TANNEX® NOVECO Green Solutions

Green Solutions

Mineral Technology in Textile Processing and
Water Saving Program

History

TANATEX Chemicals strongly believes in the use of minerals in
textile processing. Over the years we have successfully launched
products like:
TANNEX® GEO – Multi-functional product for pretreatment,
dyeing and correction of faulty finishing
TANNEX® NOVECO – Multi-functional product for
pretreatment, dyeing and correction of faulty finishing
TANATERGE® ELB – Nano-clay based composite for the pre-
treatment of elastane blends
TANASPERSE® MDA – Mineral desizing agent for PA & PES
TANATERGE® M-RE – Mineral soaping agent
TANNEX® RENA liquid 01 – Ecological stabilizer for hydrogen
peroxide of an extraordinary quality
Green Solutions. Slide <2>

TANNEX® NOVECO
Multi-functional product for pretreatment,
dyeing and correction of faulty finishing

TANNEX NOVECO
Clay-based multi-functional agents

• Clay is a so-called layered
aluminosilicate of extremely
small particle size
• In water these particles are
hydrated and they possess a
negative charge.
• There are many clay types,
depending on their chemical
structure and deposit area
• e.g. Kaolinite, Vermikulite,
Smektite, Illite
• The clay used in TANNEX
NOVECO has largest surface of
approx. 800 m²/g


TANNEX NOVECO
Scheme of a clay particle

• The negatively charged
particles have a large
potential adsorption surface
for:
•(-) •(-) •(-) – hydrophilic materials and
•(-) •(-)
•(-) polymers
•1
nm – hydrophobic waxes and oils
– metal ions
•200-10.000 nm
• Excellent stabilising effect
for H2O2
• Very good lubrication to
prevent crease marks


TANNEX NOVECO
Absorption of impurities/dirt

Absorption of clay on oil

Fat and impurities
Clay sheets


TANNEX NOVECO
The Stabilizer Concept

Traditional Organic Stabilizer

TANNEX NOVECO


TANNEX NOVECO
Special Application

• Stripping fluorcarbon & silicone finishes
1 ml/l DIADAVIN HLS Conc. 01
3 – 5 ml/l TANNEX NOVECO
3 – 5 ml/l Caustic Soda 50 %
– repair at 90 – 100 ºC during 40 –
50 minutes
– rinse thoroughly with warm & cold
water
– repair the dyeing (if required) and
apply finish again


TANNEX NOVECO
Special Application

Prevent the deposit of oil and As an lubricant in dyebath
oligomer on machine
Due to its absorption – TANNEX NOVECP shows
properties the machines are excellent lubricant
kept perfectly clean. Some properties on all cellulose
polyester dyers use based fabrics and knits, e.g.
Cotton, Viscose, Modal,
0,5 ml/l TANNEX NOVECO Polynosic and especially
Lyocell fibres and give them
To avoid soil and dyestuff
a nice soft handle
deposits in their machines
– Also on synthetics good
To remove the knitting oil
results are being obtained
from the fabric.
Cleaning operations can
drastically be reduced


Modern requirements

TANNEX® NOVECO is GOTS approved.

TANNEX® NOVECO can be used for all textiles applying for the
Öko-Tex Standard 100.

TANNEX® NOVECO can be used for textiles applying for the
EKO labeling requirements.


TANNEX® NOVECO
Physical and ecological data

- Aspect : Light brown
- Viscosity : 800 mPa·s *

- Ionicity : Nonionic
- pH : 8.0 – 9.0
- Density : 1.1 g/cm3
- Fish toxicity : LC50 > 100 mg/l
- Biological elimination : > 70% (Zahn Wellens - OECD 302B)

- MBAS value : 0 mg/g
- BiAS value : 110 mg/g
- COD value : 369 mg/g
- BOD5 value : 20 mg/g
* See additional info on rheology


TANNEX® NOVECO
Environmental awareness

TANNEX® NOVECO is the answer for environmentally responsible
textile processing.

TANNEX® NOVECO is harmless for the aquatic environment,
shows a high biological elimination (>70%) and is therefore not
dangerous for all in water living species.

TANNEX® NOVECO is our next step in sustainable textile processing.


TANNEX® NOVECO
Positive effect on COD and BOD5

Some practical measurements in a textile factory, which clearly
showed the decrease of COD and BOD figures.

Average reduction of COD values: 25%
Average reduction of BOD values: 53%

The organic substances, as soluble or dispersed substances, are
absorbed by the clay of TANNEX® NOVECO and thus removed from
the water. Of course biodegradation will continue on the clay.

But the cost for discharging this effluent water into communal
effluent streams will be reduced drastically.

TANNEX® NOVECO helps you to respond to environmental
issues in a simple way


Practical Run - Example 1

Fabric :Interlock Co.,100%
Machine: FONG’S ECO-3-D2T L.R.=1:7

Factory ‘s recipe TANNEX ’s recipe TANNEX ’s recipe
Scouring agent:C-
SCO (o.w.f): 1.0%,
Stabilizing agent:
TANNEX NOVECO: TANNEX NOVECO:
ST201(o.w.f.):0.5% ,
Dyebath lubricant, 1.0%(o.w.f.), 1.5%(o.w.f.),
FIRCHEM SF-290T:
0.7%,
COD value / Residual liquid after bleaching (don’t include acid rinse and Bio-
polishing enzyme rinse) /ppm

6750 5620 4480

COD reducing rate 16.7% 33.6%


Reduction of COD

80% of the BOD and COD values are originated from the
chemicals/waste in the pretreatment process.
Table below shows the comparison of COD of different pretreatment
conditions:

8000
7000
6000
5000
4000 Ser i es1
3000
2000
1000
0
pr evi ous TAN EX
N TAN EX
N
N VEC : 1%
O O N VEC : 1. 5%
O O


Practical Run – Example 2

Comparison of COD values of pretreatment and optical
brightening in one bath with TANNEX Noveco vs. existing recipe.
COD is reduced by 17%

12000

10000

8000

6000 Ser i es1

4000

2000

0
pr evi ous TANNEX NOVECO


TANNEX® NOVECO
Application recommendations

Again very positive effects have seen when wetting out the
material with TANNEX® NOVECO, before adding peroxide and
caustic. This also has a very positive effect on the possible foam levels.

Adding peroxide before the caustic strongly improves the bleach
bath stability, final whiteness and final Dp values.

Prefered chemical addition:
1) Water
®
2) TANNEX NOVECO, wet out the material for several minutes
®
3) Peroxide, run for 5 minutes to exhaust on TANNEX NOVECO
4) Caustic, raise temperature for bleaching


TANNEX® NOVECO
Application recommendations

Full white bleaching White for dyeing

Liquor ratio 10:1 Liquor ratio 10:1
30 – 45 min. @ 95 - 110°C 30 – 45 min. @ 95 - 110°C

®
1–2
®
ml/l TANNEX NOVECO 0.8 – 1.5 ml/l TANNEX NOVECO

2 – 3.5 g/l NaOH 100% 1.5 – 3 g/l NaOH 100%

6 – 10 ml/l H2O2 35% 2 –5 ml/l H2O2 35%
®
0.7 % BLANKOPHOR CO liquid

• Very good stabilisation • Good whiteness for dyeing
• Excellent whiteness • Very good cleaning and
scouring effect
• High Dp value
• Good rewetting effect
• Excellent absorbency
• Excellent lubrification and
• Soft handle and bulky handle
crease mark prevention


The effect of adding sequence

Fabric: 100% cotton knit
Traditional sequence: adding caustic first then adding peroxide
Recommended sequence: adding peroxide first then adding caustic
The fabric strength usually will lose after bleaching especially for high
counts yarns. Adopt the recommended sequence can reduce the loss of
fabric strength.
Fabric’s original bursting strength: 418.10 N

Trad. seq. Noveco seq.

Whiteness (CIE) 69.46 70.57

Burst Strength 367.55 N 389.05 N

Loss rate in burst
12.09% 6.95%
strength


TANNEX® NOVECO
Foam levels
Foam level at 20°C Foam level at 80°C

TANNEX® NOVECO TANNEX® NOVECO
Directly After 1 min Directly After 1 min


TANNEX® NOVECO
Silicone emulsifying

TANNEX® NOVECO contains special
surfactants giving the absolute cleaning
effect, improving the hydrophility after
bleaching, but also showing fantastic
silicone emulsifying properties.

TANNEX® NOVECO is the multi-purpose
product for all Co and Co blends in
bleaching and pre-scouring.


TANNEX® NOVECO
Silicone emulsifying (1 hour)

BLANK TANNEX® NOVECO
(After 1 hour) (After 1 hour)


TANNEX RENA liquid 01

Ecological stabilizer for hydrogen peroxide of an
extraordinary quality

TANNEX RENA LIQUID 01

– Based on a new sodium Ecological stabilizer for
silicate, which does perform hydrogen peroxide of an
in a different way compared
to classical waterglass (no
extraordinary quality
polymer structures)
– No residues on fabric,
cleaner machines
– Soft handle of the goods
– Outstanding dyeing and
printing properties


Buffer capacity & Optimum pH


Solubility and temperature, influence of hard water


TANATERGE M-RE

Mineral Soaping Agent

TANATERGE M-RE
Mineral soaping off agent for REactive dyestuffs

• Special soaping off agent for
reactive dyestuffs based on
minerals.
• The best and the most ecological Electron-microscopical picture
way to soap off hydrolyzed reactive
dyestuffs.
–Mineral based, thus very low COD
and BOD values
–Very good removal of hydrolyzed
reactive dyestuffs
–Applicable in discontinuous and
continuous processing
–Can be applied for post-washing
of reactive printed goods
–Hydrolyzed dyes are prevented
from re-striking onto the goods
–Non-foaming


TANATERGE M-RE
Mineral soaping off agent for REactive dyestuffs


TNANTERGE ELB

Nano-Clay based composite for pre-treatment of
Elastane blends

Foaming Property of TANATERGE ELB

1 unit = 0.5 cm foam TANATERGE
Jet - Simulator
ELB
Unit

Is a non foaming
10
detergent, what can
9
be used on all
8
machines where foam
7
might be a problem
6

5

4

3

2

1

0
20 30 40 50 60 70 80 90 98 °C

1,85 g/l TANATERGE ELB 0,93 g/l DIADAVIN DSP


TANATERGE ELB
Nano-Clay based composite for the pre-treatment of Elastane blends


Discontinuous Application

Ratio 10:1
Polyester (micro)/Elastan
or Polyamid/Elastan
120
Discontinuous application
100
Temperature [°C]

80

60 50°C 15
40
min Dyeing
20 drain
0
0 10 20 30 40 50 60 70 80
Time [min]

Fill the machine and add
TANATERGE ELB 1 – 2 ml/l Refill and add
Soda ash 0,5- 1 g/l TANATERGE ELB 0,5 ml/l
other dyeing auxiliaries
dyestuffs


Discontinuous Process

Example for prebleaching Knitwear, CO/ Elastan Preparation for
light and medium
Ratio 10:1 shades
100
95 °C 25‘

80
Hot overflow rinse !!!
Temperature [°C]

60
NaOH 38°Be´ 2,0 ml/l
25-40°C 10-15 min
40 Hydrogenperoxid 50% 3,0 ml/l
drain
20 TANATERGE ELB
refill 0,5 ml/l
0
0 10 20 30 40 50
Reactive dyeing
Time [min] pH 6- in the same bath
7

TANATERGE ELB 1,5 TANAZYM PK 0,15-0,25
ml/l ml/l
Prevention of formation creases: heat up slowly, use TANATERGE ELB

Discontinuous Process

Example: bleach with optical
brightener Co/Elastan
liquor ratio 1:10
95-100 °C
30‘-60‘
100

80
PLEXENE® QXL 1 ml/l
temperature °C

NaOH 50° Bé 4-6 ml/l 70°C
60 2 °C/min. H2O2 50% 6-8 ml/l
rinse overflow
BLANKOPHOR® BA fl. 0,7 %
40
(add slow)
TANAZYM PK
20 (Peroxide killer
TANATERGE ELB 1-3 ml/l acidify/softener
0
0 20 40 60 80 100
time [min]

Prevention of formation creases: heat
up slowly, use TANATERGE ELB

Water Savings Programs
Some practical examples

Water savings programs

• Water shortage is an emerging word in textile processing industry

• So everybody wants to save water in their process

• A complete new way of thinking is necessary

• TANATEX can and will play its part in this
new challenge
• This presentations will give you some
ideas and some practical experiences


Water consumption in average textile company

• Total average water consumption per kg textile will be
around 45 l/kg, however specific cases are known where up to
100 l/kg will be used.
(Information present customer: - 80.000 m production per day @ 400 g/m (32.000 kg)
- Total effluent per day 1.500 m3/day (1.500.000 liter)
- Total water consumption per day 47 l/kg (1.500.000 liter / 32.000 kg)

• Average water consumption in the pretreatment only, will already
be around 15 – 20 l/kg.


How does WATER fit in our philosophy ?

We promote WATER from different points of view:

- less total waste water and less effluent load
- cost savings in water and energy
- cleaner water by less chemical waste in effluent
- specific biological treatments

but most important:

WE BELIEVE IN WATER !


Example 1

Continuous bleach


Less total waste water

Effect of TANNEX RENA liquid 01

Using TANNEX RENA liquid 01 makes it possible to reduce the
amount of NaOH to max. 40% of the amounts use for
classical organic stabilisers.

This could easily result in a water reduction of 2 – 3 l/kg
per application (cold pad batch and/or pad steam).

Consuming less water directly reduces the energy consumption
and therefore strongly reducing costs per kg.


Objective of industrial trials in this example

• Optimize washing procedures and reduce total water consumption.

• Create a single procedure (desizing and bleaching) for all processes
(blanquear and descrudar) in order to replace the two different
procedures as for actual standard procedures.

• Replace actual alkaline boil off by an enzymatic desizing.

• Increase productivity by simplifying procedures and reducing
changing times for different procedures.

• Create a green and sustainable process based on GOTS approved
products, low harsh chemicals (NaOH and H2O2) and reduction of
water and energy.

How to achieve these objectives ?

• First pad steam treatment based on enzymatic desizing and strong
hardness and heavy metal complexing.
Without the use of NaOH in this first pad steam treatment water
consumption can be reduced.

• Reduce the amount of alkali in the second pad steam bleach so
that also there water can be reduced.

• Low alkali bleaching treatments are safer for the material,
especially for the Elastane fibres.

• Lower amounts of caustic and peroxide in combination with a good
clean up of the material using complexing agents gives less fibre
damage, higher Dp values and tearstrengths.

Standard customer process: Alkaline boil off and Bleaching
Blanquear 100% Co and Co/EL (Cama)

3 ml/kg Stabilizer No
6 ml/kg Scouring agent neutralisation
18 - 25 ml/kg NaOH 48º Be
40 - 50 ml/kg H2O2 35%
3,5 l/kg water

2 ml/l Stabilizer 3,5 l/kg water
6 ml/l Scouring agent
20 ml/l NaOH 48º Be
15 ml/l H2O2 35% 7’ – 9’ @ 99°C
2,5 l/kg water

Alkaline boil-off
3’ @ 99°C

95°C 95°C 95°C 95°C
20°C 80°C
Impregnation
X X 60°C
@ 20ºC

Total consumption 9,5 l/kg water

Alkaline boil off Bleaching

TANATEX process: Enzymatic desizing and Bleaching
Blanquear 100% Co and Co/EL (Cama)

8 ml/kg TANNEX RENA liquid 01
No
2,5 ml/kg TANATERGE ADVANCE
neutralisation
12 – 15 ml/kg NaOH 48º Be
35 – 40 ml/kg H2O2 35%
2,5 l/kg water

2,0 l/kg water
• 8 ml/l TANAZYM LTC 01
• 6 ml/l PLEXENE PREP
7’ – 9’ @ 99°C
1,0 l/kg water

3’ @ 99°C

95°C 95°C 95°C 95°C
20°C 80°C
Impregnation
X X 60°C
@ 20ºC

Total consumption 5,5 l/kg water

Enzymatic desizing to
replace Alkaline boil off Bleaching

Standard production 100% Co and Co/EL
(Tight strand or Roller bed)

1st pad steam bleaching Pad steam bleaching
- Impregnate at 20°C - Impregnate at 20°C
- Wet pick up ± 70% - Flex Nip impregnation (100%)
- Steam for ± 3 minutes at 100°C - Steam for ± 4 - 9 minutes at 100°C

2 ml/l stabilizer 3 ml/kg stabilizer
6 ml/l scouring agent 6 ml/kg scouring agent
20 ml/l NaOH 48˚Bé 18 – 25 ml/kg NaOH 48°Bé
15 ml/l H2O2 35% 40 – 50 ml/kg H2O2 35%

- Wash off in 1 unit at 95°C using - Wash off in 6 units at 95°C using
3,5 l/kg water. 3,5 l/kg water and 2,5 l/kg in unit 7.


Blanquear 100% Co and Co/EL
(Tight strand or Roller bed)

Pad steam desizing Pad steam bleaching
- Impregnate at 20°C - Impregnate at 20°C
- Wet pick up ± 70% - Flex Nip impregnation (100%)
- Steam for ± 3 minutes at 100°C - Steam for ± 4 - 9 minutes at 100°C

8 ml/l TANAZYM LTC 01 8 ml/kg TANNEX RENA liquid 01
6 ml/l PLEXENE PREP 2,5 ml/kg TANATERGE ADVANCE
12 – 15 ml/kg NaOH 48°Bé
- Wash off in 1 unit at 95°C using 35 – 40 ml/kg H2O2 35%
2,5 l/kg water.

- Wash off in 6 units at 95°C using
2,0 l/kg water and 1,0 l/kg in unit 7.


Standard waterconsumption 100% Co + Co/EL

• Standard production:
- After 1st PS treatment : 3,5 l/kg (unit 1)
- After 2nd PS treatment : 3,5 l/kg (unit 5)
: 2,5 l/kg (unit 6)
Total waterconsumption : 9,5 l/kg

• Consumption (1st and 2nd PS bleach) : NaOH H2O2
- in 1st PS treatment : 20 15 ml/kg
- in 2nd PS treatment : 25 50 ml/kg
Total consumption 45 65 ml/kg


Tanatex waterconsumption 100% Co + Co/EL

• Production trials:
- After 1st PS treatment : 2,5 l/kg (unit 1)
- After 2nd PS treatment : 2,0 l/kg (unit 5)
: 1,0 l/kg (unit 6)
Total waterconsumption : 5,5 l/kg
Water savings : 4,0 l/kg ~ 40% reduction

• Consumption (1st and 2nd PS bleach) : NaOH H2O2
- in 1st PS treatment : - - ml/kg
- in 2nd PS treatment : 15 40 ml/kg
Total consumption 15 40 ml/kg
Base-chemical savings 60 % ~ 40 %


Cost savings water and energy

• Based on process optimations saving 4,0 l/kg water
(40% reduction), using less NaOH in the total process,
using for all procedures the combination of enzymatic desizing
and pad steam bleaching it proved possible to save, within the total
process (water, chemicals and energy):

~ 100.000 €
Information customer:
- 400.000 m production per week @ 400 g/m : 160.000 kg
- Annual production (@ 42 weeks/year) : 6.720.000 kg
- Standard water consumption : 63.840 m3/year
- Water savings TANATEX system : - 26.889 m3/year


Conclusions

• Whiteness similar (Co and Co/EL) or better (Linos) than the
standards using less peroxide (~10 - 40% reduction).
• Lower damage to the fibre (confirmed in lab. controls)
• Hydrophility and desizing upto the standards.
• Single pretreatment procedure, no changes between bleaching
and boiling off.
• Strong reduction of caustic in bleaching.
• Strong reduction of water in washing off (~40% savings).
• Total cost savings upto 100.000€ for the complete process


Example 2

BioScouring

Environmentally friendly
preparation of cellulosic


BioScouring

• BioScouring

• BioScouring is an enzyme based process in which a
modified PECTINASE is used to remove pectine and
natural waxes from the fibers.

• BioScouring could replace all alkaline boiling
procedures.

• BioScouring is mild process in which the primary cell wall of the
fibre is being prepared for dyeing and/or bleaching.

• No caustic required for the saponification of natural impurities.


BioScouring

Effect of BioScouring

• Less aggressive attack of the fiber.
• Less weight loss by only preparing the pectine part.
• Smooth surface of fiber.
• No residual caustic in the fiber. After alkaline boil off

• No neutralization required.
• Softer handle of the fiber.
• Improved look/aspect of the
fiber.
• Permanent appearance of After BioScouring
the fiber.


Deformation of cellulosic fibers

• BioScouring Alkaline boil off


Proces shortening example
Preparation for dyeing

Standard procedure: Total waterconsumption 11 l/kg

CPB rinse Caustifi rinse
Neutralize
bleach 3 l/kg cation 8 l/kg

BioScouring proces: Total waterconsumption 5 l/kg

Bio rinse
Scouring 5 l/kg

• Watersavings 6 l/kg


Cost savings water and energy

Water:
Water savings : 6 l/kg

Energy:
Water to be heated : 6 l/kg
Energy savings (∆T 50°C) : 0,3498 kWh

Total water saving : 142.000 l/day
= 57.600.000 l/year = 7.600 m3/year

Total energy saving : 11.194 kWh/day
= 3.358.080 kWh/year


LOGIC Dyeing

One-bath isothermal scouring and dyeing of cotton knit goods and their blends,
with reactive dyes

LOGIC DYEING:
• Less water and energy
• One-bath
• Greige dyeing
• Isothermal
• Cellulosics


LOGIC Dyeing

LOGIC DYEING is an innovative concept to process
cotton knit goods and their blends.

A time saving one-bath isothermal scouring & dyeing
procedure enabling higher efficiency, cost reduction
and a careful use of energy.

Because we care …


Benefits obtained with LOGIC Dyeing

Short and simple process
Time saving
Higher production capacity
Less energy consumption
Higher profitability
Less fiber degradation
Higher dyes penetration
Higher shade reproducibility
More ecological


LOGIC Dyeing process with reactive dyes

DYE ALKAFLO
Salt at
the start SALT

20-30 min 60 min portions /
5 5 5 linear dosing progressive dosing
*
20-30 min
TANALEV K-DC 01

PLEXENE CA *
60°C

PERSOFTAL L pH 6-7

LEVEGAL RL where needed


Technical features of TANALEV® K-DC 01

TANALEV® K-DC 01:

One of the main characteristics to be highlighted is that it remains active during the
whole process with its wetting, detergent, emulsifying and dispersing actions.

Its effectiveness is maintained in the whole temperature range even with large
amounts of electrolytes. This differs from conventional nonionic products whose
turbidity level decreases together with their best characteristics.

(1) TANALEV® K-DC 01 (2 & 3) Conventional nonionics

Due to its anionic characteristics it does not affect the dyeing agents during
the dyeing process.
Low foam level compared with other alternative anionic products.
Pronouncing Right-First-Time processing.


LOGIC Dyeing: savings

• Where are the savings in the LOGIC dyeing system?

• We leave out the complete pretreatment
(scouring or alkaline boil-off or pre-bleach)

Shorter !
• This saves mostly 2 baths, with the
accompanying water, energy and
time reduction


But……..

• Can we approach this only technically ????

• The answer is no.

• We have to approach the customer differently.


Important !!

The customer needs to be willing to
consider his total process costs and
not only auxiliaries


TANNEX® NOVECO Green Solutions

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