Dyeing And Printing Process In Textile Industry 5lp4h

SCHOOL OF CHEMICAL AND MATERIALS ENGINEERING (SCME)

TEXTILE INDUSTRY Mushahid Ali, Raza Ur-Rehman Mir, Sumama Mongol, Raza Hassan Khan, Haseeb Akram

MAY 2010

Supervisor Dr. Noaman Ul-Haq

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Summary For any given industry, each topic could alone be the subject of a lengthy volume. However in order to produce a manageable document, this article focuses on providing summary information for each topic. This format provides the reader with a synopsis of each issue, and references where more in depth information is available. In this article, a brief description related to Textile Industrial processes is provided. Text within each profile was researched from a variety of sources, and was usually condensed from more detailed sources pertaining to specific topics. This approach allows for a wide coverage of activities that can be further explored based upon the citations and references listed at the end of this report.

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Acknowledgements No one person can be both skilled and up-to-date in all fields of life. I am indebted to all my group who helped me in preparing this report which is related to Textile Industrial History of Pakistan and processes used for dyeing and printing. Discussions with all group and especially with our Supervisor Dr. Noaman Ul-Haq were of great help to me. I am really thankful to all of them. I have ed the list of major Textile Industries of Pakistan from different websites. I have attached tables which have very important information for the readers and all the group have struggled a lot for getting this information.

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Contents 1

2

HISTORY OF TEXTILE INDUSTRY ............................................................................................................ 1 1.1

Introduction .................................................................................................................................. 1

1.2

History ........................................................................................................................................... 1

1.3

History of Textile Industry of Pakistan .......................................................................................... 1

1.4

Textile Products in Pakistan .......................................................................................................... 4

1.5

Major Textile Industries of Pakistan ............................................................................................. 4

PROCESSES INVOLVED IN TEXTILE INDUSTRY ....................................................................................... 6 2.1

Introduction .................................................................................................................................. 6

2.2

Grey Fabric .................................................................................................................................... 6

2.3

Pretreatment of fabrics................................................................................................................. 6

2.3.1

Inspection Frame .................................................................................................................. 6

2.3.2

Batcher .................................................................................................................................. 7

2.3.3

Singeing ................................................................................................................................. 7

2.3.4

De-sizing ................................................................................................................................ 7

2.3.5

Scouring................................................................................................................................. 7

2.3.6

Bleaching ............................................................................................................................... 7

2.3.7

Mercerization ........................................................................................................................ 7

2.4

Selection of Raw Materials for Dyeing and Printing ..................................................................... 7

2.4.1

PROCESS INPUTS - MATERIALS USED .................................................................................... 8

2.4.2

Dye inputs ............................................................................................................................. 8

2.5

Dyeing ........................................................................................................................................... 8

2.5.1

Dyes ....................................................................................................................................... 9

2.5.2

Dyeing Methods .................................................................................................................. 11

2.5.2.7

Package Dyeing ........................................................................................................................... 11

2.6

Printing ........................................................................................................................................ 13

2.6.1 2.7

3

Methods of Printing ............................................................................................................ 14

Finishing ...................................................................................................................................... 16

2.7.1

Finishing Wet Process ......................................................................................................... 17

2.7.2

Dyeing Process .................................................................................................................... 17

TEXTILE INDUSTRY POSES ENVIRONMENTAL HAZARDS ..................................................................... 17 IV

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4

3.1

Water Usage................................................................................................................................ 18

3.2

Water Pollution ........................................................................................................................... 18

3.3

Bleaching ..................................................................................................................................... 18

3.4

Dyeing ......................................................................................................................................... 18

HOW YOU CONTROL PROCESS RISKS WHICH APPLY ACROSS THE TEXTILES INDUSTRIES .................. 18 4.1

Autoclaves ................................................................................................................................... 18

4.1.1

Autoclave Apparatus ........................................................................................................... 18

4.1.2

Autoclave Procedures ......................................................................................................... 19

4.2

Baling Machines .......................................................................................................................... 19

4.3

Cloth Finishing and Fabric Coating .............................................................................................. 19

4.3.1

Cloth Finishing and Fabric Coating Machinery.................................................................... 19

4.3.2

Cloth Finishing and Fabric Coating Procedures................................................................... 20

4.4

Dyeing ......................................................................................................................................... 20

4.4.1

Atmospheric Dyeing Machinery .......................................................................................... 20

4.4.2

Screen Printing .................................................................................................................... 20

4.4.3

High Pressure Dyeing Machines .......................................................................................... 21

4.4.4

Dyeing Procedures .............................................................................................................. 21

4.4.5

Dye stuff handling ............................................................................................................... 22

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List of Tables

   

Table-1(Export of cotton Fabrics) ……………………………………………………………………………………………….3 Table-2(Import of Textile Machinery in Pakistan)………………………………………………………………………..5 Table-3(Major Textile Industries in Pakistan)………………………………………………………………………………7 Table-4(Percentage of unfixed dye for different dye types and applications)……………….………..8

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VII

1 HISTORY OF TEXTILE INDUSTRY 1.1 Introduction Textile Industry is the major Industry of any country which performs a major role in the economic growth of that country. In this section of report the information related to the history of Textile Industry of Pakistan, its size among the major industries of any country, its productions and sales all over the world, its performance to improve our country economically, its power to facilitate its employs and its geographic distribution has been discussed. Moreover I have added a brief introduction related to processes involved in the dyeing and printing sections of Textile Industry.

1.2 History The textile industry is one of the oldest in the world. The oldest known textiles, which date back to about 5000 B.C., are scraps of lines cloth found in Egyptian caves. Prior to the manufacturing processes being mechanized, textiles were produced in the home, and excess sold for extra money. Most of the cloth was made from wool, cotton, or flax, depending on the era and location. By the end of the 16th century, cotton was cultivated throughout the warmer regions in Asia and the Americas. In Roman times, wool, linen and leather clothed the European population. The cotton of India was a curiosity that only naturalists had heard of, and silk, imported along the Silk Road from China, was an extravagant luxury. The use of flax fiber in the manufacturing of cloth in Northern Europe dates back to Neolithic times. Cloth was produced in the home, and the excess woven cloth was sold to merchants called clothiers who visited the village with their trains of pack-horses. Some of the cloth was made into clothes for people living in the same area and a large amount of cloth was exported. The process of making cloth depends slightly on the fiber being used, but there are three main steps: preparation of fibers for spinning, weaving and knitting. The preparation of the fibers differ the most depending on the fiber used. Flax requires retting and dressing, while wool requires carding and washing. The spinning and weaving processes are very similar between fibers though. Spinning evolved from twisting the fibers by hand, to use of a drop spindle, to a spinning wheel. Spindles or parts of them have been found in very old archaeological sites; they may represent one of the earliest pieces of technology available to humankind was invented in India between 500 and 1000 AD. It reached Europe via the Middle East in the European Middle Ages. Weaving, done on a loom has been around for as long as spinning. There are some indications that weaving was already known in the Paleolithic. An indistinct textile impression has been found at Pavlov, Moravia. Neolithic textiles are well known from finds in pile dwellings in Switzerland. One extant fragment from the Neolithic was found in Fayum at a site which dates to about 5000 BC.

1.3 History of Textile Industry of Pakistan The Textile Industry is one of the major industries in Pakistan. Textile Industry has shown its tremendous performance for the economic growth of Pakistan since 1947. Increase in the cotton production and expansion of textile industry has been impressive in Pakistan since 1947. Cotton bales increase from 1.1 million bales in 1947 to ten million bales by 2000. Number of mills increased from 3 to 600 and spindles from about 177,000 to 805 million similarly looms and finishing units increased but not in the same proportion. It employs 50% of industrial labor force and earns 65% foreign exchange of total exports. Pakistan’s textile industry experts feel that Pakistan has fairly large size textile industry and 60-70% of machines need replacement for the economic and quality production of products for a highly competitive market. But unfortunately it does not have any facility for manufacturing of textile 1

Textile_Industry_________________________________________________________Semester_Project machinery of balancing modernization and replacement (BMR) in the textile mills which need to think about t ventures for the production of complete spinning units with china, Italy and production of shuttle less looms (Projectile) with Korea, Taiwan and Italy. Cotton Textile Industry has been premier industry in Pakistan and a major source of export earning and employment. It also helps in value addition to the manufacturing sector of the economy. During the six years between 1993 and 1998, Pakistan ed a growth rate of 101% per annum in yarn production. In exports, during 1993-1998, Pakistan ed a negative growth of 4.8% one important development was that till 1997, Pakistan was the world’s largest exporter yarn. The above-mentioned presentation in the context of international scenario highlights the adverse position of Pakistan’s textile industry when is likely to continue further following the full implementation of WTO agreement from 2005 onwards when an era of free trade will start globally. Notwithstanding the above fact, current stagnation in the local textile industry can be overcome through efforts, consistent with charges occurring in the international market. It must be appreciated that all successive governments since the birth of cotton textile industry in Pakistan have been encouraging the textile exporters to penetrate into new market and also to broaden the base of exportable commodities by including value added textile goods so that reliance on exports of cotton, cotton yarn and coarse fabrics gradually become minimal. The following table gives the information about the total exports of Pakistan related to Cotton Fabrics in the Era Between 1989 and 2003: Table-1 Export of Cotton Fabrics Year

Quantity

Value

Unit value

000 Sq meters

000 US$

000 Rs

$ Sq meters

1989-90

1,017,868

558,957

11,999,732

0.55

1990-91

1,056,534

675,853

15,199,262

0.64

1991-92

1,196,120

819,440

20,371,829

0.69

1992-93

1,127,584

863,101

22,430,385

0.77

1993-94

1,046,793

820,583

24,788,559

0.78

1994-95

1,160,659

1,081,444

33,373,117

0.93

1995-96

1,323,086

1,275,855

43,278,977

0.96

1996-97

1,257,430

1,262,389

49,354,342

1.00

1997-98

1,271,272

1,250,280

53,991,139

0.98

1998-99

1,355,166

1,115,181

55,980,330

0.82

1999-00

1,574,876

1,096,232

56,757,245

0.71

2000-01

1,735,824

1,035,043

60,485,633

0.60

2001-02

1,957,353

1,132,730

69,411,000

0.58

2002-03

2,005,383

1,330,982

77,818,000

0.66

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Source: Federal Bureau of Statistics, Government of Pakistan

The first textile commission, which was constituted by the first material law government in 1960 had, inter-alia, recommended that an economic size textile unit should preferably have 25,000 spindles and 500 looms. No new mill with only 12,500 spindles and without looms should be sanctioned. However, no need was paid to the advice by the sanctioning authorities with the result that an excess capacity had tented to build up in the spinning sector. Exporters of textile products have found the target of US$ 10.4 billion set by the government for the year 2002-2003, as achievable and termed it a realistic approach. The textile sector which constituted 69% of total export during 2001-2002, believes that enhanced quota by the European Union and Turkey would make this possible to fetch another US$1 billion this year. The rise in export of value-added products from Pakistan was another point of encouragement for the textile sector. “The export of value-added products rose to 57.4% from 53.9% last year-a clear sign that we are moving in the right direction, “said the Chairman of all Pakistan textile mills association. The trade policy is considered an acceptable paper, but in the industry does not fine anything that could lead to a high level exports achievement and remove trade imbalance. Pakistan’s textile sector earned US$5.77 billion during the outgoing year, compared with US$5.577 BILLION OF 2000-2001 indicating a growth of 0.69%. “Textile vision 2005” has identified the present status and opportunities to make inroads in conventional and hew markets and has developed sect-oral recommendations, hence the sect-oral committees set up by the federal textile Board (FTB) would play an important role be ensuring the availability of quality raw materials on competitive prices and improvement in deg, and would adopt quality standards and increase productivity levels. It would attract foreign brands and promote Pakistani brands with world-class standers. Pakistan has imported the latest and advanced equipment to improve its quality of all the products related to Textiles. The Table on the next page gives the data related to all machinery of Textile which was being imported by Pakistan in between 2001-2003: Table-2

Import of Textile Machinery in Pakistan (Value in Rs 000) Name of machinery

2001-2002

2002-2003

% Change

Ginning machinery, cotton Carding Machinery, cotton Combing machinery Drawing or rowing machinery Machinery for preparing textile fibers Textile spinning machines Textile doubling or twisting machines Cone winding machines Weft winding machines Textile winding throwing & reeling machines Spindles Spinning rings Card clothing Looms Circular knitting machines

13,715 152,491 34,883 144,709 2,605,067 837,375 78,017 863,363 31,332 2,319,004 209,534 14,858 120,899 3,874,715, 400,585

783,350 164,211 1,087,002 2,345,321 2,849,255 257,141 394,450 1,785,276 330,056 512,571 225,202 51,989 429,711

+414 +371 +651 -10 +240 +230 +1159 -23 +58 +3350 +86 -99 +7

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Textile_Industry_________________________________________________________Semester_Project Flat knitting machines Hand knitting machines Machines for making gimped yarn Machines for preparing textile yarn Shuttles Part and accessories of weaving machines Needle’s hosiery Parts and accessories of knitting machines Drawing machines Bleaching machines Dyeing machines Dressing and finishing machines Coating or impregnating machinery for yarn Textile printing machines Machinery for pressing bleaching Ns Ironing and textile pressing machinery Weaving machines Other machines (not specifies)

217,138 27,324 1,106,507 1,563,487 3,997 476,785 89,317 102,681 100,007 7,791 1,319,839 11,252 434 73,143 2,060,674 6,350 3,876,715 2,340,037

128,111 2,751,339 1,971,046 4,944 513,154 160,719 126,285 111,636 134,481 872,375 96,533 89,177 542,342 2,991,691 33,287 6,589,575 2,335,785

-41 +149 +26 +24 +8 +80 +23 +12 +1626 -34 +758 +20448 +641 +45 +424 +70 0

Total Total (US $000)

25,084,025 408,908

30,668,015 542,793

+22 +28

Source: Federal bureau of Statistics, Government of Pakistan

With such a positive trend, Pakistan’s textile sector is getting rid of old impediments and gearing itself up for the new opportunities in the new trade regime.

1.4 Textile Products in Pakistan Pakistan is producing all types of products related to Textiles and Pakistani Textile Industry has shown its tremendous performance in the past for the development of Pakistan. The names of products related to Textile manufactured in Pakistan are given below: Bedding, Blend Fabrics, Canvas Products, Carpets, Chemical Fabrics, Coated Fabrics, Cotton Fabrics, Denim and Jean fabrics, Embroidery and Crafts Textile, Filter Cloth, Filter Fabrics, Garments Products, Grey Cotton Canvas, Grey Fabrics and Cloths, Handmade Fabrics, handkerchief Mfrs. & Exporters Hessian Cloth, Hosiery, household Textile Product, jute and jute Goods, Knitting Fabrics, Laminated Fabrics, Men’s Wear, Quilts Cover Mfrs, Rain Coat Mfrs, Raw Silk, Ropes Twine & Cordage, Rugs, Scarves & Dupatas, Silk, Size Stickers, Sleeping Bag Mfrs, Sports Wares, Synthetic Fibers, Tailoring Materials, Terry Fabrics, Textile All Sorts, Textile Auxiliaries, Textile Paper for Jacquard, Umbrellas, Upholstery, Velvet & Velveteen, Weaving Yarn, Wire Netting, Woven Fabrics, Yarn.

1.5 Major Textile Industries of Pakistan At present Pakistan's textile sector has been ing through serious competition these days as higher input cost, rising interest rates and intense competition in the export market have brought the sector on its toes. But there is still some major Textile Industries in Pakistan which has always performed well within Pakistan and in the International Markets as well. The names of such a few industries of Pakistan are given in the following table:

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Table-3 Major Textile Industries in Pakistan No Names Address

s

1

NISHAT MILLS LTD

Nishatabad, Faisalabad, Punjab, Pakistan

0418754816/8754809

2

KOH-E-NOOR MILL

8 km Manga Raiwind Road\District Kasur

04251391942-8

3

GULL AHMED TEXTILE MILLS

Office: Plot No. 82, Landhi Industrial Area, Karachi, 75120, Pakistan

021-111486486

4

NISHAT TEXTILE MILLS

5km Nishat Avenue off 22km Ferozepur road, Lahore

042-5260061-69

5

CHENAB GROUP

Sheikhupura Road, Nishatabad, Faisalabad

041-8754472-6

6

AL-KARAM TEXTILE MILLS

KDLB Building, 58-W Wharf Road. Karachi, 74000, Pakistan

021-2313031

7

ALI ASGHAR TEXTILE MILLS LIMITED

Office: 306-8, Uni Towers I. I. Chandigarh Road, Karachi, Pakistan

021-2416060

8

TAJ TEXTILE MILLS

Office: 31-C Ghalib Rd., Gulberg 111, Lahore, Pakistan

042-5751811

9

SAIF TEXTILE MILLS

Office: Kulsum Plaza 4/F, 2020 Jinnah Ave, Blue Area, Islamabad Pakistan

051-2823924

10

STAR TEXTILE MILLS LTD

41-Fakhruddin Valika Road S.I.T.E., Karachi 75700, Sind, Pakistan

021-2561129 / 2561127/2561128

11

ADAMJEE LIMITED

Office: 503-Panorama Centre Building-2, Raja Ghazanfar Ali Road, Karachi,

12

KOH-E-NOOR MILL

INDUSTRIES

8 km Manga Raiwind Road\District Kasur, Pakistan

04251391942-8

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PROCESSES INVOLVED IN TEXTILE INDUSTRY

2.1 Introduction This section describes commonly used production processes related dyeing and printing, associated raw materials, the byproducts produced or released, and the materials either recycled or transferred off-site.

2.2 Grey Fabric The Fabric which comes after weaving process is called Grey Fabric. It might be in one of the following two forms:  Rolled  Bailed Before dyeing and printing this fabric es through some pretreatment processes which are necessary to increase the properties of fabrics. A flow chart showing all the stages during the processing of textile is given below:

Grey Fabric Inspection ↓ Sewing or Stitching ↓ Singeing ↓ Desizing ↓ Scouring ↓ Bleaching ↓ Mercerizing ↓ Dyeing ↓ Printing ↓ Finishing ↓ Final Inspection ↓ Delivery

2.3 Pretreatment of fabrics To produce colored fabric whether dyed or printed needs pre-treatment of those fabrics before dyeing and printing. The pretreatment operations involved for cotton fabric are described systematically below: 2.3.1 Inspection Frame First of all, the above mentioned fabric is then inspected by using pick pointers (pick glass) i.e., per inch fiber count is taken into . Ends and picks are counted. 10% of the total fabric is inspected. 6

Textile_Industry_________________________________________________________Semester_Project 2.3.2 Batcher After inspecting the grey fabrics, Pieces of cloths are ed together by stitching and the fabric is rolled so that a continuous process is started without breaking the sequence. 2.3.3 Singeing It is the process of burning out projecting hairy fibers from surface of the grey fabric by assigns the fabric through a gas flame. Both sides of the fabric are burnt out by the flame. It helps in subsequent chemical process of the fabric. After dyeing or printing of singed fabric, brightness and luster of color and fabric becomes better. 2.3.4 De-sizing It is the process of removing starch materials present in the gray fabric. Generally enzyme is used to degrade and remove the starch present in the gray fabric. If those size materials are not removed from the grey fabrics, then the subsequent chemical treatments on the fabric will be irregular, which will cause defective dyeing and printing. 2.3.5 Scouring It is the process of removing natural impurities present in the cotton fiber. The natural impurities are pectin’s, picots, ash, wax, mineral compounds, etc. if those impurities present in the cotton fibers are not removed, then it will be difficult to dye or print the fabric uniformly. Normally caustic soda ash is used as main reagent for scouring of cotton fabric. 2.3.6 Bleaching It is the process of removing natural coloring matters present in the cotton fiber. For this purpose, hydrogen peroxide, bleaching powder or other bleaching agents are used. Hydrogen peroxide is the best and most commonly used bleaching agent. If this bleaching treatment is not carried out before dying or printing then the color yield and shade matching may be a great problem. 2.3.7 Mercerization It is a special chemical pre-treatment on cotton fabric to improve the properties and performance of cotton fabric. The cotton fabric is treated under tension in the 20% caustic soda solution which is called mercerization. Many properties of cotton fabric are improved due to mercerization, some of them are mentioned below: Increases absorbency power Increases fabric luster Increases fabric softness and handle property Reduces dye consumption Reduces chemical consumption in dyeing Increase fabric length

2.4 Selection of Raw Materials for Dyeing and Printing Dyes and pigments from dyeing and printing operations are the principal sources of color in textile effluent. Dyes and pigments are highly colored materials used in relatively small quantities (a few percent or less of the weight of the substrate) to impart color to textile materials for aesthetic or functional purposes. In typical dyeing and printing processes, 50 to 100 percent of the color is fixed on the fiber. The remainder is discarded in the form of spent dye baths or in wastewater from subsequent textile-washing operations. 7

Textile_Industry_________________________________________________________Semester_Project 2.4.1 PROCESS INPUTS - MATERIALS USED The input materials used in textile dyeing and finishing can include: water, the fiber, yarn or cloth, e.g. wool, cotton, polyester, and a range of process chemicals including:  acids, e.g. acetic, formic;  alkalis, e.g. sodium hydroxide, potassium hydroxide, sodium carbonate;  bleach, e.g. hydrogen peroxide, sodium hypochlorite, sodium chlorite;  dyes, e.g. direct, disperse, pigment, vat;  salts, e.g. sodium chloride;  size, e.g. starch, PVA;  stabilizers, e.g. sodium silicate, sodium nitrate, organic stabilizers;  surfactants;  Auxiliary finishes, e.g. fire retardant, softeners (or handle modifiers). Any assessment of material inputs should also include auxiliary and cleaning materials. These are seldom subject to the same degree of control as dyestuffs, and limited investigation can often yield easy savings. 2.4.2 Dye inputs Not all the dye is fixed to the fiber during the dyeing process. Table 1 shows the percentage of unfixed dyes for various textiles. The reactive dyes used for cotton have the poorest fixation rate, and since 52% of the textile-fiber market is cotton, most colored effluent problems arise from dyeing cotton with reactive dyes. Heavy metals are associated with the effluents from wool dyeing.

Table-4 Percentage of unfixed dye for different dye types and applications Fiber Dye type Unfixed dye % Wool and nylon

Cotton and viscose

Polyester Acrylic polypropylene

Acid dyes/reactive dyes for wool Pre-metalized dye After chromes Azoic dyes Reactive dyes Direct dyes Pigment Vat dyes Sulphur dyes Disperse Modified basic Spun dyed

7-20 2-7 1-2 5-10 20-50 5-20 1 5-20 30-40 8-20 2-3 N/A

2.5 Dyeing Dyeing is a method which imparts beauty to the textile by applying various colors and their shades onto a fabric. Dyeing can be done at any stage of the manufacturing of textile-fiber, yarn, fabric or a finished textile product including garments and apparels. The property of color fastness depends upon two

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Textile_Industry_________________________________________________________Semester_Project factors- selection of proper dye according to the textile material to be dyed and selection of the method for dyeing the fiber, yarn or fabric. A schematic diagram of dyeing machine is given below:

2.5.1 Dyes Dyes are used for coloring the fabrics. Dyes are colored substances which absorb and reflect light at specific wavelengths to give human eyes the sense of color. There are two major types of dyes - natural and synthetic dyes. The natural dyes are extracted from natural substances such as plants, animals, or minerals. Synthetic dyes are made in a laboratory. Chemicals are synthesized for making synthetic dyes. Some of the synthetic dyes contain metals too. 2.5.1.1 Natural Dyes Direct Printing It is the most common approach to apply a color pattern onto a fabric. If done on colored fabric, it is known as overprinting. The desired pattern is produced by pressing dye on the fabric in a paste form. To prepare the print paste, a thickening agent is added to a limited amount of water and dye is dissolved in it. Earlier starch was preferred as a thickening agent for printing. Nowadays gums or alginates derived from seaweed are preferred as they allow better penetration of color and are easier to wash out. Most pigment printing is done without thickeners because the mixing up of resins, solvents and water produces thickening anyway. 2.5.1.2 Synthetic Dyes Synthetic dyes are classified based upon their chemical composition and the method of their application in the dyeing process. 9

Textile_Industry_________________________________________________________Semester_Project 2.5.1.3 Basic (Cationic) Dyes Basic (Cationic) Dyes Basic dyes are water-soluble and are mainly used to dye acrylic fibers. They are mostly used with a mordant. A mordant is a chemical agent which is used to set dyes on fabrics by forming an insoluble compound with the dye. With mordant, basic dyes are used for cotton, linen, acetate, nylon, polyesters, acrylics and mordant acrylics. Other than acrylic, basic dyes are not very suitable for any other fiber as they are not fast to light, washing or perspiration. Thus, they are generally used for giving an after treatment to the fabrics that have already been dyed with acid dyes. 2.5.1.4 Direct (substantive) Dyes Direct dyes color cellulose fibers directly without the use of mordents. They are used for dyeing wool, silk, nylon, cotton, rayon etc. These dyes are not very bright and have poor fastness to washing although they are fairly fast to light. 2.5.1.5 Mordant Dyes In Mordant Dyes the mordant or chrome dyes are acidic in character. Sodium or potassium dichromate is used with them in the dye bath or after the process of dyeing is completed. This is done for getting the binding action of the chrome. They are mostly used for wool which gets a good color fastness after treatment with mordant dyes. They are also used for cotton, linen, silk, rayon and nylon but are less effective for them. 2.5.1.6 Vat Dyes Vat dyes are insoluble in water and cannot dye fibers directly. However, they can be made soluble by reduction in alkaline solution which allows them to affix to the textile fibers. Subsequent oxidation or exposure to air restores the dye to its insoluble form. Indigo is the original vat dye. These dyes are the fastest dyes for cotton, linen and rayon. They are used with mordents to dye other fabrics such as wool, nylon, polyesters, and acrylics. 2.5.1.7 Reactive Dyes Reactive dyes react with fiber molecules to form a chemical compound. These dyes, they are either applied from alkaline solution or from neutral solutions which are then alkalized in a separate process. Sometimes heat treatment is also used for developing different shades. After dyeing, the fabric is washed well with soap so as to remove any unfixed dye. Reactive dyes were originally used for cellulose fibers only but now their various types are used for wool, silk, nylon, acrylics and their blends as well. 2.5.1.8 Disperse Dyes Disperse dyes are water insoluble. These dyes are finely ground and are available as a paste or a powder that gets dispersed in water. These particles dissolve in the fibers and impart color to them. These dyes were originally developed for the dyeing of cellulose acetate but now they are used to dye nylon, cellulose triacetate, and acrylic fibers too. 2.5.1.9 Sulfur Dyes Sulfur Dyes are insoluble and made soluble by the help of caustic soda and sodium sulfide. Dyeing is done at high temperature with large quantities of salt so that the color penetrates into the fiber. After dyeing, the fabric is oxidized for getting desired shades by exposure to air or by using chemicals. Excess dyes and chemicals are removed by thorough washing. These dyes are fast to light, washing and perspiration and are mostly used for cotton and linen. 2.5.1.10 Pigment Dyes

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Textile_Industry_________________________________________________________Semester_Project In Pigment Dyes although pigments are not dyes in a true sense, they are extensively used for coloring fabrics like cotton, wool and other manmade fibers due to their excellent light fastness. They do not have any affinity to the fibers and are affixed to the fabric with the help of resins. After dyeing, the fabrics are subjected to high temperatures. 2.5.2 Dyeing Methods Color is applied to fabric by different methods and at different stages of the textile manufacturing process. 2.5.2.1 Top dyeing Top is the combed wool. In this method, the fiber is dyed in the stage just before the appearance of finished yarn. 2.5.2.2 Piece dyeing In this method, small batches of constructed natural colored fabric are dyed according to the demands for a given color. 2.5.2.3 Solution pigments or dope dyeing Dye is added to the solution before it is extruded through the spinnerets for making synthetic filaments. 2.5.2.4 Stock dyeing In Stock dyeing the fiber is dyed even before it is spun. Stock dyeing is used to dye fibers. In this process, the staple fibers are packed into a vessel and then dye liquid is forced through them. Although the dye solution is pumped in large quantities, the dye may not penetrate completely into the fibers and some areas may be left without dyeing. However, the following blending and spinning processes mix up the fibers in such a thorough way that it results in an overall even color. Woolens are usually stock dyed. 2.5.2.5 Yarn Dyeing When dyeing is done after the fiber has been spun into yarn, it is called yarn dyeing. In this method, the dyestuff penetrates the fibers to the core of the yarn. There are many forms of yarn dyeing- Skein (Hank) Dyeing, Package Dyeing, Warp-beam Dyeing, and Space Dyeing. 2.5.2.6 Skein (Hank) Dyeing The yarns are loosely arranged in skeins or coils. These are then hung over a rung and immersed in a dye bath in a large container. In this method, the color penetration is the best and the yarns retain a softer, loftier feel. It is mostly used for bulky acrylic and wool yarns. 2.5.2.7 Package Dyeing The yarns are wound on spools, cones or similar units and these packages of yarn are stacked on perforated rods in a rack and then immersed in a tank. In the tank, the dye is forced outward from the rods under pressure through the spools and then back to the packages towards the center to penetrate the entire yarn as thoroughly as possible. Mostly, the carded and combed cotton which are used for knitted outerwear is dyed through this method. 2.5.2.8 Warp-Beam Dyeing It is similar to package dyeing but more economical. Here, the yarn is wound on to a perforated warp beam and then immersed in a tank for dyeing it applying pressure.

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Textile_Industry_________________________________________________________Semester_Project 2.5.2.9 Space Dyeing In this method, the yarn is dyed at intervals along its length. For these two procedures knit-de-knit method and OPI Space-Dye Applicator are adopted. In the first method, the yarn is knitted on either a circular or flat-bed knitting machine and the knitted cloth is then dyed and subsequently it is de-knitted. Since the dye does not readily penetrate the areas of the yarn where it crosses itself, alternated dyed and un-dyed spaces appear. The OPI Space-Dye Applicator technique produces multi colored spacedyed yarns. The yarns are dyed intermittently as they run at very high speeds through spaced dye baths. They are continuously subjected to shock waves produced by compressed air having supersonic velocities. 2.5.2.10 Piece Dyeing The constructed fabrics are piece dyed for the flexibility they provide. The textile manufacturer can dye the whole fabric in batches according to the fashion demands of the time thus avoiding wastage and resultantly loss. There are several methods prevalent or piece dyeing. 2.5.2.11 Beck Dyeing It is used for dyeing long yards of fabric. The fabric is ed in rope form through the dye bath. This rope of the fabric moves over a rail onto a reel which immerses it into the dye and then draws the fabric up and forward and brings it to the front of the machine. This process is repeated many times until the desired color intensity is obtained. 2.5.2.12 Jig dyeing It is similar to the process of beck dyeing with a slight variation. The fabric in jig dyeing is held on rollers at full width rather than in rope form as it is ed through the dye bath. 2.5.2.13 Pad dyeing Padding is also done while holding the fabric at full width. The fabric is ed through a trough having dye in it. Then it is ed between two heavy rollers which force the dye into the cloth and squeeze out the excess dye. Then it is ed through a heat chamber for letting the dye to set. After that it is ed through washer, rinser and dryer for completing the process. 2.5.2.14 Jet Dyeing Fabric is placed in a heated tube where jets of dye solution are forced through it at high pressures. The fabric too moves along the tube. The solution moves faster than the cloth while coloring it thoroughly. 2.5.2.15 Solution pigments or dope dyeing This is a method applied for dyeing the synthetic fibers. Dye is added to the solution before it is extruded through the spinnerets for making synthetic filaments. This gives a colorfast fiber as the pigments are used which are the fastest known colors. 2.5.2.16 Garment dyeing When the finished textile products such as hosiery or sweaters are dyed, it is called garment dyeing. A number of garments are packed loosely in nylon net and put into a dyestuff filled tub with a motor driven paddle. The dye is thrown upon the garments by the moving paddles' effect. 2.5.2.17 Tie Dyeing Tie Dyeing Firm knots are tied in the cloth before it is immersed in a dye. The outside portion of the immersed fabric is dyed but the color does not penetrates the inside portions of the tied knots. There are various forms of Tie dyeing like Ikat Dyeing where bundles of warp and/ or weft yarns are tie dyed 12

Textile_Industry_________________________________________________________Semester_Project prior to their weaving. In Plangi Dyeing the gathered, folded or rolled fabric is usually held with stitching to form specific patterns. 2.5.2.18 Batik Dyeing Batik Dyeing It is a resist dyeing process. Designs are made with wax on a fabric which is then immersed in a dye. The portion not having wax absorbs the color.

2.6 Printing When colored patterns and designs are applied to a finished fabric for its decoration, it is called 'Printing'. In printing, the color is firmly affixed to the fiber so that it may not be affected by washing and friction. Textile printing is related to dyeing in the sense that in both the processes color is applied to the fabric. The difference lies in the fact that in dyeing, the color is applied uniformly to the whole fabric whereas in printing one or more colors are applied to it in selected parts only, and in sharply defined patterns. The Dyes used for printing mostly include vat, reactive, naphtha and disperse colors which have good fastness properties. Pigments are also used extensively for printing. These colors are fixed to the fiber through resins that are very resistant to laundering or dry cleaning. Improved resins, better pigments or more effective anti crock agents are used to counter the problem of croaking colors on a printed fabric. Some prints are made from basic colors mixed with tartar emetic and tannic acid but they are not very acceptable in today's market. For cotton printing vat and reactive dyes are generally used. Silk is usually printed with acid colors. Wool is printed with acid or chrome dyes but before printing it is treated with chlorine to make it more receptive to colors. Manmade fibers are generally printed with disperse and cationic dyes. A typical printing machine has been shown below:

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2.6.1 Methods of Printing For printing color on a fabric, mostly three techniques are applied: Direct Printing, Discharge Printing and Resist Printing. 2.6.1.1 Direct Printing It is the most common approach to apply a color pattern onto a fabric. If done on colored fabric, it is known as overprinting. The desired pattern is produced by pressing dye on the fabric in a paste form. To prepare the print paste, a thickening agent is added to a limited amount of water and dye is dissolved in it. Earlier starch was preferred as a thickening agent for printing. Nowadays gums or alginates derived from seaweed are preferred as they allow better penetration of color and are easier to wash out. Most pigment printing is done without thickeners because the mixing up of resins, solvents and water produces thickening anyway. 2.6.1.2 Discharge Printing

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Textile_Industry_________________________________________________________Semester_Project In this technique, the fabric is dyed in piece and then it is printed with a bleaching agent that destroys the color in designated areas. Sometimes, the base color is removed and other color is printed in its place. The printed fabric is steamed and then thoroughly washed. 2.6.1.3 Resist Printing In this technique, a resist paste is fixed onto the fabric and then it is dyed. The dye affects only those parts that are not covered by the resist paste. After dyeing, the resist paste is removed leaving a pattern on the background of the fabric. There are various methods of printing in which one of the above three techniques is used - Block Printing, Roller Printing, Duplex Printing, Stencil Printing, Screen Printing, Transfer Printing, Jet Spray Printing, Electrostatic Printing, Photo Printing, Batik Dyeing, Tie Dyeing, Airbrush (Spray) Painting and Digital printing. 2.6.1.4 Block printing In Block Printing the designs are carved on a wooden or metal block and the dyestuff in paste form is applied to the design on the face of the block. The block is pressed down firmly by hand on the surface of the fabric. 2.6.1.5 Roller Printing In this method which can be called a machine counterpart of block printing engraved copper cylinders or rollers are used in place of hand carved blocks. When the rollers move, a repeat of the design is printed on the fabric. The printed cloth is ed into a drying chamber and then in a steam chamber where the moisture and heat sets the dye. 2.6.1.6 Duplex Printing Duplex Printing is done on both sides of the fabric either through roller printing machine in two operations or a duplex printing machine in a single operation. 2.6.1.7 Screen Printing It is done either with flat or cylindrical screens made of silk threads, nylon, polyester, or metal. The printing paste or dye is poured on the screen and forced through its unblocked areas onto the fabric. Based on the type of the screen used, it is known as 'Flat Screen Printing' or 'Rotary Screen Printing'. 2.6.1.8 Stencil Printing In Stencil Printing the design is first cut in cardboard, wood or metal. The stencils may have fine delicate designs or large spaces through which color is applied on the fabric. This method is very expensive and thus its use is limited. 2.6.1.9 Transfer Printing In this method of printing, the design on a paper is transferred to a fabric by vaporization. There are two main processes for this- Dry Heat Transfer Printing and Wet Heat Transfer Printing. Various types of cylinders such as electrically heated cylinder, perforated cylinder etc. are used for pressing a fabric against a printed paper which transfers the pattern to the fabric. 2.6.1.10 Airbrush (Spray) Painting Airbrush (Spray) Painting In this method, the dye is applied with a mechanized airbrush which blows or sprays color on the fabric. 2.6.1.11 Electrostatic Printing 15

Textile_Industry_________________________________________________________Semester_Project Electrostatic Printing a dye resin mixture is spread on a screen bearing the design and the fabric is ed into an electrostatic field under the screen. The dye- resin mixture is pulled by the electrostatic field through the pattern area onto the fabric. 2.6.1.12 Photo Printing In photo printing the fabric is coated with a chemical that is sensitive to light and then any photograph may be printed on it. 2.6.1.13 Jet Spray Printing Jet Spray Printing Designs are imparted to fabrics by spraying colors in a controlled manner through nozzles. 2.6.1.14 Digital printing In this form of printing micro-sized droplets of dye are placed onto the fabric through an inkjet print head. The print system software interprets the data supplied by academic Textile digital image file. The digital image file has the data to control the droplet output so that the image quality and color control may be achieved. This is the latest development in textile printing and is expanding very fast. 2.6.1.15 Flocking Flocking is the technique of depositing many small fiber particles, called "flock" onto a surface of a fabric to produce design. Instead of dyes, an adhesive is used to affix the flocks on the fabric. Then, roller printing produces design on its surface. Nowadays, this is done by the application of high-voltage electric field too. Flocks of cotton, wool, rayon, nylon and acrylic are all used for the purpose.

2.7 Finishing Finishing is the final series of operations that produces finished textile fabric from greige goods. Finishing operations are predominantly wet operations requiring large amounts of thermal energy for water heating and drying. Woven greige goods require some additional steps prior to dyeing, as compared to knit goods. As the first step in finishing woven goods, singeing burns protruding fibers by ing the fabric over an open flame or heated plates to produce a cleaner fabric and enhance future operations. Hot exhaust air is produced. Sizes and other ingredients added during slashing in the weaving mill are removed in the De-sizing operation by washing them in a detergent solution at temperatures up to 200°F and then rinsing them with fresh water. The process produces a wastewater stream of 100 to 120°F. Scouring is another washing process using steam and detergents to remove oils and mineral material. The scouring can be done by batch in pressurized vessels known as kiers or on a continuous basis. In either case, high temperatures, to 250°F, and long retention times, up to 12 hours, are used to ensure thorough saturation and cleaning. Finally, the fabric is rinsed. A waste stream of warm, contaminated water is produced. Next, the fabric is bleached, washed, and rinsed several times to achieve uniformity and improve its ability to absorb dyestuffs later in the finishing operation. Contaminated, warm wastewater is produced. Mercerizing is an optional step and consists of a caustic spray, tensioning, water rinse, water wash, acid dip, and final water wash, and produces a warm wastewater stream. For the drying step, conventional steam-heated drying cans arranged in sequence are most usually used. Finishing is the final wet process wherein size and/or other ingredients are applied to the fabric to provide particular characteristics, such as stiffness, water proofing, etc. 16

Textile_Industry_________________________________________________________Semester_Project The fabric is dried and finally heat cured with a direct flame on a tented frame to bring it to its final dimensions. Large quantities of hot exhaust gas in the 200°F range are produced. The woven fabric is now ready for dyeing. Knit goods do not require De-sizing and bleaching. The finishing process requires only scouring to thoroughly clean the goods prior to dyeing. As with woven fabric, the step involves hot water washes and rinsing, and produces warm, contaminated waste water. 2.7.1 Finishing Wet Process Finishing plants are thermal energy-intensive, requiring large quantities of hot water from 120 to 200°F for De-sizing, scouring, bleaching, mercerizing, dyeing, washing, and rinsing. The hot water is almost universally heated with steam using steam-to-water heat exchangers, direct sparging, or storage tank heating. Many plants recover heat from waste streams with heat exchangers to preheat the process water. Large quantities of steam are also used for heating drying cans and, to a lesser degree, for humidifying space conditioning air. 2.7.2 Dyeing Process The dyeing process varies considerably, depending on the type of dyestuff, type of fabric, and desired final characteristics (for example, solid color or prints.) Dyeing is a wet process and may be done in batches or continuously. Dye vats are known as dye becks and may be atmospheric dye becks (open) or pressure dye becks. Frequently, a time-temperature ramp is employed. The dye beck may start at 120°F and may be slowly raised in temperature to 160°F or higher through steam-heated heat exchangers. After the dye is set by aging or heating, the fabric may be washed again and dried and/or heat cured. Large quantities of warm, contaminated wastewater are produced.

3 TEXTILE INDUSTRY POSES ENVIRONMENTAL HAZARDS The textile industry has been condemned as being one of the world’s worst offenders in of pollution because it requires a great amount of two components:

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Chemicals

As many as 2,000 different chemicals are used in the textile industry, from dyes to transfer agents.

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Water

A finite resource that is quickly becoming scarce, and is used at every step of the process both to convey the chemicals used during that step and to wash them out before beginning the next step. The water becomes full of chemical additives and is then expelled as wastewater; which in turn pollutes the environment:  By the effluent’s heat;  By its increased pH;  And because it is saturated with dyes, bleaches, detergents, optical brighteners, equalizers and many other chemicals used during the process. Traditionally produced fabrics contain residuals of chemicals used during their Manufacture, chemicals that evaporate into the air we breathe or are absorbed through our skin. Some of the chemicals are carcinogenic or may cause harm to children even before birth, while others may trigger allergic reactions in some people. According to a research article, the population that is allergic to chemicals will grow to 60 percent by the year 2020.

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3.1 Water Usage The textile industry is one of the most chemically intensive industries on earth, and the No. 1 polluter of clean water (after agriculture). It takes about 500 gallons of water to produce enough fabric to cover one sofa. Half a billion people already live in regions prone to chronic drought, and by 2025, that number is likely to have increased five-fold, to between one-third and one-half of the entire world population. Global consumption of fresh water is doubling every 20 years.

3.2 Water Pollution Mills discharge millions of gallons of effluent each year, full of chemicals such as formaldehyde (HCHO), chlorine, heavy metals (such as lead and mercury) and others, which are significant causes of environmental degradation and human illnesses. The mill effluent is also often of a high temperature and pH, both of which are extremely damaging. The safety hazards in the two major processes of textile industry have been discussed in the following ages:

3.3 Bleaching Chlorine bleach is known to be extremely toxic to the environment and to consumers, yet chlorinebased chemicals are still often used to bleach fabrics.

3.4 Dyeing Many textile manufacturers use dyes that release aromatic amines (e.g., benzidine, toluidine). Dye bath effluents may contain heavy metals, ammonia, alkali salts, toxic solids and large amounts of pigments many of which are toxic. About 40 percent of globally used colorants contain organically bound chlorine, a known carcinogen. Natural dyes are rarely low-impact, depending on the specific dye and mordant used. Mordents (the substance used to "fix" the color onto the fabric) such as chromium are very toxic and high impact. The large quantities of natural dyestuffs required for dyeing, typically equal to or double that of the fiber’s own weight, make natural dyes prepared from wild plants and lichens very high impact.

4 HOW YOU CONTROL PROCESS RISKS WHICH APPLY ACROSS THE TEXTILES INDUSTRIES 4.1 Autoclaves 4.1.1        

Autoclave Apparatus Are safety devices, valves, gauges, controls, alarms etc simple to read and understand? Are they easily accessible to operatives of all sizes? Where machines have automatic door opening are alarms and trip devices fitted? Is there a suitable safety valve fitted? Is there a correct steam pressure gauge? Is the maximum safe working pressure clearly marked? Is a suitable reducing valve or similar automatic device fitted? Is there an isolating valve in the inlet line for each machine? 18

Textile_Industry_________________________________________________________Semester_Project  For multi and single bolted door machines is a device fitted to break the seal?  For quick opening type doors are the required devices provided? 4.1.2    

Autoclave Procedures Has the autoclave been examined according to a scheme of examination in the last 14 months? Is a permit system available and used for entering vessels for any reason? Are records kept of weekly checks on locks, guards, gauges and safety devices? Is the autoclave checked by a competent person at specified intervals and do the managers see the report?  Are operators fully instructed and properly trained in correct operating procedures, purpose and function of the controls and safety devices?

4.2 Baling Machines  Is mechanical equipment used to handle bales?  Are all bales handling equipment (including bale elevating systems) adequately guarded and regularly maintained?  Are horizontal bale presses fitted with door interlocks of a suitable design and integrity?  On other bale packing machines are all conveyor nip points guarded and trap entanglement areas guarded or safe by design?  Is access to the ram or other moving parts, guarded by fixed guards or interlocked to a suitable standard?  Are shearing points guarded or safe by distance?  Where swivel boxes are in use is the control a "hold to run" type?  Where automatic swivel boxes are in use are trip guards and warning signals in operation?  Is working at height accessible by adequate steps and platforms?  Are these interlocked where moving parts are accessible?  Is there a safe system of work, including isolation, for use when working inside guards, for example during cleaning and maintenance?  Are bales stored in a stable manner?  Is the storage space reserved for bales of adequate space to allow safe movement of equipment and bales within the area with clear gangways maintained?  Is a safe system of work employed for bale handling?  Are timber pallets used and are they in good condition?  Does the area show evidence of good housekeeping?  Is adequate personal protective equipment worn during handling, packing and unpacking of bales?  Are there any procedures for stacking and de-stacking of bales?  Has training in bale handling and handling equipment been provided?

4.3 Cloth Finishing and Fabric Coating 4.3.1 Cloth Finishing and Fabric Coating Machinery  Are all drive points, belts and shafts correctly guarded?  Are roller intakes on all types of finishing machinery correctly guarded with modern interlocks or trip devices on fast moving equipment? 19

Textile_Industry_________________________________________________________Semester_Project           

Are braking systems checked on a regular basis? Are suitable safety devices (e.g. rubber needles) provided for feed scouring machines? Are all hot parts/pipes etc guarded or insulated to prevent accidental burns? Are dry cleaning machines and tumble dryers interlocked to prevent entry to clean or remove items whilst they are running? Are operators of dry-cleaning machines trained in operation and routine maintenance such as cleaning traps and the still? Are dry cleaning machines properly maintained and checked for solvent leaks, Are there emergency procedures in place to deal with spillages of dry cleaning solvent? Where 'A' Frames are used is a suitable safety device provided for batching units? Where heavy weights are loaded to 'A' Frames are these still moved manually? Where 'A' frames are moved by motorized systems, are brakes and steering devices adequate? Are fixed or interlock guards used in pressurized finishing machines?

4.3.2 Cloth Finishing and Fabric Coating Procedures  Are specific named employees appointed to carry out sharpening work on the blades of cropping and cutting machines?  Where operatives need to climb onto machines to make adjustments, feed material or check controls are they trained in correct techniques, use of ladders and steps etc?  Are pressure vessels subject to regular inspection by the company maintenance and schemes of examination by an external competent person?  Are fault reporting procedures in operation for leaks of steam, solvents and other substance?  Where batch carts, 'A' frames etc are moved by manual labor, have measurements been made of the effort required?  Are there procedures for maintenance of carts so that they run freely?  Are employees involved in lifting, pushing and pulling been trained in these skills and has such training been recorded?  Are special permits in use for entering enclosed or confined spaces?  On pressurized finishing machines are safety devices checked each day?

4.4 Dyeing 4.4.1 Atmospheric Dyeing Machinery  On open vessels are valves and other controls located in a safe position (no risks from overflowing or boiling liquor)?  Are steam injection nozzles of a noise-reduced design?  Are hot parts guarded or lagged?  Are buckets with lids in use to prevent spillages?  Is adequate drainage provided?  Are pits and gullies guarded, fenced and clearly marked?  Where liquor preparation plants are in separate rooms are arrangements made for lone worker emergency ?  Where winding on or batching of operations takes place at speed, is access limited?  Where 'A' Frames are in use are precautions in place to stop them falling over? 4.4.2

Screen Printing 20

Textile_Industry_________________________________________________________Semester_Project  Are all traps and shearing areas guarded or safe by design?  On wide rotary or flat printing machines are platforms or walkways available?  During screen preparation where lasers, ultra violet or other special light sources are used, are systems in use to prevent access whilst operations are taking place? 4.4.3              

High Pressure Dyeing Machines Are the recommendations in HSE guidance note PM 4 followed? Is a suitable safety valve fitted? Is there a correct pressure gauge fitted? Is the safe working pressure and corresponding temperature clearly marked? Is the supply pipe fitted with a suitable reducing valve or similar automatic device? Are thermal locks fitted and maintained regularly both on main and sample machine? If hydrogen peroxide is in use have extra precautions been taken? Are safety devices and gauges simple to read and understand, and easily accessible? Where machines are inter-connected is a non-return valve fitted in each line? For multi-bolted door machines is a device fitted to break the seal? For quick opening doors are the necessary safety devices fitted? Are hot parts guarded or lagged? Is ventilation sufficient to remove steam quickly and effectively? Where winching, winding or automatic feeds are in operation, is an emergency stop button fitted to allow instant access for employees?  Is access to equipment and machinery well maintained and regularly cleaned e.g. steps, platforms, rails, gantries?

4.4.4 Dyeing Procedures  Where employees are handling hazardous chemicals and dyestuffs are they training and competent and is such training documented?  Are special permits used where employee's need to enter enclosed or confined spaces?  Where employees are lifting or pulling heavy wet weights have measurements of effort been made?  Are employees trained in good lifting and handling techniques and is this recorded?  Where hazardous substances are pumped into tanks from delivery vehicles are Safe Systems of Work in operation?  When such operations are taking place is a competent person overseeing the delivery?  Has a major spillage emergency plan been prepared and are all employees trained and aware?  Where hazardous substances are moved in buckets, are color-coded systems in operations to assist in preventing mistakes?  Is there a safe sampling procedure?  Is a documented Safe System available and used for clearing blockages?  Is a permit system available and used for entering vessels to clean and carry out maintenance duties?  Are formal fault reporting systems in use to cover leaks of steam or other substances?  Where batching, winding and automatic feeds are in use, is a documented Safe System followed which reduces the likelihood of entanglement?  Are emergency showers available and tested weekly?  Are safe systems of work in place to protect employees from trapped pockets of superheated water?  Are high pressures dyeing machines subject to a written scheme of examination? 21

Textile_Industry_________________________________________________________Semester_Project  Are operators trained and instructed in correct operating procedures and the purpose and function of controls and safety devices? 4.4.5 Dye stuff handling  Has consideration been given to the feasibility of handling dyes in dust-free reduced-dust forms?  Is handling of dry powder dyes reduced by for example the use of pre-weighed quantities, dissolving under local exhaust ventilation (levy) directly after weighing, or using water soluble bags?  Is effective levy used for handling dyestuffs?  Is good housekeeping applied to keep areas free from contamination?  Is suitable personal protective equipment such as coveralls, gloves, aprons, and respirators provided and worn where necessary?  Are all reactive dyes treated as potential respiratory sensitizers?  Does anyone using or working near reactive dyes have symptoms of respiratory sensitization, e.g. itchy/swollen eyes, runny nose/breathlessness?  Does anyone using or working near reactive dyes have symptoms of skin sensitization, e.g. red rash on body but particularly on hands?  Are workers trained to recognize and report symptoms?  Do reactive dyes have to be used - could a less hazardous dye be used?  If use of a reactive dye is essential, is the least hazardous form used, e.g. in liquid or low-dust pellets form?  Is the whole of the process involving reactive dyes, not just weighing out, covered by local exhaust ventilation?  If PPE is worn as an additional protection, do you have arrangements for cleaning it and changing filters?  Do you have a health surveillance programmer in place for people exposed to reactive dyes?  Does it include maintenance workers who may also be exposed?  Do you keep health records for employees who work with reactive dyes?

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Textile_Industry_________________________________________________________Semester_Project References 

Websites

www.wikipedia.com www.ptj.com www.textileclass.com

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