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ASUTEX , COMMITED TO THE FUTURE

ASUTEX , COMMITED TO THE FUTURE. In an each time more stringent environment-conscious future, textile processes must be adapted to fulfill the new challenges, so that means. - LESS WATER CONSUMPTION. - LESS ENERGY EXPENSES. - LESS PROCESSING TIME. - GREEN CHEMICALS.

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ASUTEX , COMMITED TO THE FUTURE

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  1. ASUTEX, COMMITED TO THE FUTURE In an each time more stringent environment-conscious future, textile processes must be adapted to fulfill the new challenges, so that means - LESS WATER CONSUMPTION - LESS ENERGY EXPENSES - LESS PROCESSING TIME - GREEN CHEMICALS

  2. ANOTHER LINK IN THE CHAIN: It is just another step for word with ecofriendly textile industry. Bangladesh is already a green country, all of us must contribute to keep this heritage for the future generations. We take the legacy of previous jobs and we just want to be another step in this way.

  3. Our commitment with constant INNOVATION in the TEXTILE FIELD, developing new procedures and modifying our offers to the newest market requirements, allows us to introduce the new LTB PROCESS LOW TEMPERATURE BLEACHING SYSTEM

  4. There are three products involved in the LTB PROCESS. All of them developed in our R&D department. THE SYNERGETIC COMBINATION OF THREE PRODUCTS ENSURES THE MAXIMUM EFFICIENCY IN GETTINGS THE SAME WHITENESS DEGREE AS IF IT IS PRODUCED ACCORDING TO A CONVENTIONAL TECHNIQUE AND ALSO THE IDEAL HYDROFILITY NECESSARY TO CARRY OUT ANY OTHER TEXTILE PROCESS WITHOUT AN SPECIAL CARE. PRODER LTB 0,5-1 GR/L ASUTOL LTB 0,5 GR/L NaOH 50% 3 CC/L H2O2 50% 2-3 CC/L ACTIVATOR LTB 0,5-1GR/L 30’ AT 75ºC

  5. There are three products involved in the LTB PROCESS. All of them developed in our R&D department. • 1.-LTB PRODER : • DETERGENT-WETTING – DISPERSING AGENT • IT HAS BEEN SPECIALLY DEVELOPED TO GET THE MAXIMUM REMOVAL OF NATURAL OCCURING WAXES CONTAINED IN COTTON SO AS TO IMPAIR THE MAXIMUM HYDROPHILITY TO THE SUBSTRATE DURING THE LOW TEMPERATURE NOVEL PROCEDURE. • IT OVERCOMES THE DRAWBACKS RESULTING FROM THE FACT OF WORKING AT LOW TEMPERATURES OFFERING VERY EFFICIENT OUTCOME.

  6. There are three products involved in the LTB PROCESS. All of them developed in our R&D department. • 2.-ASUTOL LTB : • SEQUESTERING – DISPERSING – STABILIZING AGENT • SPECIALLY DESIGNED TO ENSURE THE BEST PERFORMANCE DURING BLEACHING STAGE, AVORDING THE CATALYTIC INTERFERENCES CAUSED BY THE PRESENCE OF HEAVY METALS AND ALKALINE EARTH ELEMENTS. • ALLOWS TO GET OUTSTANDING WHITENESS LEVELS. IRON SEQUESTERING CAPACITY – QUALITATIVE ANALISE -20 ppm de Fe+++ -2,5 cc/L NaOH 50% 60 min in reflux at 100 ºC , cool down to 80ºC and filter 2 gr/L ASUTOL LTB WITHOUT AUXILIAR

  7. There are three products involved in the LTB PROCESS. All of them developed in our R&D department. • 3.-ACTIVATOR LTB : • SPECIFICALLY DESIGNED COMPLEX PRODUCT THAT ENHANCES HYDROGEN PEROXYDE ACTIVITY PERMITTING TO BLEACH CELLULOSIC FIBRES INTO MILDER AND SMOOTHER WORKING CONDITIONS. • CONTROLS PEROXYDE DESCOMPOSITION AND SPEEDS UP THE DESIRED WHITENESS DEGREE. • Alkaline hydrogen peroxide solutions can be discomposed as ion (heterolytic decomposition) or as a radical (homolytic decomposition). Radical decomposition is responsible to reduce de cellulose DP.

  8. COMPARISON BETWEEN THE NEW/CLASSICAL BLEACHING PROCEDURES 120 100 80 3ºC/min 3ºC/min 60 TEMPERATURE (ºC) 40 20 0 0 10 20 30 40 50 60 70 80 90 TIME (min.) LTB Process Traditional process

  9. ECONOMICAL AND ENVIRONMEN ADVANTATGES OF LTB PROCESS IN FRONT OF TRADITIONAL ONE • PROCESSING TIME DECREASING UP TO 30’ COMPARED TO CONVENTIONAL BLEACHING. • ENERGY SAVING (30 KCAL/KG ) COMPARED WHEN RAISING UP BATH TEMPERATURE TO BOIL IS NOT NECESSARY. • ENERGY SAVING AND TIME & WATER SAVINGS WHEN COOLING DOWN BATH TEMPERATURE FROM 98ºC TO 75ºC IS NOT NECESSARY. • DECREASING BLEACHING TEMPERATURE INVOLVES LESS FUEL CONSUMPTION, THIS FACT SUPPOSES LESS CO2 RATES RELEASED TO THE ATMOSPHERE.

  10. TECHNICAL ADVANTAGES WHEN COMPARING LTB PROCESS AGAINTS CONVENTIONAL PROCESS • WHEN USING LESSER PROCESSING TIMES, THE PILLING FORMATION IS ALSO OF LESS IMPORTANCE. • RESULTING HANDLE IS BETTEER, THIS IS MORE RELEVANT WHEN BLEACHING FINER NUMBERS OR OPEN-END YARNS. • CELLULOSIC YARNS BLEACHED AT LOWER TEMPERATURES UNDERGO LESS DAMAGE, SO THAT RESULTING POLYMERIZATION DEGREE ARE HIGHER. • WHEN BLEACHING YARN PACKAGES DUE TO THE LESS SHRINKAGE AT LOWER TEMPERATURES, WIND AND REWIND OPERATIONS ARE EASIER AND YARN BREAKINGS ARE LESS. • WHEN USING LOWER BLEACHING TEMPERATURES, THE TREND TO CREASING FORMATION IS LESS, THIS FACT IS OF MAIN IMPORTANCE WHEN HANDLING CELLULOSIC ELASTANE MIXTURES.

  11. LTB PROCESS, BENEFITS IN FRONT OF TRADICIONAL BLEACHING PROCESSES Lower modification of Cellulose Polymerization Degree (DP) Results for polymerization degree test: Polymerization degree from raw cotton: 3327 LTB Process at 75 ºC using 2cc/L NaOH 50% & 2cc/L H2O2 50% : 3253 LTB Process at 75 ºC using 3cc/L NaOH 50% & 3cc/L H2O2 50%:3170 Traditional Bleaching at 100 ºC using 3cc/L NaOH 50% & 3cc/L H2O2 50%: 2515

  12. POLYMERIZATION DEGREE DECREASE 3327 3253 3170 2515 Raw Cotton LTB PROCESS 75 ºC 2 NaOH / 2 H2O2 LTB PROCESS 75 ºC 3 NaOH / 3 H2O2 Traditional Process 100 ºC

  13. SPECIAL APPLICATION: CONE YARN BLEACHING • CORN YARN DYERS ARE SPECIALLY PLEASED WITH THE BENEFITS BROUGHT BY THE NEW LTB BLEACHING PROCESS. WHEN BLEACHING AT 75 ºC AND DYEING AT 60ºC THE SHRINKAGE LEVEL BECOMES MINIMUM WHAT IS TRANSLATED DIRECTLY TO A MORE STABLE BOBBINE AND MORE HOMOGENEOUS YARN PACKAGE. • YARN’S STRENGH IS INCREASED STRIKINGLY, SPECIALLY IN SHIRT-YARNS (40-50/1H NE OR SUPERIORS) WHERE NUMBERS OF BREAKINGS DECREASES AROUND 80%. • THE HIGHEST YARN RESISTANCE ALLOWDS INCREASING SIGNIFICANTLY THE REWINDING SPEED WHAT BECOMES AT THE END AND SHORTAGE OF TIME. • THIS ALSO HELPS REDUCING LIQUID PARAFINE’S PERCENTAGE OR REPLACE IT BY USING MORE ECONOMIC CHEMICALS AS POLIETHILENES.

  14. SPECIAL APPLICATION: CELLULOSIC ELASTANE MIXTURES. • ONE OF THE MOST CRITICAL POINTS WHEN WORKING WITH THE COTTON-LYCRA IS HOW TO AVOID THE CREASE MARKS. THIS PROBLEM IS SPECIALLY WEIGHTLY ONCE WE REACH 80ºC. • EVEN AFTER PRE-SETTING, IT IS ADVISABLE TO WORK WITH SPECIFIC ANTICREASE AGENTS AND TAKE AN EXTRA CONTROL REGARDING PROCESS TEMPERATURE. CONCRETLY, ONCE WE OVERPASS 80ºC IT IS IMPORTANT TO INCREASE OR REDUCE THE TEMPERATURE VERY SLOWLY, FOR EXAMPLE AT 1 ºC/min. • WORKING WITH LTB, WE WILL NEVER CROSS THE CRITICAL TEMPERATURE WORKING FULL TIME BELOW 80 ºC, IT MEANS IN THE SAFE CONDITIONS. • REDUCING THE TEMPERATURE WILL ALSO PROTECT THE LYCRA ELASTICITY.

  15. COMPARISON LTB vs CLASSICAL BLEACHING PROCEDURES 120 100 1 ºC/min 1 ºC/min 80 3ºC/min 60 TEMPERATURE (ºC) 40 20 0 0 10 20 30 40 50 60 70 80 90 TIME (min.) LTB Process Traditional process

  16. BLEACHING OF COTTON KNITTING AT DIFFERENT TEMPERATURES USING LTB PROCESS 80 78,3 78 CHEMICALS DOSES 76,8 75,5 1 gr/L Proder LTB 0,5 gr/L Asutol LTB 1 gr/LActivator LTB 76 74 73,3 WHITENESS DEGREE 72 71,1 30' at 70ºC 70,1 70 30' at 75ºC 68 66 2 cc/L NaOH 50% 2 cc/L H2O2 50% 3 cc/L NaOH 50% 3 cc/L H2O2 50% 4 cc/L NaOH 50% 4 cc/L H2O2 50%

  17. INDUSTRIAL TRIALS ACCORDING TO LTB PROCESS WICKING TEST FOR HYDROPHILITY After 5 min of fabric contact with the coloured solution 3” 2” DROP TEST TIME IN SECONDS FOR COMPLETE WETTING Instantaneous Instantaneous Instantaeous Instantaneous

  18. AS FINAL SUMMARY FOR LTB PROCESS, WE HAVE: • 1.- WHITENESS DEGREE – THE MOST IMPORTANT POINTS ARE: • NAOH / H2O2 CONCENTRATION • TEMPERATURE: THE HIGHER (75 ºC) THE BETTER WITHENESS DEGREE • THE ACTIVATOR: THE HIGHER DOSAGE (1 GR/L) THE BETTER WHITENESS DEGREE. • 2-. HYDROPHILITY – THE MUST IMPORTANT POINTS ARE: • NAOH / H2O2 CONCENTRATION • TEMPERATURE: THE HIGHER (75 ºC) THE BETTER HYDROPHILITY • THE DETERGENT DOSAGE: THE HIGHER (1 GR/L) THE BETTER HYDROPHILITY. • 3-. OTHER FACTORS SUCH AS COTTON ORIGIN, SUBSTRATE FORM (PACKAGE, HANK, WOVEN, KNITTED FABRIC, …), TYPE OF MACHINERY (JIG, OVERFLOW, DYE BECK,…) AND LIQUOR RATIO ARE ALSO OF MAIN IMPORTANCE IN THE FINAL RESULTS. • 4-. ADVISABLE RECIPE FOR BLEACHING ACCORDING TO LTB PROCESS IS: • PRODER LTB 0,5-1 GR/L • ASUTOL LTB 0,5 GR/L • NaOH 50% 3 CC/L • H2O2 50% 2-3 CC/L • ACTIVATOR LTB 0,5-1GR/L • 30’ AT 75ºC

  19. STANDARD PROCESS ON CONE YARN BLEACHING – INDUSTRIAL TRIAL • Yarn : 80/2 Ne CO 100% 10 min 75 ºC 30 min 75 ºC 3 min Overflow rinse 3 min Overflow rinse 4 º/min 15 min 40 ºC 30-50 ºC 2 min 2 min A.- PRODER LTB 1 gr/L ASUTOL LTB 0,5 gr/L Caustic Soda 50% 3 cc/L D.- AceticAcid E.- PEROXFIN MI 0,5 % A B C E In case de-mineralizationprocessisneed, thenadd ASUTOL A-P in acidconditions B.- Peroxide 50% 3 cc/L C.- ACTIVADOR LTB 1 gr/L

  20. STANDARD OPTICAL BLEACHING ON CORN YARN – INDUSTRIAL TRIAL • Yarn : 70/1 Ne CO 100% 75 ºC 30 min 20 min 75 ºC 3 min Overflow rinse 3 min Overflow rinse 2 º/min 4 º/min 50 ºC 15 min 30-50 ºC 2 min 2 min A.- PRODER LTB 1 gr/L ASUTOL LTB 0,5 gr/L Caustic Soda 50% 4 cc/L D.- ASUBLANC PIB E.- Water AceticAcid pH 5 D A B C E In case de-mineralizationprocessisneed, ASUTOL A-P can beadded in thelastrinsing/neutralizingbath B.- Peroxide 50% 5 cc/L C.- ACTIVADOR LTB 1 gr/L

  21. STANDARD PROCESS ON KNITTED FABRIC BLEACHING – INDUSTRIAL TRIAL • Fabric: Jersey 50/1 Liquor Ratio : 1:11 30 min 10 min 75 ºC 75 ºC E 4 º/min 3 min Overflow rinse 3 min Overflow rinse 40 ºC 30-50 ºC 2 min 10 min 2 min 5 min 2 min 2 min F G H I A load B C D A.- PRODER LTB 1 gr/L ASUTOL LTB 0,5 gr/L E.- Water at 75ºC F.- AceticAcid pH 6-7 In case de-mineralizationprocessisneed, proceed as in cornyarnprocess G.- PEROXFIN MI 0,5 % B.- Caustic Soda 50% 3 cc/L H.- AceticAcid pH 5 C.- Peroxide 50% 3 cc/L I.- BiopolishorDye D.- ACTIVADOR LTB 1 gr/L

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