3. Batching

In the jute yarn manufacturing, batching refers to all the preparatory steps undertaken before the carding of jute fibre.

Objects of Batching

Or, importance of batching

• To help the fiber movement freely during processing.
• To get expected dampness and flexibility.
• To reduce hardness or stiffness.
• To control and reduce the yarn cost.
• To reduce waste.
• To intermix the batch component effectively.
• To produce improve graded yarn.

Piecing out

Opening of jute bale and separation of stiff root jute and making of morah according to specific weight (1-2 lb) is called piecing out.

Emulsion

• Emulsion: Mixture of two immiscible liquids where one is dispersed in small globules, on the other hand addition of a third substance brings stability.
• Water, oil and emulsifier are the ingredients for a batching emulsion.
• Jute Batching Emulsion: A mixture of some lubricating agents which is applied on jute fiber to make the fiber soften and flexible.

General recipe

• Water: 73%
• Oil: 25.4%
• Emulsifier: 1.6%

Emulsion for CBC

• Water: 89-91%
• Oil: 8-10%
• Emulsifier: 0.5-1%

Functions of elements of emulsion

• Function of oil:
  • It lubricates the fibre.
  • It helps fibre to move freely during processing.
  • It makes the fibre soft and gives more spinning property.
  • It cleans the pins and rollers of the machine.
• Function of water:
  • It increases extensibility of fibre which resists fibre breakage during processing.
  • It gives sufficient dampness and flexibility to the fibre.
• Function of emulsifier: Emulsifier is a surface active agent. These are soaps, detergents, wetting agents, etc.
  • It removes temporary hardness of water.
  • It helps emulsion to remain in stable form.
  • It reduces surface tension.
  • It makes droplet formation easier.
  • It stabilizes the emulsion.
  • It prevents separation of oil from water.
• Function of urea:
  • It helps easy penetration of emulsion into the fibre.
  • It helps fibre to be soft quickly.
  • It reduces maturity time to half.

Requirements of elements of emulsion

• Requirements of emulsifier:
  • It must not impair the lubricating properties.
  • It should not have objectionable color and odor.
  • It should be chemically inert with fiber.
  • Moisture regain should be less than 30%.
  • It should have good wetting properties.
• Requirements of water:
  • It should be soft (free from CO, Mg, Fe etc.)
  • Hard water should be treated before using.
  • It should be colorless and odorless.
  • It should be free from suspended mineral.
  • It should be acceptable.

Reasons/Objectives of using emulsion:

• To make soft fiber.
• To increase cohesiveness,
• Pliability increase,
• To increase flexibility,
• To make spinning satisfactory,
• To make the fiber suitable for carding,
• To give twist and easy movement.
• To avoid stiffness.

Pilling/Conditioning

• The process by which after applying emulsion jute fiber is stored at a specific condition for certain time is called pilling.
• Objects:
  • To soften and split up of jute fiber,
  • To loosen the fiber,
  • To convert the rooty material into spinnable fiber.

Acknowledgement

• Reference: Class Lecture