Optimization of energy usage in the hydroentanglement process

Abstract

The hydroentanglement process is highly energy intensive compared to other methods of manufacturing nonwoven fabrics. This paper presents an exploratory study on optimizing the usage of hydroentanglement energy so as to lower the processing cost. The experiments were based on a Box-Behnken experimental design (BBD) and multivariate linear regression analysis to model the tensile strength as response to variables. Three variables were selected, namely fabric area weight (150-400 g/m 2 ), machine speed (5-15 m/min) and waterjet pressure (40-200 bars). These parameters were employed in two sets of experiments to achieve maximum tensile strength of viscose nonwoven fabrics. The first experiment was conducted using higher waterjet pressures of 100, 150 and 200 bars, which were proved to have exceeded the optimum levels. The second experiment was conducted at relatively lower waterjet pressures of 40, 60 and 80 bars. The results on tensile strength were analyzed using the SYSTAT 10 software package and response surface plots were prepared. The linear, quadratic and interactive effects of the main variables were shown to be significant. Interactions amongst the variables were found to have either a synergistic (positive) or offsetting (negative) relationship with the fabric tensile strength. The interactions involving machine speed were predominantly offsetting. The 400 g/m 2 area weight fabric produced at 80 bars of waterjet pressure achieved a fabric tensile strength of 222 cN, which compared favorably with that of 232 cN obtained at 200 bars of waterjet pressure. In this exploratory study using BBD, linear, quadratic and interactive effects were observed to be significant and the usage of hydroentanglement energy was successfully optimized. This indicates the possibility of achieving high fabric strength but at lower waterjet pressures; in other words, by employing low hydroentanglement energy and thereby minimizing the processing cost.

Micromechanics of hydroentangled nonwoven fabrics

“…The machine bonded the top and bottom sides of the cross-lapped batt successively in a single pass. 23 Nonwoven fabrics produced from two different fiber types, cotton (C) and viscose (V), were hydroentangled at different WJPs of 80 bar (P 1 ), 100 bar (P 2 ) and 120 bar (P 3 ).…”

“…This can be attributed to use of optimum WJP of 80 and 100 bar to form the two nonwoven fabrics as their areal weights are similar. Moyo et al 23 showed that for hydroentangled nonwoven fabrics, there is an optimum processing WJP beyond which the structural integrity of the fibers is adversely affected.…”

A S tudy of the Factors Affecting the Bursting Strength of Bicomponent Hydroentangled Non - woven Fabrics

“…Generally higher jet energy produces fabrics with higher tensile strength, while reducing the fabric basis weight will affect the fabrics tensile property. Moyo et al [12] has undertaken a study for the optimization of the usage of energy during the hydroentanglement process. It should be important to note that there is a limit to the amount of energy used, since at some level, increase in higher energy may adversely affect the mechanical property of the fabric.…”