Progress 07/28/10 to 05/18/15
Outputs
Progress Report Objectives (from AD-416): Objective 1: Enhance and promote cotton�s natural sustainability features in the context of disposable nonwovens applications. Objective 2: Characterize and correlate the relationships among the cotton fiber quality parameters, the nonwovens process-ability, and the final fabric performance characteristics. Objective 3: Develop and optimize hydro-entanglement chemistry and process parameters for cotton fiber and the nonwoven fabrics thus produced. Objective 4: Develop innovative end-use functional technologies that enable increases in the amount and value of cotton used in nonwoven applications. Objective 5: Develop processes for producing nonwoven fabrics from greige cotton. Approach (from AD-416): The ultimate goal of this research project is to increase value-added utilization of cotton via development of performance-specific nonwoven products containing cotton. The term "cotton" used here includes cotton lint, ginning motes and linters, comber noils, processing wastes, recycled cotton, and the like. The research approaches broadly involve 1) characterization of fibers and fiber blends to be used; 2) selection of optimum processes and conditions for fiber opening, cleaning, and web formation; 3) selection of appropriate nonwovens production system; 4) evaluation of process and product performances; 5) physical, mechanical and/or chemical modifications of nonwoven products to attain and/or enhance the required functionality; 6) within the scope of the project, determine biodegradability, cost-effectiveness, environmental impact and sustainability of the products produced; and 7) disseminate the research results via publications, technical forums, and technology transfer to industry. Specifically, the research involves developing fiber-processing technology to obtain supply of clean greige/virgin (scour/bleach-less) cotton that is appropriate for the intended end-use application. Most of the existing manufacturers of nonwoven rollgoods do not have the resources, facilities and/or technical expertise to open and clean supply bales of greige cotton(s). It is imperative to develop a protocol that would enable the nonwovens manufacturers to either both open and clean cotton in their in-house facilities or obtain some readily available pre- cleaned cotton. Depending on individual products, we will determine efficient routes for processing cotton into a clean web for downstream processes. SRRC has the equipment, including cotton carding, to thoroughly open and clean virgin cotton and also the resources to procure and process pre-cleaned supply cottons (say, UltrcleanTM cotton). The preferred research focus is on using greige cotton, instead of bleached cotton that currently is primarily used in premium quality nonwovens. However, nonwoven fabrics made with cleaned greige cotton may be satisfactorily scoured and bleached, if necessary. To determine which cotton would be most cost effective for certain specific end-use applications, certain experimental investigations and small-scale industry-like production trials have been planned. They involve studies of the fiber, process and product metrics and their relationships. Research efforts will be redirected to improve any marginal outcomes. In general, carding process will be deployed to form a web for the downstream needle-punching and/or hydroentangling systems of producing nonwoven products. Optimizations of the N-P and H-E processes and products will be sought through planned investigations. Comprehensive testing of in-process products and end-products will be conducted to realistically evaluate the research outcomes. Statistical tools will be used for reliability of the results. Issues concerning the biodegradability, disposability, environmental impact, safety, government/ industry-compliance,and cost-analysis will only be conducted to the extent feasible within the scope of the project. This is the final report for project 6054-41000-104-00D which terminated in May 2015. To ultimately promote the volume and value-added utilization of cotton in nonwovens, Agricultural Research Service scientists implemented a research plan of blending cotton with some selected fibers to address industrial concerns that so far have severely limited the use of cotton in modern nonwovens. Toward achieving this objective, progressive and cumulative fabric effects of multiple hydro- entangling (H-E) impacts at different water pressure on a greige cotton substrate were examined. The research indicated that classical properties of greige cotton-based nonwoven fabrics are greatly influenced by the H-E water pressure and the number of H-E impacts. Generally, the higher the values of these critical H-E process metrics, the better are the fabric characteristics. In short, the H-E energy supplied, or essentially consumed by a fabric, greatly affects the fabric properties such as tensile and tear strengths and absorbency. Thus, depending on the desired fabric characteristics, the H-E water pressure and the number of H-E impacts can be widely varied to attain optimum results in the energy consumption. Agricultural Research Service scientists conducted research on the effect of cotton micronaire on oil sorption in nonwoven sorbents. The off-shore oil drilling has had several disastrous oil spills, worldwide. Although there are quite a few techniques and technologies now available to clean up the spills, the search for a more effective, economical and efficient clean-up method has been ramped up in recent years. A collaborative research effort by scientists at Texas Tech University and the USDA is focusing on the development of novel industrial applications for low micronaire greige (raw) cotton. It was discovered that low micronaire cotton, especially in a fibrous bundle form, is potentially effective oil sorbent when compared to a high micronaire cotton for cleaning-up the off-shore oil spills. This effect is related to both the hydrophobic nature of raw cotton and the increased surface area of low micronaire in bundle form compared to equal amounts of high micronaire cotton. Agricultural Research Service scientists conducted research that studied the correlations of cotton fiber quality parameters with nonwoven fabrics performance. The four typical cotton fiber characteristics (length, length uniformity, micronaire, and tensile strength fiber) whose values were within commonly observed ranges of American Upland cottons do not appreciably affect the processing nor performance of the nonwoven fabrics produced. Since the fiber properties studied greatly influence traditional cotton spinning and fabric formation, it may be concluded that a quite wide variety of cottons including co-product streams are suitable for use in nonwoven fabrics. Agricultural Research Service scientists studied the effects of jet strip�s orifice size and H-E water pressure on properties of cotton nonwovens. The research has shown that the H-E jet strip�s orifice size considerably influences the H-E water pressure, both of which ultimately affect properties of a greige cotton-based nonwoven fabric. The energy consumption of a fabric, which partly varies with the orifice size and water pressure and which was determined and indicated that the nozzle�s orifice size and the water pressure can be considerably varied to provide the optimum energy level to efficiently achieve the desired fabric strength and/or absorbency, depending on the end-use of the fabric. Agricultural Research Service scientists conducted research that studied the fundamental and comprehensive adsorption kinetics and isotherms data for designing an optimally desirable cotton-blended adsorption system. H- E raw cotton/polyester blends were found to have a distinctive adsorption property for alkyl-dimethyl-benzyl-ammonium chloride (ADBAC), a cationic surfactant commonly employed as an antimicrobial agent in disinfecting wipes and cleaning solutions. A nonlinear adsorption of ADBAC was observed and linked with high adsorption rates of ADBAC on H-E raw cotton that was associated with its unique surface characteristics including retained pectin, partial removal of waxes, and surface fibrillation. Agricultural Research Service scientists are screening diverse cotton lines for unique properties that can be applied to specific, specialty use nonwoven products. Cotton lines were selected based on previous research by USDA scientists by which inbred cotton lines were developed by randomly mating eleven cotton lines with genetically diverse backgrounds. The inbred lines exhibited a broader range of fiber quality characteristic (e.g. yield, strength, length and fineness) than the parent lines presumably due to additive genetic effects. The eleven parent lines are currently being grown for harvest and fibers will be processed into nonwoven fabrics. Some nonwoven properties of interest that will be screened are absorbency, hydrogen peroxide generation for wound healing applications, nanoparticle uptake and durability, and flame retardancy. Preliminary flame retardancy screening revealed a greater than 20% difference among the parents that is more than sufficient to map the genes responsible for the trait. Since the inbred lines developed from the eleven parent lines exhibit a wider range of fiber quality characteristics, they will be subsequently examined for presence of quality trait genes and even greater specific nonwoven fabric performance parameters. Agricultural Research Service scientists conducted infrared (FT-IR) spectral imaging of developing cotton fibers that were correlated with fiber quality parameters. Studies were performed with an infrared microscope equipped with a detector with high spatial resolution. Representative cotton samples were harvested during fiber development from different cultivars in order to access changes in the cell wall structures of the fibers. The experimental setup allowed for the examination of thousands of sample points simultaneously. The preliminary results suggest that FT-IR microscopy can be utilized as a tool to estimate important cotton fiber properties. Accomplishments 01 Transfer of technology and release of a commercial diaper product. Internal and collaborative research efforts between stakeholders and research scientists at the USDA culminated in the release of a commercial diaper product that utilizes a 100% raw cotton topsheet. Research efforts that contributed to this transfer of technology included determination of nonwoven cotton fabric fluid handling characteristics and assessment of microbial burden on raw and processed cotton fiber and fabrics. 02 A novel method to synthesize silver (Ag) nanoparticle that uses the unique structure of the cotton fiber enabled the development of novel and green methods to synthesize silver nanoparticles on and within cotton fibers for antimicrobial cotton. It is likely that the treatment is permanent and wash durable. This nanofluidic reaction using the cotton substructure, the methodology of which was exploited for the first time, expands the utilization of cotton to high- technology areas. This stable, non-leaching Ag-cotton nanocomposite will find many uses in technical applications that require continuous, long-lasting antimicrobial activity. 03 Successful efficacy testing of optimized quaternary ammonium compound solutions with cotton wipes. Optimized disinfecting solution chemistries were designed by statistical modeling. Results indicated that co-formulation non-ionic surfactants and added electrolytes had the greatest effect on reducing the depletion of quaternary ammonium compounds onto cotton fabrics. A selected optimized formulation with a 100% raw cotton wipe was subjected to Good Laboratory Practice (GLP) efficacy testing at the level of EPA registration. The wipe successfully passed using the microorganisms Staphylococcus aureus and Pseudomonas aeruginosa, which are the representative microorganisms for registration of hospital-grade disinfectants. Currently, chemical characterization testing, stability testing, and further GLP efficacy testing are being conducted that includes the clinically important microorganisms methicillin-resistant Staphylococcus aureus (MRSA) and vancomycin-resistant enterococci (VRE). Successful testing results in all these categories would be a major milestone for the use of cotton with quat-based disinfecting solutions and will be aggressively promoted and marketed by our CRADA partners at Cotton Incorporated. 04 Mechanical scouring of cotton fibers by hydroentanglement reduces the need for chemical scouring. Demonstrated that cotton nonwoven fabrics produced via hydroentanglement at two different levels of bonding pressure exhibit dye-ability whether they are scoured and bleached or bleached only. Reduction of the scouring process and the associated costly chemicals and time involved in the process are expected to offer a significant benefit to the development of cotton-based nonwoven products requiring bleaching and/or dyeing. Scoured and bleached cotton staple fibers are typically twice the cost of greige cotton staple fibers so adoption of this process to produce absorbent and dyeable H-E nonwoven cotton fabrics without the need for further chemical processing represent significant cost savings for industrial stakeholders that adopt this technology. 05 Raw cotton has better thermal and combustion resistance than scoured cotton. Raw cotton exhibited slower thermal decomposition at low temperatures, higher char yield, decreased heat release capacity, and decreased total heat release as compared with scoured cotton. This enhanced thermal stability of unscoured cotton was linked to naturally occurring inorganic components of raw cotton. This is a significant fundamental finding with broad potential applications requiring heat and fire resistant characteristics. 06 Biodegradation of nonwoven cotton fabrics compared to synthetic nonwoven fabrics. Measured soil burial biodegradation half-life times of hydroentangled raw cotton in aerobic Captina silt loam soil to encourage consumers and manufacturers to choose disposable cotton nonwoven products and materials that support a clean environment. The biodegradation rate of hydroentangled raw cotton exhibited a half-life time of only 12.6 days whereas nonwoven fabrics made of polypropylene and polylactic acid (current industry standards) showed no weight loss or degradation. Since most nonwoven disposable products� environmental fate is a landfill, these research findings support the use of cotton in nonwovens as a sustainable and environmentally friendly new alternative. 07 Physical and flammability characteristics of nonwoven fabrics produced from brown and white fiber cottons. Combustion properties were determined as a function of processing brown cotton and conventional white cotton fibers into nonwovens fabrics. Nonwovens production parameters included needlepunching (NP), hydroentanglement (H-E), and post-processing chemical treatments such as scouring and bleaching. The results suggest a multi-faceted and synergistic combination of physical and compositional properties that give increased flame retardancy (FR) to brown cotton fibers that include higher levels of elements known to impart FR properties; higher water content at moisture equilibrium; and unknown factors potentially related to coloration. Nonwoven NP fabrics produced from brown fibers in the natural, greige state also passed standardized testing requirements for use in fire sensitive components in automotive interiors and aircraft interiors without the addition of chemical FR additives. 08 Phytohormonal regulation of cotton fiber initiation. Genes and developmental processes were identified that provide an insight on molecular mechanisms controlling when and how cotton fiber initiation occurs on cotton ovules. How and when fiber initiation occurs on cotton ovules is an important question for biologists, cotton producers, and textile industry since the density and numbers of fibers on the surface of cotton ovules directly affect cotton yield and fiber quality. The ability to manipulate the expression of genes regulating fiber initiation process may lead to strategies for improving cotton yield and fiber quality.
Impacts
(N/A)
Publications
- Hinchliffe, D.J., Condon, B.D., Delhom, C.D., Chang, S., Montalvo Jr, J.G., Madison, C.A., Reynolds, M.L., Von Hoven, T.M., Santiago Cintron, M. 2015. Physical and combustion properties of nonwoven fabrics produced from conventional and naturally colored cottons. Textile Research Journal. 85(16):1666-1680.
- Sawhney, A.P., Reynolds, M.L., Allen Jr, H.C., Slopek, R.P., Condon, B.D. 2015. Progressive and cmuulative fabric effects of multiple hydroentangling impacts at different water pressures on greige cotton. Textile Research Journal. 1-10. DOI: 10.1177/0040517515580517.
- Nam, S., Slopek, R.P., Wolf, D., Warnock, M., Condon, B.D., Sawhney, A.P., Gbur, E., Reynolds, M.L., Allen Jr, H.C. 2015. Comparison of biodegradation of low-weight hydroentangled raw cotton nonwoven fabric and that of commonly used disposable nonwoven fabrics in the aerobic Captina silt loam soil. Textile Research Journal. 1-12. DOI: 10.1177/ 0040517514551468.
- Kim, H.J., Hinchliffe, D.J., Triplett, B.A., Yeater, K.M., Moon, H.S., Gilbert, M.K., Thyssen, G.N., Turley, R.B., Fang, D.D. 2015. Phytohormonal networks promote differentiation of fiber initials on pre-anthesis cotton ovules grown in vitro and in planta. PLoS One. 10(4):e0125046.
- Edwards, J.V., Ningtao, M., Stephen, R., Edmund, C., Condon, B.D., Hinchliffe, D.J., Gary, L., Graves, E.E., Bopp, A., Wang, Y. 2015. Fluid handling and fabric handle profiles of hydroentangled greige cotton and spunbond polypropylene nonwoven topsheets. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 1-13. DOI: 10.1177/1464420715586020.
- Rodgers III, J.E., Naylor, G., Cui, X., Delhom, C.D., Hinchliffe, D.J. 2015. Cottonscope fiber maturity fineness, and ribbon width measurements with different sample sizes. Textile Research Journal. 85(9):897-911.
- Nam, S., Slopek, R.P., Condon, B.D., Sawhney, A.P. 2015. Effect of polyester blends in hydroentangled raw and bleached cotton nonwoven fabrics on the adsorption of alkyl-dimethyl-benzyl-ammonium chloride. Textile Research Journal. 85(12):1221-1233.
- Dong, H., Carr, W., Cook, F.L., Nam, S. 2014. Development of rapid continuous dyeing process for heavy-weight nylon 6,6 carpet. Journal of Engineered Fibers and Fabrics. 9(2):93-98.
- Nam, S., Condon, B.D. 2014. Internally dispersed synthesis of uniform silver nanoparticles via in situ reduction of [Ag(NH3)2]+ along natural microfibrillar substructures of cotton fiber. Cellulose. 21:2963-2972.
- Sawhney, A.P., Condon, B.D., Allen Jr, H.C., Reynolds, M.L., Slopek, R.P. 2014. Bleaching of hydroentangled greige cotton nonwoven fabrics without scouring. Textile Research Journal. 84(18):1931-1938.
- Santiago Cintron, M., Hinchliffe, D.J. 2015. FT-IR examination of the development of secondary cell wall in cotton fibers. FIBERS. 3:30-40.
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Progress 10/01/13 to 09/30/14
Outputs
Progress Report Objectives (from AD-416): Objective 1: Enhance and promote cotton�s natural sustainability features in the context of disposable nonwovens applications. Objective 2: Characterize and correlate the relationships among the cotton fiber quality parameters, the nonwovens process-ability, and the final fabric performance characteristics. Objective 3: Develop and optimize hydro-entanglement chemistry and process parameters for cotton fiber and the nonwoven fabrics thus produced. Objective 4: Develop innovative end-use functional technologies that enable increases in the amount and value of cotton used in nonwoven applications. Objective 5: Develop processes for producing nonwoven fabrics from greige cotton. Approach (from AD-416): The ultimate goal of this research project is to increase value-added utilization of cotton via development of performance-specific nonwoven products containing cotton. The term "cotton" used here includes cotton lint, ginning motes and linters, comber noils, processing wastes, recycled cotton, and the like. The research approaches broadly involve 1) characterization of fibers and fiber blends to be used; 2) selection of optimum processes and conditions for fiber opening, cleaning, and web formation; 3) selection of appropriate nonwovens production system; 4) evaluation of process and product performances; 5) physical, mechanical and/or chemical modifications of nonwoven products to attain and/or enhance the required functionality; 6) within the scope of the project, determine biodegradability, cost-effectiveness, environmental impact and sustainability of the products produced; and 7) disseminate the research results via publications, technical forums, and technology transfer to industry. Specifically, the research involves developing fiber-processing technology to obtain supply of clean greige/virgin (scour/bleach-less) cotton that is appropriate for the intended end-use application. Most of the existing manufacturers of nonwoven rollgoods do not have the resources, facilities and/or technical expertise to open and clean supply bales of greige cotton(s). It is imperative to develop a protocol that would enable the nonwovens manufacturers to either both open and clean cotton in their in-house facilities or obtain some readily available pre- cleaned cotton. Depending on individual products, we will determine efficient routes for processing cotton into a clean web for downstream processes. SRRC has the equipment, including cotton carding, to thoroughly open and clean virgin cotton and also the resources to procure and process pre-cleaned supply cottons (say, UltrcleanTM cotton). The preferred research focus is on using greige cotton, instead of bleached cotton that currently is primarily used in premium quality nonwovens. However, nonwoven fabrics made with cleaned greige cotton may be satisfactorily scoured and bleached, if necessary. To determine which cotton would be most cost effective for certain specific end-use applications, certain experimental investigations and small-scale industry-like production trials have been planned. They involve studies of the fiber, process and product metrics and their relationships. Research efforts will be redirected to improve any marginal outcomes. In general, carding process will be deployed to form a web for the downstream needle-punching and/or hydroentangling systems of producing nonwoven products. Optimizations of the N-P and H-E processes and products will be sought through planned investigations. Comprehensive testing of in-process products and end-products will be conducted to realistically evaluate the research outcomes. Statistical tools will be used for reliability of the results. Issues concerning the biodegradability, disposability, environmental impact, safety, government/ industry-compliance,and cost-analysis will only be conducted to the extent feasible within the scope of the project. The majority of the research was conducted on a pilot-scale needlepunching machine and hydroentanglement system for producing cotton- based nonwoven fabric structures to determine the effects of, and/or any relationships between, the process parameters and the properties of the resulting fabric structures. This research is directly related to NP 306 Problem Statement 2.B � Enable technologies for (1) expanding market applications of existing biobased products, and (2) producing new marketable non-food biobased products derived from agricultural products and byproducts, and estimate the potential economic value of the new products. This objective was substantially met since we were able to select cottons of different fineness/micronaire values. These cottons of varying micronaire were processed through a normal mill-like protocol and the process and products were also evaluated using standard industrial procedures and practices. The research indicated that the cotton micronaire, which is extremely critical in the process performance and product quality in traditional textile manufacturing, was not as critical in nonwoven sector of cotton textile manufacturing. This is mainly due to the fact that the number of fibers in the yarn construction or structure in a woven fabric greatly influences the yarn strength and, consequently, the fabric strength. In the absence of any yarns in a nonwoven fabric, the fabric strength mainly depends on the fiber slippage rather than the fiber breakage which generally occurs in a woven fabric. Nonwoven disposable wipes composed entirely of cotton, both greige and scoured/bleached, and also blended with polyester, were used to examine the depletion of quaternary ammonium compounds (quats) from disinfecting solutions. The preferential depletion of quats onto cotton fabrics removes the quats from solution and reduces the efficiency of the disinfectant. For this reason, cotton and other cellulosic compounds such as rayon are considered incompatible with quat disinfecting solutions. The use of specific chemicals and compounds that interfere with the quats ability to interact with the cotton surface were demonstrated to reduce or eliminate this depletion effect. Using statistical modeling called response surface methodology, the quat formulations were optimized and efficacy testing was conducted by standardized protocols using representative microorganisms for the registration of hospital-grade disinfectants. Cotton wipes with optimized quat formulations passed preliminary efficacy tests. The next phase of testing is currently underway and involves long-term of the cotton-containing and polyester wipes in optimized quat solutions to monitor the effects of prolonged exposure on quat depletion and efficacy. Accomplishments 01 Optimum processing parameters for producing mid-weight cotton-based nonwoven fabrics. Since no prior article or publication on the subject matter existed, it was imperative for the Agricultural Research Service of the U.S. Department of Agriculture to explore the feasibility of and the optimum process parameters for efficiently producing cotton-based nonwoven fabrics. The research conducted by the ARS scientists in the Cotton Chemistry and Utilization Research Unit at the Southern Regional Research Center in New Orleans, Louisiana, demonstrated that greige cotton lint can be efficiently processed on a commercial-grade hydroentanglement system to produce nonwoven fabrics of acceptable properties, such as the strength, durability, multiple household laundries, and liquid absorbency. The hydroentangling water pressure, in a range of 90-120 bars, and the number of hydro impacts (from 2 to 8) have been found to be adequate for producing a specific nonwoven fabric on the system investigated. However, the non-uniformity, stiff hand, and harsh feel of the developmental fabrics remain serious challenges that require significantly more research involving superb ingenuity and textile research and manufacturing expertise of the researchers involved. The demonstrated feasibility in using greige cotton fibers in nonwoven processing greatly promotes the use of cotton in the nonwovens market as an environmentally friendly and sustainable staple fiber. 02 The hydroentangling water pressure significantly removes cotton fiber waxes without the conventional chemical scouring process. ARS scientists in the Cotton Chemistry and Utilization Research Unit at the Southern Regional Research Center in New Orleans, Louisiana, demonstrated this process transforms the water repelling character of cotton fibers into a hydrophilic (water absorbent) character of the resulting nonwoven fabric. Since the fabric production speed involved in the research was only 5 meters per minute, it is likely that the production line speed, the number and profiles of hydroentangling jet heads available, the cotton fiber quality, and the feed material density, among others, will also play significant roles, beside the water pressure, in establishing the optimum process metrics for efficiently producing a cotton-based nonwoven fabric for a specific product and endues application. Hydroentangled cotton-based nonwoven fabrics may also be dyed without traditional scouring and bleaching. Chemical scouring and bleaching of greige cotton fabrics are generally required in finishing the fabrics for many end-use products and applications. Preliminary results indicate that some hydroentangled greige cotton nonwoven fabrics may be dyed and/or specially finished without the traditional scouring and bleaching for certain end-use products, such as table mats, industrial wipes, and towelettes. Developing and optimizing the process of scouring greige cotton during nonwoven fabric production can bypass the need for chemical scouring, which represents saving in both time and resources for nonwovens fabric manufacturers that want to utilize cotton fibers in their products. 03 Cotton-containing nonwoven disposable wipes can be made compatible with quaternary ammonium compound (quat) disinfectants through optimized chemical formulations. Cellulosic material such as cotton, rayon, and wood pulp adsorb quats onto their surface through chemical interactions to such a degree that the quats do not deplete onto target surfaces for disinfection. ARS scientists in the Cotton Chemistry and Utilization Research Unit at the Southern Regional Research Center in New Orleans, Louisiana, utilizes statistical modeling and co-formulation of quats with other specific chemicals and successfully reduced or eliminated the quat adsorption onto cellulosic substrates. Preliminary efficacy testing conducted by standardized protocols indicated that optimized co- formulations were successful in allowing the quats to deplete and successfully disinfect hard surfaces coated with representative microorganisms. This research was showcased in the Nonwovens Industry international trade publication January 2014 issue and could increase cotton fibers� role and market share in surface care applications.
Impacts
(N/A)
Publications
- Nam, S., Condon, B.D., Foston, M.B., Chang, S. 2014. Enhanced thermal and combustion resistance of cotton linked to natural inorganic salt components. Cellulose. 21(1):791-802.
- Hinchliffe, D.J., De Lucca, A., Condon, B.D., O'Regan, J., Clemmons, J., Zeng, L., Byler, R.K., Reynolds, M.L., Allen Jr, H.C., Santiago Cintron, M. , Madison, C.A. 2014. A pilot-scale nonwoven roll goods manufacturing process reduces microbial burden to pharmacopeia acceptance levels for nonsterile hygiene applications. Textile Research Journal. 84(5):546-558.
- Naoumkina, M.A., Thyssen, G.N., Fang, D.D., Hinchliffe, D.J., Florane, C.B. , Yeater, K.M., Page, J.J., Udall, J.A. 2014. The Li2 mutation results in reduced subgenome expression bias in elongating fibers of allotetraploid cotton (Gossypium hirsutum L.). PLoS One. 9(3):e90830.
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Progress 10/01/12 to 09/30/13
Outputs
Progress Report Objectives (from AD-416): Objective 1: Enhance and promote cotton�s natural sustainability features in the context of disposable nonwovens applications. Objective 2: Characterize and correlate the relationships among the cotton fiber quality parameters, the nonwovens process-ability, and the final fabric performance characteristics. Objective 3: Develop and optimize hydro-entanglement chemistry and process parameters for cotton fiber and the nonwoven fabrics thus produced. Objective 4: Develop innovative end-use functional technologies that enable increases in the amount and value of cotton used in nonwoven applications. Objective 5: Develop processes for producing nonwoven fabrics from greige cotton. Approach (from AD-416): The ultimate goal of this research project is to increase value-added utilization of cotton via development of performance-specific nonwoven products containing cotton. The term "cotton" used here includes cotton lint, ginning motes and linters, comber noils, processing wastes, recycled cotton, and the like. The research approaches broadly involve 1) characterization of fibers and fiber blends to be used; 2) selection of optimum processes and conditions for fiber opening, cleaning, and web formation; 3) selection of appropriate nonwovens production system; 4) evaluation of process and product performances; 5) physical, mechanical and/or chemical modifications of nonwoven products to attain and/or enhance the required functionality; 6) within the scope of the project, determine biodegradability, cost-effectiveness, environmental impact and sustainability of the products produced; and 7) disseminate the research results via publications, technical forums, and technology transfer to industry. Specifically, the research involves developing fiber-processing technology to obtain supply of clean greige/virgin (scour/bleach-less) cotton that is appropriate for the intended end-use application. Most of the existing manufacturers of nonwoven rollgoods do not have the resources, facilities and/or technical expertise to open and clean supply bales of greige cotton(s). It is imperative to develop a protocol that would enable the nonwovens manufacturers to either both open and clean cotton in their in-house facilities or obtain some readily available pre- cleaned cotton. Depending on individual products, we will determine efficient routes for processing cotton into a clean web for downstream processes. SRRC has the equipment, including cotton carding, to thoroughly open and clean virgin cotton and also the resources to procure and process pre-cleaned supply cottons (say, UltrcleanTM cotton). The preferred research focus is on using greige cotton, instead of bleached cotton that currently is primarily used in premium quality nonwovens. However, nonwoven fabrics made with cleaned greige cotton may be satisfactorily scoured and bleached, if necessary. To determine which cotton would be most cost effective for certain specific end-use applications, certain experimental investigations and small-scale industry-like production trials have been planned. They involve studies of the fiber, process and product metrics and their relationships. Research efforts will be redirected to improve any marginal outcomes. In general, carding process will be deployed to form a web for the downstream needle-punching and/or hydroentangling systems of producing nonwoven products. Optimizations of the N-P and H-E processes and products will be sought through planned investigations. Comprehensive testing of in-process products and end-products will be conducted to realistically evaluate the research outcomes. Statistical tools will be used for reliability of the results. Issues concerning the biodegradability, disposability, environmental impact, safety, government/ industry-compliance,and cost-analysis will only be conducted to the extent feasible within the scope of the project. This report highlights the third year research accomplishments made by Agricultural Research Service (ARS) scientists at the Southern Regional Research Center (SRRC) in New Orleans, Louisiana, on the development, chemical treatment, and modification of cotton-based nonwoven products. Although the installation of the fiber processing equipment is an ongoing process, numerous trials have been conducted on the existing equipment to optimize the machinery and process parameters for the production of cotton-based nonwovens. These studies have revealed that pre-cleaned raw/ greige (non-bleached) cotton can successfully be used to produce nonwoven substrates for commercial end-use applications, such as wipes, medical products, and perhaps even apparel. Thousands of yards of various cotton- and cotton blend-based nonwoven fabrics have been produced, some of which are currently being evaluated by commercial entities. Specifically, comparative biodegradability studies have shown that cotton-based fabrics biodegrade faster than synthetic nonwovens, and consequently, an exposure to simple surface soil may be an efficient and eco-friendly means of disposal. In another study, discounted cottons including cotton ginning and processing byproducts were successfully processed and converted into hydroentangled nonwoven fabrics of considerable strength. In separate studies conducted on the commercial- grade hydroentanlement equipment, it was revealed that hydroentangled greige cotton-based nonwovens processed at certain conditions could be bleached, dyed, and even specially finished without the traditional chemical and costly scouring process. Separately, under a renewed Cooperative Research and Development Agreement with a U.S. cotton producer and ginner, it was found that unlike the traditional textile process of weaving, the production of cotton nonwovens is mostly independent of cotton fiber properties (within their standard ranges investigated). In addition, laundering these cotton-based nonwovens demonstrated the fabrics retain approximately 80% of their original mechanical integrity and dimensional stability after 20 cycles. Research on improving the flame resistance of cotton nonwovens has effectively shown that a urea additive is a cost effective alternative to diammonium phosphate in specific flame retardants. In yet another study on the development of cotton-based antimicrobial wipes, it was determined that greige cotton adsorbs three times more of antimicrobial agent than bleached cotton nonwovens. The adsorption of antimicrobial agent on both greige and bleached cotton nonwovens can be significantly reduced via chemical treatment of the fabrics and modification of the antimicrobial solution. Research on cotton fiber bioloads to improve cotton�s status in nonwovens has yielded valuable new information on the microbial and bacterial content of greige and hydroentangled cottons, which supports the expanded use of cotton in nonwovens and has resulted in one Cooperative Research and Development Agreement(s). Accomplishments 01 Bleaching and possibly dyeing of cotton nonwoven fabrics without the traditional, costly and eco-sensitive chemical scouring process. Greige raw cotton naturally has certain waxes that must be removed, using a rather costly and environmentally-sensitive chemical process called scouring, in the production of almost all cotton-based textile fabrics. Agriculture Research Service (ARS) scientists at the Southern Regional Research Center (SRRC) in New Orleans, Louisiana, have discovered that the hydroentangling (high) water pressure used in fabricating cotton nonwoven fabrics plays a significant role in considerably removing these waxes. This significant research milestone eventually led to a hypothesis in that a hydroentangled greige (raw) cotton nonwoven fabric could be bleached and possibly dyed without the traditional scouring process. The research investigations directed toward proving the hypothesis have indeed shown that an appropriately hydroentangled greige cotton nonwoven fabric can be bleached satisfactorily without the scouring process. This research outcome will contribute to saving money, energy, chemicals and above all, the earth�s ecology, which ultimately will expand use of cotton in nonwovens. A manuscript has been prepared for publication in a peer- reviewed textile research journal. 02 Utilization of cotton gin motes and textile processing comber noils in nonwovens for incontinence and related products. Production of cotton lint fiber in ginning process produces a by-product called gin motes and production of combed yarns and fabrics from cotton lint produces a by-product known as comber noils. Both of these cotton co-products in their 'greige' (raw/non-bleached) stage are generally unsuitable for traditional textile fabrics and, therefore, sell for far less than the cotton lint. Although these (nearly waste) materials in their bleached stage have long been used in production of value-added nonwoven products for medical and hygienic end-use products, the greige gin motes and comber noils have had only limited uses as bio mass and 'filling' materials (for certain household and industrial products). However, the United States Department of Agriculture (USDA), Agricultural Research Service research in New Orleans, Louisiana, has found that these less expensive, greige materials, when cleaned of their foreign matter and, preferably, in blend with other fibers, can be beneficially utilized as a cover stock (a component of value-added continence products), since these greige cotton by-products have been found to be more absorbent (moisture uptake) than their bleached counterparts. The research has led to preparation of a peer-reviewed manuscript that is expected to be published soon. 03 Deploying a series of multiple hydro impacts at different water pressures. An investigation was conducted by Agricultural Research Service (ARS) scientists to determine the effect of cumulative hydro energy consumption on properties of the greige cotton nonwoven fabric produced on a commercial-grade hydroentangling nonwovens system. The results have shown that, depending on the end product, a series of hydro impacts at a relatively lower water pressure may reduce energy consumption in production of certain nonwoven fabrics. A manuscript has been prepared for publication in a refereed journal. 04 Development of quat-loaded greige cotton decontaminating industrial wipe. Most decontaminating and/or antimicrobial wipes available in the market today use synthetic and other manufactured fibers, although some pulp is also used. Use of natural cotton fiber is minimal in these end- use products, mainly because of the strong adherence of quat onto cotton fiber, which, consequently, resists the desired ease and functionality of dispensing the quat when the quat-loaded wipe is wiped onto a contaminated surface for decontamination. Therefore, the underlying research issue was how to optimally reduce adsorption of the quat by greige cotton, while improving ease of release and effectiveness of the quat onto a contaminated surface. The research has shown that greige cotton�s pectin content and to a lesser extent its wax content actually played significant roles in the adsorption of decontaminating agents by the nonwovens made with greige (non-bleached) cotton. The research has also revealed that the addition of alcohol, electrolytes, and a nonionic surfactant to the decontaminating solution greatly reduces, or even completely eliminates, adsorption of the decontaminating agent by both the greige and bleached cotton nonwovens. The research is believed to have led to a scale-up evaluation of the United States Department of Agriculture (USDA), Agricultural Research Service developmental decontaminating wipes by outside commercial entities. The research results have been published in the Textile Research Journal, a refereed journal. 05 Effect of the water jet intensity in a hydroentanglement system on properties of the nonwoven fabrics made with greige cotton lint. Hydroentanglement is a modern system of efficiently producing nonwoven fabric structures. Although this system has been in vogue for decades, it mostly has been used in making nonwoven structures using synthetic and other manufactured fibers. The system has been rarely used in manufacturing especially greige cotton goods, although pulp has been extensively used to make papers by the system. The water jet intensity, which essentially depends on the orifice size of the high-water- pressure-strip and the magnitude of the high water pressure deployed in the system, has been found to considerably affect removal of greige cotton�s natural waxes. This finding, in turn, has led to development of producing absorbent nonwoven fabrics made with non-absorbent greige cotton, thus at least reducing, if not completely eliminating, the traditional burden of cotton scouring process that involves costly chemicals, time and energy and, consequently, adversely impacts the environment. 06 Novel chemical concepts to make cotton textiles flame-suppressant, antimicrobial and/or decontaminating. Making cotton textiles of certain desired functionalities (e.g., flame/fire retardant (FR), etc.) have been serious challenges for many years. Diligent research approaches by several Agriculture Research Service (ARS) scientists and especially postdoctoral fellows have resulted in some interesting new chemicals and their reactions with cotton. However, the durability of these newly discovered formulations is still a challenge to overcome. The research has attracted attention of industrial entities, who are interested in certain function-specific cotton fabrics for both woven and nonwoven goods. A few manuscripts on these new research developments have been published. 07 Cotton-based nanotechnology. Nanotechnology is a rapidly progressing tool for advanced research, development and even production of improved products from almost all the basic materials, including cotton, our planet earth provides. Agriculture Research Service (ARS) scientists at Southern Regional Research Center (SRRC) have developed phosphorous- nitrogen rich polymers that, unlike the conventional bulk applications, can be applied on a nano scale, using the layer-by-layer deposition of ionic particles. The research is expected to develop unique methods of efficiently applying special textile finishes, such as flame retardant (FR) and antimicrobial (AM) (just to mention a few) to cotton-based textile products. 08 Bio-based research to further improve status and utility of cotton in nonwovens. Use of cotton in quality nonwoven products has been minimal partly due to lack of the desired physical and microbial cleanliness of classical greige raw cotton. The Agricultural Research Service (ARS) scientists at Southern Regional Research Center (SRRC) are obliged to meet this rather difficult and perhaps politically complex challenge through a distinct, 3-prong research approach, viz., 1) specifically for the nonwovens industry, develop ARS technology for efficiently processing and cleaning the classical greige cotton at the gins; 2) identify, certify and support a reliable commercial supply source of pre-cleaned greige cotton that is free of the common physical contaminants such as the cotton plant and seed residues, dirt and trash, etc. of classical greige cotton; and 3) develop technology to assess and eliminate any bacterial and/or microbial presence in greige cotton. This research approach, when successfully executed, will considerably enhance the use of cotton in nonwovens. The SRRC scientists so far have identified an excellent commercial source of cleaned greige cotton that repeatedly has been tested and later processed into acceptable nonwoven fabrics. This commercial greige cotton�s microbial contamination, or bio load, at various stages of its processing was also measured and no hemolytic microorganisms were detected. The research has demonstrated that the pre-cleaned greige cotton indeed can be successfully utilized to produce a variety of medical, antimicrobial, and other (non-sterile) hygienic nonwoven products. The research results have been assembled into a manuscript (of 12 authors, however without the Lead Scientist) for broad dissemination of the research outcome.
Impacts
(N/A)
Publications
- Sawhney, A.P., Reynolds, M.L., Allen Jr, H.C., Slopek, R.P., Condon, B.D. 2013. Effects of greige cotton lint properties on hydroentangled nonwoven fabrics. Textile Research Journal. 83(1):3-12.
- Sawhney, A.P., Allen Jr, H.C., Reynolds, M.L., Slopek, R.P., Condon, B.D., Hui, D., Wojkowski, S.K. 2012. Effect of web formation on properties of hydroentangled nonwoven fabrics. World Journal of Engineering. 9(5):407- 416.
- Parikh, D.V., Ingber, B.F., Nam, S., Bhat, G., Warnock, M., Harrington, L. 2013. Flame retardant cotton barrier nonwovens for mattresses. Fire Sciences Journal. 0(0) 1-16.
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Progress 10/01/11 to 09/30/12
Outputs
Progress Report Objectives (from AD-416): Objective 1: Enhance and promote cotton�s natural sustainability features in the context of disposable nonwovens applications. Objective 2: Characterize and correlate the relationships among the cotton fiber quality parameters, the nonwovens process-ability, and the final fabric performance characteristics. Objective 3: Develop and optimize hydro-entanglement chemistry and process parameters for cotton fiber and the nonwoven fabrics thus produced. Objective 4: Develop innovative end-use functional technologies that enable increases in the amount and value of cotton used in nonwoven applications. Objective 5: Develop processes for producing nonwoven fabrics from greige cotton. Approach (from AD-416): The ultimate goal of this research project is to increase value-added utilization of cotton via development of performance-specific nonwoven products containing cotton. The term "cotton" used here includes cotton lint, ginning motes and linters, comber noils, processing wastes, recycled cotton, and the like. The research approaches broadly involve 1) characterization of fibers and fiber blends to be used; 2) selection of optimum processes and conditions for fiber opening, cleaning, and web formation; 3) selection of appropriate nonwovens production system; 4) evaluation of process and product performances; 5) physical, mechanical and/or chemical modifications of nonwoven products to attain and/or enhance the required functionality; 6) within the scope of the project, determine biodegradability, cost-effectiveness, environmental impact and sustainability of the products produced; and 7) disseminate the research results via publications, technical forums, and technology transfer to industry. Specifically, the research involves developing fiber-processing technology to obtain supply of clean greige/virgin (scour/bleach-less) cotton that is appropriate for the intended end-use application. Most of the existing manufacturers of nonwoven rollgoods do not have the resources, facilities and/or technical expertise to open and clean supply bales of greige cotton(s). It is imperative to develop a protocol that would enable the nonwovens manufacturers to either both open and clean cotton in their in-house facilities or obtain some readily available pre- cleaned cotton. Depending on individual products, we will determine efficient routes for processing cotton into a clean web for downstream processes. SRRC has the equipment, including cotton carding, to thoroughly open and clean virgin cotton and also the resources to procure and process pre-cleaned supply cottons (say, UltrcleanTM cotton). The preferred research focus is on using greige cotton, instead of bleached cotton that currently is primarily used in premium quality nonwovens. However, nonwoven fabrics made with cleaned greige cotton may be satisfactorily scoured and bleached, if necessary. To determine which cotton would be most cost effective for certain specific end-use applications, certain experimental investigations and small-scale industry-like production trials have been planned. They involve studies of the fiber, process and product metrics and their relationships. Research efforts will be redirected to improve any marginal outcomes. In general, carding process will be deployed to form a web for the downstream needle-punching and/or hydroentangling systems of producing nonwoven products. Optimizations of the N-P and H-E processes and products will be sought through planned investigations. Comprehensive testing of in-process products and end-products will be conducted to realistically evaluate the research outcomes. Statistical tools will be used for reliability of the results. Issues concerning the biodegradability, disposability, environmental impact, safety, government/industry-compliance,and cost-analysis will only be conducted to the extent feasible within the scope of the project. This report highlights the second year research accomplishments made by Agricultural Research Service (ARS) scientists at the Southern Regional Research Center (SRRC) in New Orleans, Louisiana, on the development, chemical treatment, and modification of cotton-based nonwoven products. Although the installation of the fiber processing equipment is an ongoing process, numerous trials have been conducted on the existing equipment to optimize the machinery and process parameters for the production of cotton-based nonwovens. These studies have revealed that pre-cleaned raw/greige (non-bleached) cotton can successfully be used to produce nonwoven substrates for commercial end-use applications, such as wipes, medical products, and perhaps even apparel. Thousands of yards of various cotton- and cotton blend-based nonwoven fabrics have been produced, some of which are currently being evaluated by commercial entities. Specifically, comparative biodegradability studies have shown that cotton-based fabrics biodegrade faster than synthetic nonwovens, and consequently, an exposure to simple surface soil may be an efficient and eco-friendly means of disposal. In another study, discounted cottons including cotton ginning and processing byproducts were successfully processed and converted into hydroentangled nonwoven fabrics of considerable strength. In separate studies conducted on the commercial- grade hydroentanlement equipment, it was revealed that hydroentangled greige cotton-based nonwovens processed at certain conditions could be bleached, dyed, and even specially finished without the traditional chemical and costly scouring process. Separately, under a renewed Cooperative Research and Development Agreement with a U.S. cotton producer and ginner, it was found that unlike the traditional textile process of weaving, the production of cotton nonwovens is mostly independent of cotton fiber properties (within their standard ranges investigated). In addition, laundering these cotton-based nonwovens demonstrated the fabrics retain approximately 80% of their original mechanical integrity and dimensional stability after 20 cycles. Research on improving the flame resistance of cotton nonwovens has effectively shown that a urea additive is a cost effective alternative to diammonium phosphate in specific flame retardants. In yet another study on the development of cotton-based antimicrobial wipes, it was determined that greige cotton adsorbs three times more of antimicrobial agent than bleached cotton nonwovens. The adsorption of antimicrobial agent on both greige and bleached cotton nonwovens can be significantly reduced via chemical treatment of the fabrics and modification of the antimicrobial solution. Research on cotton fiber bioloads to improve cotton�s status in nonwovens has yielded valuable new information on the microbial and bacterial content of greige and hydroentangled cottons, which supports the expanded use of cotton in nonwovens and has resulted in one and one- half Cooperative Research and Development Agreement(s) with Cotton Incorporated. Significant Activities that Support Special Target Populations: In recent years, the farming in the United States somewhat has transformed from relatively small farms to now some huge and multiple farms, some of which even are operated under some big name, publically traded companies. This transformation or trend, to some extent, has affected some small farmers/producers of agricultural commodities. One way of helping these small, disadvantaged farmers is for the Agricultural Research Service (ARS), United States Department of Agriculture (USDA) to develop new technologies and, ultimately, some new, low-volume, cotton- based niche products/markets with potentially high economic payback (profitability). A preliminary research project, conducted by ARS scientists in New Orleans, Louisiana, on the hydroentanglement of naturally colored brown cotton has revealed a very interesting and significant outcome. The naturally-colored cottons historically are known to have some inherently less-than-satisfactory attributes and have been considered unsuitable and uneconomical in the traditional textile manufacturing in the United States. However, based on the results of this research project, the naturally colored cottons now can be considered 'ideal' for processing and, consequently, for profitability when they are utilized via a nonwovens manufacturing route. The manufacturing of nonwovens does not involve the traditional yarn spinning and weaving processes that were and still continue to be the underlying complex processes that partly thwart the use of naturally colored cottons in traditional woven fabrics. The Agricultural Research Service research has shown beyond any doubt that some remarkably good nonwoven textiles can now be made with the naturally colored cotton. And this could greatly help, specifically, some small, minority and/or disadvantaged farmers who, either alone or in a consortium, can have their own fiber production, ginning and, possibly, even processing and converting facilities on optimum, limited scale. Accomplishments 01 Effect of water pressure in the hydroentanglement of greige cotton. Greige raw cotton naturally has high-molecular hydrocarbons (waxes) that must be removed, through a rather costly and environmentally-sensitive chemical process called scouring, in the production of almost all cotton based textile end-use products. Agricultural Research Service (ARS) scientists at Southern Regional Research Center (SRRC) in New Orleans, Louisiana, have discovered that the hydroentangling (high) water pressur used in fabricating cotton nonwoven fabrics plays a significant role in removing the waxes without involving the traditional scouring process. This is a significant research milestone that will contribute to saving money, energy, chemicals and, above all, our planet�s environment. The nonwovens industry leaders have expressed great interest in this development, which is expected to encourage increased use of cotton in nonwovens. The research was published in the Textile Research Journal (TRJ) and also highlighted in the industry�s popular journals. In a related, secondary development, a miniature research tool of converting, in minutes, a small sample of any staple fiber into a hydroentangled nonwoven fabric was developed, using a commercial-grade nonwovens (tabletop) lab card (with fixed plates instead of revolving flats of a cotton card) placed in tandem (series/line) with an in-house-fabricated, prototype hydroentanglement system. This research tool will be used to conduct preliminary investigative projects that otherwise would be costl time-consuming and perhaps even unsafe when conducted on the commercial- grade pilot plant equipment that is expensive and prone to possible dama due to unproven chemicals, procedures and practices. 02 Efficient utilization of discounted cotton and cotton co-products. Each year, substantial quantity of cotton (crop) is discounted in quality, which subsequently and substantially reduces its selling price since the discounted cotton generally is unsuitable for efficient processing and products for traditional textiles involving spinning and weaving yarns. Research conducted by Agricultural Research Service (ARS) scientists at Southern Regional Research Center (SRRC) in New Orleans, Louisiana, has revealed that the quality-discounted cotton as well as the cotton-ginnin and cotton-textile-processing byproducts, such as gin motes and comber noils, respectively, can be efficiently processed into viable 'nonwoven' products, using the hydroentanglement system of fabricating the fabrics. The research seemingly has advanced and expanded the value-added utilization of cotton that is considerably discounted in price. 03 Durable cotton nonwovens. Nonwoven end-use products for a long time hav been thought and actually termed 'disposable,' since they generally are good for one, short or long, use only. The Agricultural Research Servic (ARS) conducted at Southern Regional Research Center (SRRC) in New Orlea Louisiana, has changed that universal concept by demonstrating for the first time ever that cotton nonwoven fabrics made with an optimized process of hydroentanglement can, indeed, be strong, wet-finish able, launderable for up to 20 (and, in some cases, even 40) household washing and drying cycles and, hence, they can be durable in multiple uses. The research has the industry and academia rethink cotton nonwovens not only as the 'disposables' but also as the 'durable' textile products that can be repeatedly washed and dried with minimal changes in their properties and functionality. 04 Adsorption of antimicrobial agents (quats) on cotton compared to synthet fibers. Most antimicrobial wipes available in the market today use synthetic and manmade fibers, although some pulp is also used. Use, if all, of natural cotton fiber is minimal in these end-use products and applications, mainly because of the strong adherence of quat onto cotton fiber, which, consequently, resists the desired ease and functionality o dispensing the quat when the quat-loaded wipe is wiped onto a contaminat surface for decontamination. Various cotton, synthetic, rayon, and cott blend-based nonwoven fabrics were immersed in antimicrobial quat solutio of varying concentrations for a variety of liquor ratios and times. Cotton, both bleached and greige versions, and rayon adsorbed significan amounts of the antimicrobial agent, with the greige cotton and rayon adsorbing nearly three times more antimicrobial agent than the bleached cotton nonwovens. The underlying issue was how to optimally reduce adsorption of quats by greige cotton, while improving their ease and effectiveness of release onto a contaminated surface. The greige cotton fabrics were bioscoured using an enzyme (pectinase) and/or boiled to remove the majority of greige cotton�s natural waxes. It was discovered that cotton�s pectin content and to a lesser extent wax content played a significant role in the adsorption of antimicrobial agent by the greige cotton nonwovens. It was also discovered that addition of alcohol, electrolytes, and a nonionic surfactant to the antimicrobial solution greatly reduced and/or even completely eliminated the adsorption of the antimicrobial agent onto both the greige and bleached cotton nonwovens. The research has led to yet a new potential use of pre-cleaned greige cotton in the antimicrobial nonwoven products. 05 Waste management for a better tomorrow. The waste management of commonl used nonwoven products made with synthetic fibers largely relies on land filling and incineration, which cause serious environmental pollution an related problems. In collaboration with the University of Arkansas, a study conducted by the Agricultural Research Service (ARS) scientists at Southern Regional Research Center (SRRC) in New Orleans, Louisiana, has shown that cotton-based nonwoven fabrics, compared to those made with synthetic fibers, biodegrade much more rapidly when subjected to aerobic soil. The attentuated total reflectance Fourier transform infrared spectroscopy (ATR-FTIR) spectra and scanning electron microscope (SEM) analyses revealed that the cotton fabric degraded in 14 days and almost totally disintegrated within 21 days of aerobic soil burial, whereas the fabrics made with synthetic/manmade fibers showed little or no biodegradability even 140 days of the burial. This is an interesting finding which may lead to 'composting' as an efficient and eco-friendly alternative for safe disposal of cotton-based nonwovens. 06 A totally novel chemical technology to make cotton textiles flame- suppressant. Making cotton textiles flame/fire retardant (FR) has been serious challenge for many years, worldwide. Diligent research approach by Agricultural Research Service (ARS) scientists until now had been directed towards investigations of FR chemicals that were costly and soluble only in organic solvents, which obviously were neither economica and nor eco-friendly. The Agricultural Research Service (ARS) scientist at Southern Regional Research Center (SRRC) in New Orleans, Louisiana, recently have discovered new molecules that are less expensive and water soluble and impart acceptable degree of fire retardancty/protection to cotton fabrics. The research has attracted the attention of industrial stakeholders who are interested in FR cotton for a variety of consumer, industrial, furnishing and household products. 07 Cotton-based nanotechnology. Nanotechnology is the wave of the future. Agricultural Research Service (ARS) scientists at the Southern Regional Research Center (SRRC) in New Orleans, Louisiana, have developed phosphorous-nitrogen rich polymers that, unlike the conventional bulk applications, can be applied on a nano scale, using the layer-by-layer deposition of ionic particles. The research is expected to have a significant impact on how we now can efficiently apply special textile finishes, such as FR, antimicrobial (AM), permanent-press (PP) (just to mention a few) to cotton-based textile products. 08 Bio-based research to improve status and utility of cotton in nonwovens. Use of cotton in nonwoven products until now has been minimal partly due to greige raw cotton�s lack of the desired physical and microbial cleanliness. The Agricultural Research Service (ARS) scientists at the Southern Regional Research Center (SRRC) in New Orleans, Louisiana, have met this grave challenge through a distinguished, 2-prong research approach, viz., 1) develop technology, and/or a supply source thereof, f efficiently processing greige cotton that does not have the common physical contaminants, such as plant residues, dirt, etc., and 2) develo technology to assess and eliminate any bacterial and/or microbial presen in greige cotton, which will enhance use of cotton in nonwovens. A molecular biologist, who heads the second prong of the research at SRRC, has extensively measured the greige cotton�s microbial contamination, or bio load, at various stages of the cotton processing. Based on the measurements, no hemolytic microorganisms were detected on any of the source fibers investigated in the production of hydroentangled nonwoven fabrics. The removal of trash content in the form of extraneous/foreign matter, such as leaf and stem, resulted in a 10-fold reduction in the microbial contamination levels on the greige cotton fibers. These research findings have demonstrated that the hydroentangled nonwoven fabrics made with pre-cleaned greige cotton do not have any objectionabl level of microbial contaminant. This finding has had a significant scientific impact and has been awarded a significant Cooperative Researc and Development Agreement (CRADA) to continue the research to demonstrat that a pre-cleaned greige cotton indeed can be beneficially utilized in variety of medical, antimicrobial, and other hygienic cotton-based nonwoven products.
Impacts
(N/A)
Publications
- Sawhney, A.P., Allen Jr, H.C., Reynolds, M.L., Condon, B.D., Slopek, R.P., Edwards, J.V. 2011. Effect of water pressure on absorbency of hydroentangled greige cotton nonwoven fabrics. Textile Research Journal. 82(1):21-26.
- Sawhney, A.P., Reynolds, M.L., Allen Jr, H.C., Condon, B.D., Slopek, R.P., Hinchliffe, D.J., Hui, D. 2011. Greige cotton comber noils for sustainable nonwovens. World Journal of Engineering. 8(3):293-296.
- Hinchliffe, D.J., Turley, R.B., Naoumkina, M.A., Kim, H.J., Tang, Y., Yeater, K.M., Li, P., Fang, D.D. 2011. A combined functional and structural genomics approach identified an EST-SSR marker with complete linkage to the Ligon lintless-2 genetic locus in cotton (Gossypium hirsutum L.). Biomed Central (BMC) Genomics. 12:445.
- Kim, H.J., Triplett, B.A., Zhang, H., Lee, M., Hinchliffe, D.J., Li, P., Fang, D.D. 2012. Cloning and characterization of homeologous cellulose synthase catalytic subunit 2 genes from allotetraploid cotton (Gossypium hirsutum L.). Gene. 494(2):181-189.
- Nam, S., Parikh, D.V., Condon, B.D., Zhao, Q., Yoshioka-Tarver, M. 2011. Importance of poly(ethylene glycol) conformation for the synthesis of silver nanoparticles in aqueous solution. Journal of Nanoparticle Research. 13(9):3755-3764.
- Nam, S., Condon, B.D., Parikh, D.V., Zhao, Q., Santiago Cintron, M., Madison, C.A. 2011. Effect of urea additive on the thermal decomposition of greige cotton nonwoven fabric treated with diammonium phosphate. Polymer Degradation and Stability. 96(11):2010-2018.
- Nam, S., Condon, B.D., White, R.H., Zhao, Q., Fei, Y., Santiago Cintron, M. 2012. Effect of urea additive on the thermal decomposition kinetics of flame retardant greige cotton nonwoven fabric. Polymer Degradation and Stability. 97(5):738-746.
- Uppal, R., Bhat, G., Akato, K., Parikh, D.V., Nam, S., Condon, B.D. 2011. Flame retardant antibacterial cotton high-loft nonwoven fabrics. Journal of Industrial Textiles. (41)4:281-291.
- Parikh, D.V., Nam, S., He, Q. 2012. Evaluation of three flame retardant (FR) grey cotton blend nonwoven fabrics using micro-scale combustion calorimetry. Fire Sciences Journal. 30(3):187-200.
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Progress 10/01/10 to 09/30/11
Outputs
Progress Report Objectives (from AD-416) Objective 1: Enhance and promote cotton�s natural sustainability features in the context of disposable nonwovens applications. Objective 2: Characterize and correlate the relationships among the cotton fiber quality parameters, the nonwovens process-ability, and the final fabric performance characteristics. Objective 3: Develop and optimize hydro-entanglement chemistry and process parameters for cotton fiber and the nonwoven fabrics thus produced. Objective 4: Develop innovative end-use functional technologies that enable increases in the amount and value of cotton used in nonwoven applications. Objective 5: Develop processes for producing nonwoven fabrics from greige cotton. Approach (from AD-416) The ultimate goal of this research project is to increase value-added utilization of cotton via development of performance-specific nonwoven products containing cotton. The term "cotton" used here includes cotton lint, ginning motes and linters, comber noils, processing wastes, recycled cotton, and the like. The research approaches broadly involve 1) characterization of fibers and fiber blends to be used; 2) selection of optimum processes and conditions for fiber opening, cleaning, and web formation; 3) selection of appropriate nonwovens production system; 4) evaluation of process and product performances; 5) physical, mechanical and/or chemical modifications of nonwoven products to attain and/or enhance the required functionality; 6) within the scope of the project, determine biodegradability, cost-effectiveness, environmental impact and sustainability of the products produced; and 7) disseminate the research results via publications, technical forums, and technology transfer to industry. Specifically, the research involves developing fiber-processing technology to obtain supply of clean greige/virgin (scour/bleach-less) cotton that is appropriate for the intended end-use application. Most of the existing manufacturers of nonwoven rollgoods do not have the resources, facilities and/or technical expertise to open and clean supply bales of greige cotton(s). It is imperative to develop a protocol that would enable the nonwovens manufacturers to either both open and clean cotton in their in-house facilities or obtain some readily available pre- cleaned cotton. Depending on individual products, we will determine efficient routes for processing cotton into a clean web for downstream processes. SRRC has the equipment, including cotton carding, to thoroughly open and clean virgin cotton and also the resources to procure and process pre-cleaned supply cottons (say, UltrcleanTM cotton). The preferred research focus is on using greige cotton, instead of bleached cotton that currently is primarily used in premium quality nonwovens. However, nonwoven fabrics made with cleaned greige cotton may be satisfactorily scoured and bleached, if necessary. To determine which cotton would be most cost effective for certain specific end-use applications, certain experimental investigations and small-scale industry-like production trials have been planned. They involve studies of the fiber, process and product metrics and their relationships. Research efforts will be redirected to improve any marginal outcomes. In general, carding process will be deployed to form a web for the downstream needle-punching and/or hydroentangling systems of producing nonwoven products. Optimizations of the N-P and H-E processes and products will be sought through planned investigations. Comprehensive testing of in-process products and end-products will be conducted to realistically evaluate the research outcomes. Statistical tools will be used for reliability of the results. Issues concerning the biodegradability, disposability, environmental impact, safety, government/industry-compliance,and cost-analysis will only be conducted to the extent feasible within the scope of the project. This is the first-year report of a new in-house research project that involves a comprehensive nonwoven research program and a massive installation of new equipment. Significant progress has been made in successfully attaining almost all of the planned objectives and goals. All of the new equipment is now fully operational and productive. Numerous experimental studies and trials to optimize the machinery parameters for producing cotton nonwoven fabrics have been conducted. These studies and trials have demonstrated that pre-cleaned raw/greige (non-bleached) cotton indeed can be used for producing nonwoven substrates for many end-use applications, such as wipes, fleece, sheets, etc. The research products are currently being evaluated commercially. Studies conducted to determine the comparative biodegradability (for the life-end disposal) of cotton-based and manufactured-fiber-based nonwoven fabrics have shown that the cotton-based fabrics biodegrade much faster than the others and that their exposure to soil may be a better bet than a landfill for efficient disposal, which may encourage the replacement of synthetic fibers with cotton in certain disposable products. In another study, certain discounted cotton products, such as cotton ginning and processing wastes, were processed at Clemson University and converted into hydroentangled nonwoven fabrics at the Southern Regional Research Center (SRRC) in New Orleans, Louisiana. The preliminary results indicate that these cotton byproducts may also be beneficially utilized in nonwoven products. In another study to improve flame resistance of cotton nonwovens, the function of a less expensive urea additive, compared to the commonly used, three times more expensive diammonium phosphate fire-retardant (FR), was elucidated. The results have been satisfactory. The extensive research efforts devoted to producing mostly greige cotton-based nonwoven substrates have led to the possibility of eliminating the traditional scouring process. This may lead to even more efficient bleaching, possibly by reducing �burden� of the process. Separately, under a CRADA with a U.S. Cotton Producer and Ginner, an experimental study was conducted to determine the effect of fiber properties of pre-cleaned (UltraCleanR) cotton on the nonwovens process and product. The study has demonstrated that, unlike the traditional woven textiles, the fiber properties, within the normal ranges investigated, did not significantly affect properties of the fabrics produced. In addition, the laundering of these hydroentangled cotton fabrics has revealed, for the first time ever, that the fabrics can be repeatedly machine washed and dried for up to 20 cycles, while still retaining most (~80%) of their original mechanical integrity and dimensional stability. In another comprehensive study of application of �quats� or other chemistry to cotton to improve the latter�s �adherence� and �release� attributes of the anti-microbial agents, a new fundamental information has been obtained in that the greige cotton-based nonwoven fabrics adsorb and retain significantly more quat than similar fabrics that have been scoured and bleached. Accomplishments 01 Utilization of raw/greige cotton in nonwoven products. Although nonwove fabrics are growing rapidly, the use of cotton in these fabrics has been minimal. This is partly because the raw cotton requires substantial cleaning of its non-cotton contaminants, for which the existing nonwoven rolls manufacturing entities are not equipped since they mostly process synthetic/manufactured fibers that inherently are almost 100% pure, clea and white. In order to explore the feasibility of processing greige cotton for use in nonwovens, the ARS scientists at the Southern Regional Research Center (SRRC) in New Orleans, Louisiana, devoted extensive research efforts to find practical ways to produce viable nonwoven fabri using raw cotton as well as pre-cleaned raw cotton. The research has demonstrated that raw/greige (non-bleached) indeed can be efficiently converted into viable nonwoven substrates. 02 Elimination of the traditional chemical scouring process for hydroentangled greige cotton nonwoven fabrics. Raw cotton fibers always have some amount of high molecular-weight hydrocarbons (waxes, pectins, etc.) in the form of a sort of protective membrane. These waxes are wat repellent and thus do not permit the cotton fiber to absorb water. Sinc absorbency of most textile materials for apparel and other similar applications is critical for chemical modifications, wear comfort, washi etc., it is imperative that these waxes are completely removed at the first opportunity. Therefore, almost all cotton textiles are scoured an generally bleached to attain the desired absorbency. ARS researchers at the Southern Regional Research Center (SRRC) in New Orleans, LA, have discovered that hydroentangled raw cotton nonwoven fabrics, produced wit certain specific operating conditions, can be made absorbent without the traditional scouring process which is costly, cumbersome and environmentally sensitive. 03 Development of certain novel nonwoven products containing greige cotton. Applied research conducted at the Southern Regional Research Center's (SRRC�s) in New Orleans, LA, Cotton-Based Nonwovens research program has led to the development of some unique, potentially high-volume, value- added products containing cotton. The two promising products that currently are being evaluated by commercial entities are: 1) 100% cotton and 80:20 cotton:polyester-film composites for quilts, blankets and othe similar handicrafts; and 2) an environment-friendly kitchen (100% cotton wipe that has a naturally growing plant dye/pigment that is naturally antimicrobial and needs minimal (candle) light to activate its antimicrobial feature for up to 20 repeated washes. Incidentally, both products are readily biodegradable and are in or near the market, as wel 04 Discovery of new knowledge. Industry is seeking antimicrobial wipes tha can efficiently perform in the meat/food plants. The existing products mostly containing manufactured fibers, especially polyester, fall short the industrial expectation, mainly because of the less-than-satisfactory absorption, retention and dispensing (delivery) of the antimicrobial ingredient(s). Although cotton fiber, compared to polyester, has much greater absorbency, it also poses certain difficulties of its own, especially in the more retention and less dispensing of the chemical agents. Research done at the Southern Regional Research Center (SRRC) h revealed new knowledge that is expected to promote use of greige cotton for producing nonwovens for the wiping and other end-use applications.
Impacts
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Publications
- Sawhney, A.P., Reynolds, M.L., Condon, B.D., Slopek, R.P., Hui, D. 2010. An Efficient process for producing economical and eco-friendly cotton textile composites for mobile industry. World Journal of Engineering. 7(1) :150-153.
- Condon, B.D., Reynolds, M.L., Sawhney, A.P., Gary, L., Slopek, R.P., Grimm, C.C., Hui, D. 2010. Analysis of effluent filtrate in the hydro- entanglement process for producing cotton nonwovens: a progress report. World Journal of Engineering. 7(2):292-295.
- Condon, B.D., Gary, L., Sawhney, A.P., Reynolds, M.L., Slopek, R.P., Delhom, C.D., Hui, D. 2010. Properties of nonwoven fabrics made with UltraClean� cotton. World Journal of Engineering. 7(2):180-184.
- Sawhney, A.P., Reynolds, M.L., Condon, B.D., Slopek, R.P., Gary, L., Allen Jr, H.C. 2011. A comparative study of nonwoven fabrics made with two distinctly different forms of greige cotton lint. Textile Research Journal. 81(14):1484-1492.
- Slopek, R.P., Condon, B.D., Sawhney, A.P., Reynolds, M.L., Allen Jr, H.C. 2011. Adsorption of alkyl-dimethyl-benzyl-ammonium chloride on differently pretreated nonwoven cotton substrate. Textile Research Journal. 81(15) :1617-1624.
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