duration (months) : 24
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 19.62
Location : Mumbai
Status : Completed

DEVELOPMENT OF AN ALTERNATIVE AND COST-EFFECTIVE ROUTE FOR HEAT-SETTING OF DIFFERENT SYNTHETIC FIBRES/FILAMENTS/FABRICS USING MICROWAVE RADIATION TECHNIQUE

HIGHLIGHTS:

The project opened up new avenues for the use of microwave radiation technique in man-made fibre industry, especially for polyester. Efforts are made to develop high tenacity PET fibre by reducing molecular relaxation during microwave treatment. Effect of microwave radiations with different lossys on the surface of these fibres are studied and compared with conventionally heat set samples. (Patent Received).

Date of Start : 01.09.1999
Duration (months) : 30
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 55.20
Location : Mumbai
Status : Completed

FIBRE QUALITY ENHANCEMENT BY PROCESS CONTROL AT GINNING

HIGHLIGHTS:

Under this project, studies were carried out to find out the effect of moisture level on the quality of ginned cotton by varying the moisture level in the kapas before ginning. Various varieties of cotton fibres ranging from short staple to extra long staple were studied. The results show that there is an improvement in 2.5 % span length and bundle strength of fibres when it is processed with medium(7-8%) and high moisture (10-12 %) level in the kapas.

Date of Start : 01.09.1999
Duration (months) : 17
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 10.00
Location : Mumbai
Status : Completed

USE OF 'STROBOSCOPE' KIT TO ESTIMATE AND OPTIMIZE AIR CONSUMPTION ON AIR-JET LOOM AND TO EXPLORE THE POSSIBILITIES OF MODIFYING THE ASSEMBLIES OF AIR MEDIA TO ENHANCE ENERGY CONSERVATION

HIGHLIGHTS:

Consumption of compressed air, used in air-jet looms for weft insertion, was studied with the help of Stroboscope in a number of mills. Various makes of air-jet looms were observed for air consumption and air losses. After collecting required data and conducting different studies, controlled trials were taken to reduce air consumption and the results were encouraging. Also, studies were undertaken by using modified design of the relay nozzle and its effect on air consumption. Results show that there is a scope for enhancing production and reducing air consumption.

Date of Start : 01.09.1999
Duration (months) : 27
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 23.01
Location : Mumbai
Status : Completed

DYEING LYOCELL FIBRE WITH DIFFERENT CLASSES OF REACTIVE DYES

HIGHLIGHTS:

Lyocell fibre is a new type of regenerated cellulosic fibre. This fibre is completely manufactured by eco-friendly process. Further, Lyocell fibre offers several advantages as compared to viscose or other regenerated fibres Bi-functional dyed fabric, before or after enzyme treatment, showed lower fibrillation as compared to monofunctional dyed fabric. Information gathered from the studies has been transferred to technologists engaged in textile processing industry, both in the organized and decentralized sector through group discussions, presentation at All-India Conference and Seminars, exhibitions, etc.

Date of Start : 01.03.1999
Duration (months) : 27
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 16.50
Location : Mumbai
Status : Completed

MEASUREMENT AND CONTROL OF DUST LEVEL GENERATED ON MODERN WEAVING, PREPARATORY MACHINES AND SHUTTLELESS LOOMS

HIGHLIGHTS:

This study has created a good awareness among the mill management and technicians towards reducing air pollution and creating healthy work atmosphere.

Date of Start : 18.02.1999
Duration (months) : 30
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 25.28
Location : Mumbai
Status : Completed

STANDARDISATION OF WET PROCESSING CONDITIONS FOR WATER CONSERVATION VIS--VIS REDUCED WATER POLLUTIONAL LOAD

HIGHLIGHTS:

Shopfloor survey and evaluation of the consumption data, after part/full implementations of the recommendations for standardizing the processing conditions, in the participating units in woven, knitted and worsted mills showed, not only reduction of water consumption from 25 to 38 % for the similar production pattern, but also helped in reducing the cost of thermal and electrical energy. In addition, the measures suggested helped the mills to reduce the wet processing cost/unit production on colours and chemicals, improve consistency of results, lower reprocessing, load of pollutant in the discharged effluent stream, etc.

Date of Start : 18.02.1999
Duration (months) : 27
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 43.97
Location : Mumbai
Status : Completed

DEVELOPMENT OF MICRO-CONTROL SYSTEM TO MONITOR PRODUCTIVITY AT POWERLOOM SECTOR

HIGHLIGHTS:

BTRA has developed and installed a prototype microprocessor-based on-line performance monitoring system on a loom. This system greatly enhances the productivity of the unit and improve the quality of its products. The system evaluates the performance of loom in terms of production, efficiency, stoppage rate, duration of stoppage and cottonwise loss of the efficiency of the loom, which assist in prompt follow-up action. Parameters evaluated, on comparison with manual observations, were found to be satisfactory.

Date of Start : 18.02.1999
Duration (months) : 15
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 10.07
Location : Mumbai
Status : Completed

UPGRADING THE QUALITY OF KNITTED GOODS THROUGH THE USE OF COMBED ROTOR YARNS

HIGHLIGHTS:

The knitted fabric produced from combed rotor yarn showed higher bursting strength than the corresponding fabric produced from carded rotor yarns. The use of long staple, low micronnaire, stronger cotton fibre for rotor spinning improved yarn and fabric quality considerably.

Date of Start : 10.02.1999
Duration (months) : 18
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 16.50
Location : Mumbai
Status : Completed

DEVELOPMENT AND IDENTIFICATION OF HIGH PERFORMANCE AND MULTIFUNCTIONAL PRODUCTS AND PROCESSES FOR VALUE-ADDED FABRICS FOR EXPORT AND FOR MANUFACTURE BY DECENTRALIZED SECTOR

HIGHLIGHTS:

With respect to bio-scouring of cotton fabrics appropriate conditions for bio-scouring and peroxide bleaching have been standardized which in turn makes the process completely eco-friendly as compared with conventional alkaline scouring-peroxide bleaching. These results are transferred to process houses who are interested in switching over to bio-scouring and peroxide bleaching as such a process was beneficial with added advantage of saving in time, water and energy. (Technology transferred to M/s.Novozymes, Bangalore).

Date of Start : 10.02.1999
Duration (months) : 24
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 35.44
Location : Mumbai
Status : Completed

DEVELOPMENT OF ECO-FRIENDLY PATCHLESS STAIN REMOVER WITH SPECIAL REFERENCE TO THE NEEDS OF THE EXPORT OF TEXTILES

HIGHLIGHTS:

An eco-friendly patchless stain remover has been developed which is highly concentrated, has low odour and is biodegradable. It contains ecological solvents that are free from chlorine derivatives. The product can be safely used without injuring/fraying the yarn or fibre as the process does not involve any rubbing and mopping. The product is being supplied to the user industry. (Technology Transferred to M/s. Rossari Biotech, Mumbai)

Date of Start : 10.02.1999
Duration (months) : 18
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 11.79
Location : Mumbai
Status : Completed

ESTABLISHING NORMS FOR AIR CONSUMPTION IN SPINNING AND WEAVING DEPARTMENTS

HIGHLIGHTS:

This study, the first of its kind in the Indian Textile Industry has helped in understanding the pattern of compressed air consumption rate (in cubic feet per minute)for spinning and weaving machines. The computed ratios of compressed air consumption (in cubic feet) per unit of production has helped in understanding the impact of compressed air usage on the cost of production. Based on this air consumption, norms were established for the industry.

Date of Start : 10.02.1999
Duration (months) : 24
Target Beneficiaries : Textile Industry
Grants Received (Rs. In Lakhs) : 24.07
Location : Mumbai
Status : Completed

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