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The carbonization in the piece Pag. 18
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Purpose of processing
In the carbonization in the piece, the woolly fiber is treated in an acid environment to burn the plant parts
(straws, lappole, cagnole, etc.) still present.
This operation, which is carried out on fabrics in pure wool or with a small percentage of synthetic fibers,
it affects the fibers even if the acid concentration is such as to alter only minimally
the structure of the wool and the resistance of the fabric.
Processing technology
This processing can take place in continuous or discontinuous phases, each work cycle deals with a certain
number of pieces sewn in the head-tail between them and spread wide.
The phases of carbonization are:
A. Acidification
Impregnation of the patches
in the bathroom (see figure A, point
1) composed of sulfuric acid
diluted in water to 30/50 gr
liter (3 ° / 5 ° Be, degrees Baumè) and hydroextraction with squeezing cylinders (fig. A, 2).
B. Pre-drying - Carbonization
The pieces are fed continuously into the machine which consists of two or more chambers (fig. A, 3),
the first, drying, has an increasing temperature from 50 ° to 90 ° C.
the second, called carbonization (fig. A, 4), can reach 100/110 ° C in relation to:
heaviness of the fabric, speed of passage, extent of the vegetable parts to be carbonized.
The carbonization process therefore takes place in two successive moments, in the first of which the piece
it dries up and the sulfuric acid is concentrated; in the second moment, at a higher temperature, the acid acts
on the vegetable parts by carbonizing them.
At the end of the process the fabric is folded (fig. A, 5).
Dry typing
A. Dry typing
This operation, which eliminates most of the carbon residues, can
be carried out:
in a normal dry fuller, with the dry fabric in rope;
with a dry machine, but working the fabric wide
(see figure B), a solution that is adopted in the carbonization
continuously.
A. Neutralization or de-aciding
The piece that came out of the charring and beating still shows all the acidification
administered. The sulfuric acid used is harmful to all
subsequent processing but also for the integrity of the woolly part; an operation is therefore necessary
de-acidification to be carried out immediately after beating.
De-aciding is a continuous process in which the large piece of fabric passes first into one
tub of water, then in a tub with sodium acetate which chemically neutralizes much of the acid,
finally in a tank in which clean water circulates violently.
The fabric then passes through the squeezing cylinders and is then folded onto a still wet
platform and covered with waterproof cloth, ready for subsequent fulling and dyeing operations.
Execution of processing
The carbonizer must:
present the pallets of the pieces to be treated at the entrance to the carbonizing machine.
Check, on the appropriate control devices, the regularity of the main process parameters,
Which:
- concentration of the squeezing rate acidification bath;
- temperature and speed of passage.
Make sure personally, based on your own experience, of the uniform resistance of the fabric
and the uniformity of the color of the wool.
At the end of the process, cover the folded fabric with a waterproof sheet, to avoid
partial drying and uneven responses to subsequent treatments.
Most recurring defects
Incorrect carbonization can cause problems and defects that are difficult to recover especially
for the pieces that will continue in the dyeing process, given that more or less acid is present
result in a different response of the fibers to the dye, thus revealing treatment anomalies.
The carbonizer must always pay the utmost attention in processing, in particular avoiding:
unequal impregnation of the patches in the acid bath;
excessive pause of the acid-etched pieces waiting for the work shift or uneven drying;
heat stroke or prolonged exposure to the sun of the etched patches;
irregular squeezing, which can lead to a defect in the center edge (lack of uniformity between
the central area of the piece and the side areas, near the selvedges).
Labor management
Due to the dangerousness of the process, due to sulfuric acid, the carbonizer must set the maximum
pay attention to your own safety and wash immediately with plenty of running water, if any
burns due to acid or vapors.
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