JUTE

Md. Reajul Islam

Lecturer, BUTex

FLOW CHART OF JUTE MANUFACTURING

PROCESS

Selection of Jute for a batch

↓

Piecing up

↓

Softening and lubricating

↓

Batching, conditioning or piling

↓

→ Breaker card

Carding

→ Finisher card

↓

→ 1st

Drawing and doubling → 2nd

→ 3rd

↓

Spinning

Bappi BUTex

Batch

A number of bales of jute selected for the purpose of manufacturing a particular type of yarn in known as “Batch”.

Batching

Batching covers all the processes preparatory to carding.

Or,

the term batching strictly refers to the addition of oil and water to the jute.

OBJECTS OF BATCHING

To make the fibre flexible and extensive.

To remove hardness, stiffness of lower jute fibre.

To prevent the production of lower quality yarn.

To make the fibre for effective carding.

Emulsion

Jute fibre is consists of lignin, so it is hard and

brittle. Easily breaks down due to abrasion and

mechanical treatment. To make it soft and easy a

mixture of some lubricating agent is used.

The mixture of these elements is called emulsion.

Oil → 25%

Water → 74.5%

Emulsifier → 0.5%

CHARACTERISTICS OF EMULSION

Should be stable for the specific time.

No harmful effect on either machine or jute.

Should have high softening capacity.

It must be colorless, odorless, cheap and

available.

The droplet of emulsion will have to be very small

that it can penetrate in to fibre easily.

REQUIREMENT OF JUTE BATCHING OIL

No harmful; effect on either machine or jute.

Color must be acceptable.

It should not sticky.

Not have any objectionable odor.

Cheap and plentiful supply.

Requirement of Water

Should be free from color, odors, suspended

matter and hardness.

Requirement of Emulsifier

Reduce surface tension and stabilizes the

emulsion.

EMULSION PREPARATION TECHNIQUE

1. Pedal type machine

2. Colloidal machine

3. Ultrasonic machine

Procedure:

Equal quantity oil and emulsifier

↓ (Agitation)

Rest of the oil

↓

Water

↓

Agitation

SELECTION TECHNIQUE OF JUTE

A).HESSIAN WARP YARN:

Must be good, strong, clean and free from specks

with high luster.

Batch containing 70% hard jute and 30% soft jute

give good result.

Tossa Jute has good spinning quality

SELECTION TECHNIQUE OF JUTE

B). HESSIAN WEFT YARN:

Should be clean and softer than Hessian warp

jute.

For light Hessian weft yarn a batch of 50% hard

jute and 50% soft jute is quite satisfactory.

For heavy Hessian weft yarn a batch containing

30% hard jute and 70% soft jute.

In this case as much as 30% Tossa may be used.

SELECTION TECHNIQUE OF JUTE

C). SACKING WARP YARN:

Sacking warp jute should be good and strong but

specks do not matter much in this case.

Batch containing 60% hard jute 40% soft jute

give good result.

70% to 80% low grade Tossa jute can be used in

the sacking warp batch.

SELECTION TECHNIQUE OF JUTE

D). SACKING WEFT YARN:

Sacking weft batch may contain

Runners and rejections.

Line cuttings.

Bale cuttings.

Soft and hard waste.

Rope waste and jute dust.

Habijabi and tangled jute.

Rejection long jute varies from 10% to 20% of the total of

batch. Jute dust may not exceed 10%.

STAINLESS EMULSION

In an emulsion the oil percentage is less and the

water percentage is high. Jute yarns which are used

to make carpet are applied stainless emulsion.

Stainless emulsion is prepared by following recipe →

Water → 92 to 95%

Oil → less than 1%

Emulsifier → 0.5% to 1%

DEFECTS OF EMULSION

1.CREAMING

When an emulsion is prepared it is not possible to make all

the drops exactly same size. Some will be smaller than

others and there will be quite a few large drops. In general

the smaller drops less is the scatter in the diameter,

comparatively the larger, droplets will slowly move up to

surface of emulsion as larger the droplets lower is the

specific gravity in comparison to water and forms a layer at

the surface causing uneven distribution of emulsion. This

defect is called creaming.

1.CREAMING

Causes:

Oil selection improper.

Oil water and emulsion are not mixed accurate ratio.

Agitation solution is not to be good.

Remedies:

Keeping the size of droplets as small as possible.

By using oil having high specific gravity.

After make the emulsion should not be more time storage

2.BREAKING

If by mixing internal oil phase droplets become a

large droplet then its float upwards of the

emulsion surface and it cannot be broken re –

agitation.

Remedy:

This breaking fault removed by the high speed re

– agitation.

TYPES OF SOFTENING MACHINE

Single softener (long jute is used)

Tandem softener (cutting)

Good spreader (for long jute)

JUTE CARDING

The process by which long reeds of jute which

passing through high speed pinned rollers and

broken down into an entangled mass and

delivered in the form of ribbon of uniform weight

per unit length called Jute Carding.

OBJECTS OF JUTE CARDING:

To break down and split up to the fibre.

To make the sliver of uniform weight/unit length.

To remove dirt, dust.

To individualize and parallelism the fibre.

To extent the fibre by drafting and reduce weight

per unit length.

To produce spin able fibre.

To mix different quality of jute.