Calendering

Calendering:
After a grey fabric is subjected to scouring, bleaching,
mercerizing etc. it is finally dried to retain its true shape and
dimensions. But in this state the fabric becomes least
lustrous. Because, for those operations the threads in fabric
become wavy and crimped. But if a fabric is to appear
highly lustrous then its surface should be perfectly flat and
fibres appeared on the surface should be parallel to each
other and all should lie in the length direction.
To fulfill this object cotton, linen, rayon, silk materials are
applied a temporary physical finish which is known as
calendaring. In this process fabric is passed through a series
of heated rollers under pressure in open width form.
Objects of calendaring:
The main objects or purpose of calendaring process are
mentioned below:-
1.To cause a closing together of the threads of the fabric by
flattening them and thus tending to fill up the interstitches
between warp and weft.
2.To produce a smooth, glossy and highly lustrous
appearance on the surface of the cloth.
Essential elements of calendaring:
The following 3 elements should be controlled during
calendering namely:
•High pressure
•High temperature
•Suitable degree of dampness.
Besides these the number, composition & arrangements of
pressure bowls and speed of running cloth also should be
controlled carefully.
Now these elements are described below:
High pressure:
About 2-10 tonns of pressure should be applied on
pressure bowl. This pressure can be applied-
-By compound lever and weight, (used in jute mills)
-By hydraulics,
-By pneumatic action, (mostly used in the industry)
High temperature:
Temperature is applied on metallic bowls. These bowls are
generally hollow. They are heated
•By steam (most common, most economical, conventional,
mostly used in the industry)
•By thermo oil (also conventional, but not popular as
steam)
•By electricity (specialized used)
•By gas
Suitable dampness:
Suitable degree of dampness is created by passing fabric
through brush or roller damping machine. But now-a-days
in calendaring machines, in the entry zone there remains a
damping zone which creates dampness on fabric.
Bowl arrangement:
In industrial calendaring machines, there are 2-11 no of
bowls. But commonly the no. of bowl is 3, 5 or 7. Sometimes
in jute mills 9 or 11 bowl calendering machines are found.
Bowl material:
Bowls are made of cast iron and compressed materials like
synthetic rubber, cotton etc. The compressed material is as
hard as iron. The metallic bowls has a polished surface.
Now-a-days synthetic rubber coated bowls are used.
Bowl placing:
In general the metallic bowls are never placed in contact with
each other. Between two metallic bowls a compressed
material coated bowl is placed. This is done to prevent
shearing action.
Damping:
To prepare the cloth for finishing operations, conditioning
machine is useful in restoring the moisture content of the
goods before making up and hence improving the handle
and appearance. Damping can be done in 3 ways:-
•By brush damping machine.
•By spray damping machine.
•By steam.
Brush damping machine:
Brush damping machine is described below:-
Working principle & construction:
•There is a brush made of fibres, bristles and copper spikes in
this machine.
•The brush revolves/rotates at high speed in contact with
water in a trough.
•The cloth passes over usual tension rails, scrimp and guide
rollers to the position above the water trough.
•The water in spray form falls on the passing due to
centrifugal force produced by high speed of brush
roller.
•The fabric then passes round draw drawn over a
pressing roller which forms a nip to the batching
apparatus or plating device.
Advantages:-
•Machine construction is simple.
•Damping process is easy.
•Damping can be regulated (more/less damping) easily.
•Not require highly skilled labors.

Disadvantages:
•Water droplet size is big, so damping may not be uniform.
•The machine requires more space.
•High labor cost.
•Over damping may occur if the m/c is not stopped
frequently.
•As the regulating systems are manual so it is not easy to
operate uniformly.
Spray damping machine:
A spray damping machine is described below:
Working principle with construction:
•The no of nozzles which are essential parts of this machine,
varies according to the width of machine.
•Nozzles are attached to a common feed pipe which supplies
water under pressure.
•The feed pipe and nozzles are enclosed in a wooden box.
•An inclined disc is arranged in the front of the nozzle inside
the box.
•Due to high pressure, water discharges through the nozzle
on the disc and from there the fine droplets of water deposits
on the cloth which passes over the box at a suitable distance.
Advantages:
•Very fine droplet can be sprayed on the cloth.
•Uniform damping is possible.
•No risk of over damping in case of m/c stoppage.
•M/C construction is simple.
•No need of skilled labor.

Disadvantages:
•More floor space is required.
•More electricity is required to run the machine.
•More labor cost.
Damping by steam:
This is not a separate damping m/c. In this method fabric
passed between two perforated steam pipes which are
placed in the entry zone of the calendaring m/c.
Advantages:
•Regulating can be done by regulating valve.
•Process of damping is more uniform.
•Not require more space.
•Loss of electricity can be reduced.
•Labor cost can be reduced.
•No risk of over damping.
•Less costly process.
•Quick process of damping.
Various types of calendaring finishes:
There are 4 processes of calendaring finishes namely,
1.Swizzing finish.
2.Chasting finish.
3.Friction calendaring.
4.Embossing calendaring
1. Swizzing Calendars
Swizzing is a British term used to denote that the fabric runs
through all of the nips at the same surface speed as the rolls.
 Swizzing calendars usually consists of seven to ten bowls
and are run at ambient temperatures.
The fabric effect is closed interstices, a smooth appearance
and gloss without the high glaze characteristic of a friction
calendar.
A schematic of 7 bowl calendar is shown in
figure 1.
Figure 1: Swizzing Calendar
2. Chasing Calendars
Chasing calendars are similar to swizzing calendars. The
major difference is that the thread-up is such that the cloth
makes several passes through the nips before it exits to a take-
up roll.
This is done by having cloth pass over chasing rolls which
feed it back through the nips.
The cloth is compressed against itself with as many as 5 to 6
layers being in a nip. This gives the cloth a thready-linen
appearance and a soft special feel.
Figure 2: Chase Calendar
3. Friction Calendars
As the name implies, friction calendars (see figure 76) apply
a friction force to the face of the fabric. This is done by driving
the pattern roll faster than the support bowl.
 Friction is created by speed differentials ranging from 5% to
100% so it is necessary to have a strong fabric to withstand
the strains. Frictioning produces a high degree of luster on
one side.
4. Embossing Calendar
Embossing calendars are normally two or three roll
calendars with one engraved roll and one or two bowls.
 The moire effect can be obtained by using a moire pattern
embossing roll.
Thermoplastic fabrics can be permanently embossed with
heated rolls and the effect can withstand repeated
laundering.
Natural fibers are more difficult to emboss and usually
starch is needed for the embossing to take; however, this
effect is not durable to laundering.
Certain melamine resins can be added prior to embossing
and when properly cured, the embossing effect is more
durable.