New Technology Warp Sizing Lubricant is Introduced to the Textile Industry

Calgati Chemical Company Ltd.

Most of us have experienced problems associated with the removal of traditional lubricants such as tallow (animal fat) based waxes or mineral type oils. For decades, such lubricants were the only alternatives for the slashing and weaving processes. Neither of these lubricating agents is water-soluble and therefore they cannot be in solution during subsequent wet processing. Insolubility can and usually does cause great difficulty in textile wet processing. Such tallow and mineral oil lubricants for sizing usually demonstrate removal problems in preparation and thereby create subsequent processing difficulties in dyeing, printing, and finishing. These difficulties include dye resist spots, streaks, light shade spots, and poor adherence of finishes and coatings, to mention a few.
Let us review the history of so-called lubricating agents for sizing and weaving and their purpose for use. Originally, tallow based wax lubricants were not incorporated into sizing formulae solely for lubrication in weaving. In fact, by most definitions, tallow based materials are not lubricants at all. They are softeners. One major reason for their use in slashing was to stop sizing agents from sticking on the drying cylinders. This was before the use of Teflon coatings when size build up on the old metal drying cans was a serious problem. The industry needed a solution to the sticking problem and animal fat was an answer.

Another reason for use of tallow-based products was to reduce or eliminate foam resulting from the process or the sizing chemicals. When these traditional lubricants were utilized to address the sticking and foaming problems, no one anticipated down stream processing difficulties. Tallow and oil are hydrophobic (they hate water) in nature and this characteristic interferes with the adhesion of a sizing agent, while at the same time weakening the film formed by the dried size agent. Weaving performance is seriously impaired by poor adhesion of size to yarn and weak film formation. Size shedding, increased yarn breaks, and low weaving efficiency characterize this impairment. Difficulties of tallow or oil "float-off" and subsequent redeposition during preparation are also a result of the hydrophobic and insoluble nature of tallow and oil. This "float-off" and redeposition lead to the dyeing, printing, and finishing problems mentioned earlier.

Eventually, tallow and oil were combined with emulsifiers (surfactants designed to lend some water loving nature) in an effort to reduce or eliminate some of the problems associated with these products. This was a good idea. However, as the emulsions and dispersions (formed from water, wax or oil, and emulsifier) exhibited a strong tendency to breaking (separation of the water, wax or oil, and emulsifier either due to chemical or mechanical reasons) and thereby allowing the wax or oil to return to its insoluble state, the same old problems reappeared. Dye resist spots and streaks from either an inability to remove the wax and oil or redeposition onto the fabric after removal were common. Hydrophobic and insoluble tallow wax and paraffinic and napthenic oils simply do not wash out readily and redeposit easily.

In 1996, research was conducted to seek new ways to eliminate the downstream problems associated with sizing lubrication. The Institute for Textile Technology, ITT, was evaluating at a totally different method for lubricating warp yarns. Dr. Howard Thomas, now with Auburn University, was investigating the use of soluble surfactant (detergent) based lubricants that would remain in solution throughout wet processing. The idea was excellent, but there were problems of foaming and sticking on the cans. Detergents foam! Size additives stick! Resolving these difficulties was beyond the scope of the ITT evaluations. Although the results in weaving and preparation were excellent, the application was not perfected. Calgati Chemical Company, Ltd., an American company specializing in textile chemicals, focused attention on solving these problems. The incorporation of a system of wetting agents, and leveling agents, along with the proper defoamers and anti sticking agents was found to be key. Once the problems were eliminated, the application of SUPERLUBE (the surfactant based warp lubricating system) became a very workable alternative to traditional lubricants. SUPERLUBE use is a great asset in solving problems in weaving, preparation, dyeing, printing, and finishing.

SUPERLUBE stays in solution, does not float-off, and does not redeposit during wet processing. Performance in weaving has been outstanding. Tests show as much as 35% reduction in warp stops and a remarkable decrease in shedding and fiber fly. So, what does this do for the textile manufacturers? Here are some of the benefits that can be realized:

• Compatible with most chemicals used in sizing, including the water.
  
• Low dosage rates (1/3 or less compared to wax and oil), reduced inventory, and less freight expense.
  
• No separation or kick-out in the cooking or storage kettle.
  
• Significantly reduced shedding in sizing and weaving.
  
• Increased weaving efficiency and lower warp stops.
  
• Readily removed at reduced water temperatures.
  
• No float-off and redeposition in preparation.
  
• No interference with adhesion in fabric coating applications.
  
• No interference with heat setting.
  
• Eliminates dye resist spots, streaks, and light shade areas.

To date, commercial testing has been positive in most every case. Textile customers are regularly buying SUPERLUBE. However, more data is needed to answer other questions. As this is a new technology, there remain factors that have not been fully evaluated, such as the impact on the life span of machinery parts. It may happen that some of the properties of the product will be seen as disadvantages, as they are different to the properties that have been accepted for many years. There is still much to learn about this technology. Changing the attitude of textile manufacturers toward traditional lubricants is a difficult task. Many people are resistant to change in the textile industry, but some people are forward thinking and have openly embraced this new technology. In any case, the textile industry will determine if SUPERLUBE technology will become the standard lubricant of the XXI century.