International Journal of Chemistry and Applications.

ISSN 0974-3111 Volume 12, Number 1 (2020), pp. 1-11

© International Research Publication House
http://www.irphouse.com

Ozone Modified Starch and its Application in Yarn

Sizing and Advantages

Chandramohan Marimuthu*, Priyadharshini Chandrasekar, Jayaganesh

Murugan, Karthik Perumal and Iswarya Marimuthu
*
Microcore Research Laboratories India Pvt Ltd.,
9th km, 30 Feet Road, 204 - A Poondurai Main Road,
Checkmedu, Erode - 638115, Tamil Nadu, India.
www.microcoreresearch.com
* Corresponding Author: info@microcoreresearch.com

ABSTRACT
The main objective of the study describes about the process for the
modification of the Tapioca starch, Maize starch and Potato starch with Ozone
O3 and its application for yarn sizing. Sizing is the process of applying a
protective adhesive coating upon the yarn surface. This is the most important
operation to attain maximum weaving efficiency specially for blended &
filament yarns. An adhesive material for sizing cotton should have the
following characteristics, High degree of polymerization, large number of
−OH groups and ease of removal. Due to the large number of hydroxyl group
in starch, it is considered as best adhesive sizing material in this study. Starch
is usually composed of two components, a straight chain polysaccharide of
glucose and a branched chain polysaccharide of glucose. This study
demonstrates the three types of natural starch such as Native tapioca starch,
maize starch and Potato starch used for the process. Two different process
conditions has been discussed that includes simultaneous treatment of ozone
and alkali process, stepwise addition of Ozone and alkali process compared to
without ozone and alkali treatment. After the treatment process, analysis of
viscosity, abrasion resistance and tensile strength are the most important factor
to be considered in yarn sizing. From the result analysis, Tapioca starch with
stepwise addition of Ozone and alkali has the low viscosity of 182 cps than
maize and potato starch. Tapioca starch has the higher abrasive resistance of
2200 CN/cm2 than maize and potato starch. Tensile strength test resulted that
2 Chandramohan Marimuthu et al.

decreasing weft count, increases fabric assistance as the pick density increases.
Stepwise process of tapioca starch contains higher tensile strength than Maize
and potato starch. Tapioca starch with stepwise addition of Ozone and alkali
of single yarn strength was 8.89 N, when the pick density increases, fabric
assistance of single yarn strength increased to 8.95 N. Among the three types
of modified starch, Tapioca starch has the highly potent sizing material
provides high strength, efficient desizing, improved adhesion and high
abrasion resistance with reduced cost for yarn sizing.
Keywords: Tapioca starch, Maize starch, Potato starch, Yarn Sizing,
Viscosity, Abrasion resistance, Universal strength

1. INTRODUCTION
Sizing is a technological process of wet processing of warp yarns to obtain additional
properties which are necessary for weaving. This is the most important operation to
attain maximum weaving efficiency specially for blended & filament yarns (Maatoug
S et al., 2007). Sizing efficacy does not depend only on the adhesion between the
applied sizing agent and the yarn, but also on the ability to form a film, on rheological
properties of the size, physical-chemical yarn properties, as well as on the
technological parameters in the sizing process (Stegmaier T et al, 2008).
Furthermore, it is necessary to completely remove the sizing agent from the fabric
after the weaving process in an environmentally friendly manner. The sizing process
is nowadays more aimed towards the development and use of natural-based sizing
agents. Sizing agents used nowadays can be divided into the following groups:
starches, carboxymethylcellulose, polyvinyl alcohols, polyacrylates and polyester
resins (Sandhu K S et al, 2008) (Hebeish A et al., 2008). With the advent of
synthetic fibers such as polyester and nylon, the use of high-speed shuttle less
weaving technology, higher performance is required for sizing the fabric. Polyvinyl
alcohol (PVOH) is a preferred ingredient in size compositions because of its excellent
adhesion to synthetic fibers but PVOH has some disadvantages, such as high cost and
the high dry-breaking strength of the warp. The high dry-breaking strength causes
difficulties for the warp to split at the breaker bars of the slasher (Down J, 1999).
Currently, hydroxylated starches are extensively used for textile sizing. Starch is
treated with propylene oxide to produce hydroxylated starch. However, propylene
oxide is classified as carcinogen (Category 2) and can cause cancer. Stringent risk
control measures to reduce exposure to low level (ppm) of propylene oxide are being
evaluated by environmental agencies. In the past, acid and enzyme thinned and
hydroxylated starches have been the preferred ingredients in starch formulations for
cotton warps and weaving on shuttle looms. This is due to the low costs and capability
of these types of starches to enhance yarn sizing. The acid and enzyme thinned starch
have been used with PVOH to reduce sizing cost and the high dry breaking strength
of PVOH-sized warps. The acid-thinned starch is not compatible with PVOH, which
causes a decrease in the adhesion of size to the warp and consequently a decline in the
quality of the sized warp and weaving efficiency (Down J, 1999).
Ozone Modified Starch and its Application in Yarn Sizing and Advantages 3

An adhesive material for sizing cotton should have the following characteristics, High
degree of polymerization, large number of −OH groups and ease of removal. Due to
the large number of hydroxyl group in starch, it is considered as best adhesive sizing
material. Starch properties depend on the relationship between amylose and
amylopectin, but also on other constituents found in a starch granule, such as
phosphates, lipids, phospholipids, etc. The complexity of the sizing process is
reflected in a number of parameters related to the properties of sizing agents, used
yarns and sizing and weaving machines which is always a challenge and is a
significant field of research. However, amylopectin, as the main starch ingredient,
exerts a dominant influence on starch properties (Sandhu K S et al, 2008) (Hebeish
A et al., 2008). Starch is mostly commercially applied in sizing cotton warp yarns,
although with considerable shortcomings: (a) molecule size which limits the
penetration into the yarn, (b) instability of size viscosity due to temperature changes
during cooking until preparation and sizing process, (c) film rigidity (in particular in
the absence of a high-quality lubricant), (d) sensitivity to microorganisms (decay,
degradation) (Kova cevic S and Penava Z, 2004). Modification of natural starches is
done just to eliminate the above mentioned shortcomings and to increase their
usability for industrial applications (Ashdown S P, 2007).
In this present study, to overcome the disadvantages of acid and enzymes thinned
starch, modified tapioca starch maize starch and potato were treated with ozone under
alkaline condition and its use in sizing. The sizing formulation of the present
invention is better than other known size formulations because it has high PVOH
compatibility and possesses other characteristics such as strength and flexibility on
the yarn, adhesion to the yarn, resistance to abrasion, control of penetration into and
encasement of the yarn, and viscosity stability, which is essential for a high-
performance textile sizing agent. Modified starch can be easily de-sized by alfa-
amylase enzymes without involving detergents. In contrast, the modified starch has
advantage over PVA (poly-vinyl alcohol) based sizing agents cannot be de-sized and
discharged directly, since PVA is hazardous to the eco-system. In addition, viscosity
is very important for highly efficient sizing.

2. MATERIALS & METHODS

2.1 Sample collection
Tapioca starch, Maize starch and Potato starch were collected from the local market.
2.2 Modification of Starch using alkali and ozone treatment
This study relates to modified starch, a process for its preparation and its use in yarn
sizing. The new starch derivative of the present method can be used in conjunction
with very less polyvinyl alcohol as a size composition. The sizing formulation of the
present study is better than other known size formulations because it has high PVOH
compatibility and possesses other characteristics such as strength and flexibility on
the yarn, adhesion to the yarn, resistance to abrasion, control of penetration into and
encasement of the yarn, and viscosity stability, which is essential for a high-
4 Chandramohan Marimuthu et al.

performance textile sizing agent. Modified starch can be easily de-sized by alfa-
amylase enzymes without involving detergents. The following are the process for the
modification of Tapioca starch, Maize starch and Potato starch.
2.2.1 Tapioca starch with simultaneous treatment of ozone and alkali
One kg of Tapioca starch was suspended in 1000 ml water to provide a suspension of
50% solids. The flask containing this suspension was equipped with an impeller to
keep the starch in suspension and to avoid agglomeration. The suspension was heated
to 46 °C and maintained at this temperature. The pH was adjusted to 8.0 by using 10%
NaOH or KOH and immediately 2 mL of ozone (OZONETEK) was added and the
mixture was stirred for 24 to 36 hrs under 200 rpm agitation. Further the starch is
separated by filtration and the treated starch is water washed and dried at 600 c for 4 to
6 hrs to obtain nearly 970 g.
2.2.2 Tapioca starch with sstepwise treatment of ozone and alkali
One kg of Tapioca starch was suspended in 1000 ml water to provide a suspension of
50% solids. The flask containing this suspension was equipped with an impeller to
keep the starch in suspension and to avoid agglomeration. The suspension was heated
to 46 °C and maintained at this temperature. The initial pH was measured 7.0 and two
milliliters of ozone (OZONETEK) added and the reaction was allowed to proceed for
4 to 6 hrs for starch thinning and further the pH is adjusted with sodium or potassium
hydroxide to 8 and reacted for 24 to 36 hrs under 200 rpm agitation. Further the
starch is separated by filtration and the treated starch is water washed and dried at 60
deg c for 4 to 6 hrs to obtain nearly 950 g.
2.2.3 Maize starch with simultaneous treatment of ozone and alkali
One kg of Maize starch was suspended in 1000 ml water to provide a suspension of
50% solids. The flask containing this suspension was equipped with an impeller to
keep the starch in suspension and to avoid agglomeration. The suspension was heated
to 46 °C and maintained at this temperature. The pH was adjusted to 8.0 by using 10%
NaOH or KOH and immediately 2 mL of ozone (OZONETEK) was added and the
mixture was stirred for 24 to 36 hrs under 200 rpm agitation. Further the starch is
separated by filtration and the treated starch is water washed and dried at 60 deg c for
4 to 6 hrs to obtain nearly 965 g.
2.2.4 Maize starch with stepwise treatment of ozone and alkali
One kg of Maize starch was suspended in 1000 ml water to provide a suspension of
50% solids. The flask containing this suspension was equipped with an impeller to
keep the starch in suspension and to avoid agglomeration. The suspension was heated
to 46 °C and maintained constant at this temperature. The initial pH was measured 7.0
and two milliliters of ozone (OZONETEK) added and the reaction was allowed to
proceed for 4 to 6 hrs for starch thinning and further the pH is adjusted with sodium
or potassium hydroxide to 8 and reacted for 24 to 36 hrs under 200 rpm agitation.
Further the starch is separated by filtration and the treated starch is water washed and
dried at 60 deg c for 4 to 6 hrs to obtain nearly 905 g.
Ozone Modified Starch and its Application in Yarn Sizing and Advantages 5

2.2.5 Potato starch with simultaneous treatment of ozone and alkali

One kg of Potato starch was suspended in 1000 ml water to provide a suspension of
50% solids. The flask containing this suspension was equipped with an impeller to
keep the starch in suspension and to avoid agglomeration. The suspension was heated
to 46 °C and maintained at this temperature. The pH was adjusted to 8.0 by using 10%
NaOH or KOH and immediately 2 mL of ozone (OZONETEK ) was added and the
mixture was stirred for 24 to 36 hrs under 200 rpm agitation. Further the starch is
separated by filtration and the treated starch is water washed and dried at 60 deg c for
4 to 6 hrs to obtain nearly 950 g.
2.2.6 Potato starch with stepwise treatment of ozone and alkali
One kg of Potato starch was suspended in 1000 ml water to provide a suspension of
50% solids. The flask containing this suspension was equipped with an impeller to
keep the starch in suspension and to avoid agglomeration. The suspension was heated
to 46 °C and maintained constant at this temperature. The initial pH was measured 7.0
and two milliliters of ozone (OZONETEK) added and the reaction was allowed to
proceed for 4 to 6 hrs for starch thinning and further the pH is adjusted with sodium
or potassium hydroxide to 8 and reacted for 24 to 36 hrs under 200 rpm agitation.
Further the starch is separated by filtration and the treated starch is water washed and
dried at 60 deg c for 4 to 6 hrs to obtain nearly 890 g.

2.2 Viscosity (Nattapulwat N et al., 2009)

The flow viscosity of native starch and modified starch from each example in
centipoises, of the 5% starch paste contained in the 300 ml beaker was determined
using a Brookfield Viscometer DV -II+Pro by using Spindle RV4 100 RPM. The
Brookfield is run up and down the scale twice with the second set of readings used.
The yarn sizing process is essential in reducing the molecular weight of starch and
viscosity reduction and consequently improving the efficiency of binding to the
matrix to facilitate weaving. Modified starch derived from examples are prepared with
10 % w/v continuous stirring at temperature 75 °C to allow gelatinization to the
viscosity tabulated in table 1 and coated on the thread of 20’s size and dried.

2.3 Abrasion resistance

The sizing effect is of decisive importance for the weaving properties of a warp yarn.
This effect is closely connected with the abrasion resistance of the sized yarn. The
abrasion resistance of the yarn was measured with the Zweigle abrasion tester (G552
abrasion tester, Zweig Textile GmbH&Co.KG, Germany) (Wei Q et al.,
2009).Twenty; weighted threads (cotton staple yarn English count Ne12) are laid over
the shaft and abraded at the same speed and under the same pressure until they break.
To ensure that fibrous deposits in the abrasive do not affect the abrasive action, the
shaft is advanced after each stroke. The number of abrasive strokes withstands before
breaking is read off from a counter, and the average figure calculated. The higher the
abrasion number obtained, the higher the abrasion resistance of the yarn at working
pressure on test specimen 2.5 cN/cm2 and rotational speed 47.5+/- 2.5 rpm.
6 Chandramohan Marimuthu et al.

2.4 Tensile Strength (Haque M, 2009)

Both the warp and weft yarns were tested to determine the tensile strength. The
instrument used for the test was Titan Universal Strength Tester. The jaws for yarn
testing were set and the maximum air pressure maintained in the compressor was 7
Bar. After opening the titan software in the computer the yarn testing standard was set
to ASTM D2256 (sample length 250 mm and time of extension 20 seconds) and the
other required parameters (pretension, break detection, rate of extension, no. of
specimen) were set. Then the test was started after mounting the yarn sample between
the jaws. Strength is one of the most important parts of parameter of woven fabric.
Strength is directly related to the useful life of a garment/and textile article. Both warp
and weft way strength of the fabric was investigated by using Titan Universal
Strength Tester available in the AUST textile testing lab. The specimen size was
(Length X Width = 14 X 7.62 cm). The test results are shown in the Table 3.

3. RESULTS & DISCUSSION

3.1 Viscosity
The viscosity value is important in size application, as it has a considerable effect on
the amount of liquor pickup. Saving of the drying energy associated with surface
sizing can be made by increasing the solids content of the starch solution in size press.
Therefore, it is highly desirable to develop low viscosity starches for surface sizing.
Viscosity was analyzed for three types of modified starch compared with control
shown in the Table 1. From the result analysis, Tapioca starch with stepwise addition
of ozone and alkali has the low viscosity of 182 cps than maize and potato starch
shown in Graph 1.

Table 1: Brookfield Viscosity of 5% cooked solution at 50 deg C

S.No Details Viscosity (cps)
1 Native Tapioca Starch Control 1500
2 Maize Starch Control 1100
3 Potato Starch Control 2450
4 Modified Tapioca 804
5 Modified Tapioca 182
6 Modified Maize 888
7 Modified Maize 434
8 Modified Potato 765
9 Modified Potato 421
Ozone Modified Starch and its Application in Yarn Sizing and Advantages 7

Graph 1: Brookfield Viscosity of 5% cooked solution at 50 deg C

3.2 Abrasion resistance

Abrasion is wearing a way of any part of material by rubbing against another surface.
Higher the abrasion account value gives the higher abrasion resistance. Abrasion test
was analyzed for three types of modified starch compared with control shown in the
Table 2. From the result analysis, Tapioca starch with stepwise addition of ozone and
alkali has the higher abrasion account value of 2200 CN/cm2 gives the higher abrasion
resistance shown in Graph 2.
Table 2: Abrasion tested (G552 abrasion tester)
Abrasion account
S.No Details of the samples
number 5 CN/cm2
1 Native Tapioca Starch Control 265
2 Maize Starch Control 200
3 Potato Starch Control 175
4 Modified Tapioca 1950
5 Modified Tapioca 2200
6 Modified Maize 2010
7 Modified Maize 1850
8 Modified Potato 1750
9 Modified Potato 1650
8 Chandramohan Marimuthu et al.

Graph 2: Abrasion tested (G552 abrasion tester)

3.4 Tensile strength Test

Both the warp and weft yarns were tested to determine the tensile strength. Single
weft yarn strength was calculated using two different ways. It was observed (Table 3)
that single yarn strength calculated from the fabric strength is always greater than that
of the single yarn strength. This is because the strength of the yarn while in the fabric
is assisted by some other factors like the cohesive forces of the adjacent yarns and the
force due to the interlacement of yarns. This additional yarn strength is regarded as
“fabric assistance”. It can be seen in the Table 3 that the fabric assistance increases as
the pick density increases. Strength was analyzed for three types of modified starch
compared with control shown in the Table 2. From the result analysis, Tapioca starch
with stepwise addition of Ozone and alkali of single yarn strength was 8.89 N, when
the pick density increases, fabric assistance of single yarn strength increased to 8.95
N. According to the finding of Table 3 shows that we can generate a relatively
stronger fabric by increasing threads/inch. The strength of very lighter fabrics can also
be increased by increasing the threads/inch.
Ozone Modified Starch and its Application in Yarn Sizing and Advantages 9

Table 3: Effect of Fabric assistance on individual weft yarn Strength

[Force required to break the specimen (N)]
S.No Weft count (Ne) Single yarn No. Pick wheel No. Pick wheel No. Pick wheel
Strength (N) teeth = 42 teeth = 52 teeth = 66
Control Tapioca
1 28.5 2.7625 2.4565 2.635 2.6435
2 20 2.38 2.754 2.8305 2.9155
3 10 7.5565 7.548 7.5735 7.6075
Control Maize
4 28.5 2.925 2.601 2.79 2.799
5 20 2.52 2.916 2.997 3.087
6 10 8.001 7.992 8.019 8.055
Control Potato
7 28.5 2.275 2.023 2.17 2.177
8 20 1.96 2.268 2.331 2.401
9 10 5.9563 5.9496 5.9697 5.9965
Modified Tapioca
10 28.5 3.25 2.89 3.1 3.11
11 20 2.8 3.24 3.33 3.43
12 10 8.765 8.755 8.785 8.825
Modified Tapioca
13 28.5 3 2.64 2.85 2.86
14 20 3.05 3.49 3.58 3.68
15 10 8.89 8.88 8.91 8.95
Modified Maize
16 28.5 3.025 2.701 2.89 2.899
17 20 2.64 3.036 3.117 3.207
18 10 8.151 8.142 8.169 8.205
Modified Maize
19 28.5 2.77 2.52 2.78 2.88
20 20 2.5 3.04 3.13 3.07
21 10 7.7 8.4 8.69 8.79
Modified Potato
22 28.5 2.4 2.148 2.295 2.302
23 20 2.081 2.389 2.452 2.522
24 10 6.0773 6.0706 6.0907 6.1175
Modified Potato
25 28.5 2.2 1.948 2.095 2.102
26 20 1.981 2.289 2.352 2.422
27 10 5.6273 5.6206 5.6407 5.6675
10 Chandramohan Marimuthu et al.

4. ADVANTAGES OF MODIFIED TAPIOCA STARCH IN YARN SIZING

1. Eco-friendly starch modification process and product.
2. Provides higher affinity to yarn.
3. Increased performance of yarn sizing than propylene oxide which is a
carcinogen.
4. Reduced use of PVOH additives in sizing compositions.
5. Reduces sizing cost

CONCLUSION
Modification of tapioca, maize and potato starch was processed using ozone and
alkali. After the treatment process, analysis of viscosity, abrasion resistance and
tensile strength are the most important factor to be considered in yarn sizing. From the
result analysis, Tapioca starch with stepwise addition of Ozone and alkali has the low
viscosity of 182 cps than maize and potato starch. Tapioca starch with stepwise
addition of Ozone and alkali has the higher abrasive resistance of 2200 CN/cm2 than
maize and potato starch. Tensile strength test resulted that decreasing weft count,
increases fabric assistance as the pick density increases. Among the three types of
modified starch, Tapioca starch with stepwise addition of Ozone and alkali treatment
is higher tensile strength than Maize and potato starch. Tapioca starch with stepwise
addition of Ozone and alkali of single yarn strength was 8.89 N, when the pick
density increases, fabric assistance of single yarn strength increased to 8.95 N. It was
to conclude that among the three types of modified starch, Tapioca starch is the highly
potent sizing material used for yarn sizing with reduced sizing cost. This is an eco-
friendly process and do not emits environmentally toxic residues. The modified starch
provides high strength, efficient desizing, improved adhesion and high abrasion
resistance to yarn sizing using a high powered weaving loom. All of these contribute
for better sizing and high fabric quality.

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