Intermediate reports of my PhD project which reports the results of a Stated Preference Experiment conducted within 18 companies within the chemical industry
The scope of this thesis of Gerrit Bouwhuis, lecturer at Saxion Research Centre for Design and Technology in Enschede is the development of a new industrial applicable pre-treatment process for cotton based on catalysis. The pre-treatment generally consists of desizing, scouring and bleaching. These processes can be continuous or batch wise. Advances in the science of biocatalytic pre-treatment of cotton and catalytic bleaching formed the scientific basis for this work. The work of Agrawal on enzymes for bio-scouring and of Topalovic on catalytic bleaching led to the conclusion that reduced reaction temperatures for the pre-treatment processes of cotton are possible. A second reason for the present work is a persistent and strong pressure on the industry to implement ‘more sustainable’ and environmental friendlier processes. It was clear that for the industrial implementation of the newly developed process it would be necessary to ‘translate’ the academic knowledge based on the catalysts, into a process at conditions that are applicable in textile industry. Previous experiences learned that the transition from academic knowledge into industrial applicable processes often failed. This is caused by lack of experience of university researchers with industrial product and process development as well as a lack of awareness of industrial developers of academic research. This is especially evident for the so-called Small and Medium Enterprises (SME’s). To overcome this gap a first step was to organize collaboration between academic institutes and industries. The basis for the collaboration was the prospect of this work for benefits for all parties involved. A rational approach has been adopted by first gathering knowledge about the properties and morphology of cotton and the know how on the conventional pre-treatment process. To be able to understand the conventional processes it was necessary not only to explore the chemical and physical aspects but also to evaluate the process conditions and equipment that are used. This information has been the basis for the present lab research on combined bio-catalytic desizing and scouring as well as catalytic bleaching. For the measurement of the performance of the treatments and the process steps, the performance indicators have been evaluated and selected. Here the choice has been made to use industrially known and accepted performance indicators. For the new bio-catalytic pre-treatment an enzyme cocktail, consisting of amylase, cutinase and pectinase has been developed. The process conditions in the enzyme cocktail tests have been explored reflecting different pre-treatment equipment as they are used in practice and for their different operation conditions. The exploration showed that combined bio-catalytic desizing and scouring seemed attractive for industrial application, with major reduction of the reaction and the rinsing temperatures, leading to several advantages. The performance of this treatment, when compared with the existing industrial treatment showed that the quality of the treated fabric was comparable or better than the present industrial standard, while concentrations enzymes in the cocktail have not yet been fully optimized. To explore the application of a manganese catalyst in the bleaching step of the pre-treatment process the fabrics were treated with the enzyme cocktail prior to the bleaching. It has been decided not to use conventional pre-treatment processes because in that case the combined desizing and scouring step would not be integrated in the newly developed process. To explore catalytic bleaching it has been tried to mimic the existing industrial processes where possible. The use of the catalyst at 100°C, as occurs in a conventional steamer, leads to decomposition of the catalyst and thus no bleach activation occurs. This led to the conclusion that catalytic bleaching is not possible in present steamers nor at low temperatur
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A lot of research effort is put in developing enzymatic treatment of textiles by focusing on the performance of enzymes on lab-scale. Despite all this work upgrading of these developments from lab-scale to industrial scale has not been really successful. Companies are nowadays confronted with rapid developments of markets, logistics and social and environmental responsibilities. Moreover these organizations have to supply an evenincreasing amount of information to the authorities, shareholders, lobbyists and pressure groups. Companies have tried to fulfill all these demands, but this led often to the loss of focus on new product and process development. However, both theory and practices of breakthrough innovations has shown that those rightfully proud on previous successes in the past, are usually not the ones that lead the introduction of new technology, aswas shown and excellently documented by Harvard professor Clayton Christensen [Christenson, 2003]. The textile industry is no exception in this observation. With the lack of management impulses on new product and process developments companies began to reduce the investments in these activities. Finally, however, this will result in a reduction of the size of the company or even closing down. Besides the hesitation from the topmanagement of textile companies to focus on new developments it is also seen that the middle management level is reluctant to evaluate and implement developments in new products and processes. One of the reasons for this reluctance is that many processes in textile industry are not fully explored and known yet. From this lack of knowledge it is easy to explain that there is hesitation for changes, since not all consequences of a change inprocessing or production can be overseen. Often new developments cannot be fully tested and evaluated on labor pilot scale level. This is caused by the impossibility to mimic industrial scale production in a lab. Besides of that, pilot scale equipment is very expensive and for many companies it is not realistic to invest in this type of equipment.Fortunately an increasing number of textile companies realize that they have to invest in new products and processes for their future survival and prosperity. New developments are decisive for future successes. If such companies decide to invest in new developments it is obvious that with the scarcity of capital for product- and process developments, the chance of failures should be minimized. For successful process- and product development it is necessary to organize the development process with external partners, as it is clear that it is almost not possible for individual textile companies to control the process from idea generation, academic research, implementation research and development and industrial testing. These issues are specially characteristic for small and medium sized enterprises (SME’s). In the present work the collaboration has been organized on two research levels. The first research level is knowledge and know-how based. Here the universities and the chemical supplier worked closely together to investigate the new process. The aim was to explore the influence of process conditions and interaction of the chemicals in the sub process steps on the result of the treatment. The second level is that of the industrialimplementation of the new process. Here universities and chemical supplier worked closely together with different industries to implement the newly developed process. The focus in this part of the research was the interaction between the chemistry of the new process, equipment and fabrics.A co-operation between the beneficiaries of the new process has been established. The selection criterion for the co-operation was “who will earn something with the new process”. Paper from the Saxion Research Centre for Design and Technology for Proceedings of IPTB Conference, Milan, Italy, M
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Size measurement plays an essential role for micro-/nanoparticle characterization and property evaluation. Due to high costs, complex operation or resolution limit, conventional characterization techniques cannot satisfy the growing demand of routine size measurements in various industry sectors and research departments, e.g., pharmaceuticals, nanomaterials and food industry etc. Together with start-up SeeNano and other partners, we will develop a portable compact device to measure particle size based on particle-impact electrochemical sensing technology. The main task in this project is to extend the measurement range for particles with diameters ranging from 20 nm to 20 um and to validate this technology with realistic samples from various application areas. In this project a new electrode chip will be designed and fabricated. It will result in a workable prototype including new UMEs (ultra-micro electrode), showing that particle sizing can be achieved on a compact portable device with full measuring range. Following experimental testing with calibrated particles, a reliable calibration model will be built up for full range measurement. In a further step, samples from partners or potential customers will be tested on the device to evaluate the application feasibility. The results will be validated by high-resolution and mainstream sizing techniques such as scanning electron microscopy (SEM), dynamic light scattering (DLS) and Coulter counter.
Currently, many novel innovative materials and manufacturing methods are developed in order to help businesses for improving their performance, developing new products, and also implement more sustainability into their current processes. For this purpose, additive manufacturing (AM) technology has been very successful in the fabrication of complex shape products, that cannot be manufactured by conventional approaches, and also using novel high-performance materials with more sustainable aspects. The application of bioplastics and biopolymers is growing fast in the 3D printing industry. Since they are good alternatives to petrochemical products that have negative impacts on environments, therefore, many research studies have been exploring and developing new biopolymers and 3D printing techniques for the fabrication of fully biobased products. In particular, 3D printing of smart biopolymers has attracted much attention due to the specific functionalities of the fabricated products. They have a unique ability to recover their original shape from a significant plastic deformation when a particular stimulus, like temperature, is applied. Therefore, the application of smart biopolymers in the 3D printing process gives an additional dimension (time) to this technology, called four-dimensional (4D) printing, and it highlights the promise for further development of 4D printing in the design and fabrication of smart structures and products. This performance in combination with specific complex designs, such as sandwich structures, allows the production of for example impact-resistant, stress-absorber panels, lightweight products for sporting goods, automotive, or many other applications. In this study, an experimental approach will be applied to fabricate a suitable biopolymer with a shape memory behavior and also investigate the impact of design and operational parameters on the functionality of 4D printed sandwich structures, especially, stress absorption rate and shape recovery behavior.
Denim Democracy from the Alliance for Responsible Denim (ARD) is an interactive exhibition that celebrates the journey and learning of ARD members, educates visitors about sustainable denim and highlights how companies collaborate together to achieve results. Through sight, sound and tactile sensations, the visitor experiences and fully engages sustainable denim production. The exhibition launches in October 2018 in Amsterdam and travels to key venues and locations in the Netherlands until April 2019. As consumers, we love denim but the denim industry, like other sub-sectors in the textile, apparel and footwear industries, faces many complex sustainability challenges and has been criticized for its polluting and hazardous production practices. The Alliance for Responsible Denim project brought leading denim brands, suppliers and stakeholders together to collectively address these issues and take initial steps towards improving the ecological sustainability impact of denim production. Sustainability challenges are considered very complex and economically undesirable for individual companies to address alone. In denim, small and medium sized denim firms face specific challenges, such as lower economies of scale and lower buying power to affect change in practices. There is great benefit in combining denim companies' resources and knowledge so that collective experimentation and learning can lift the sustainability standards of the industry and lead to the development of common standards and benchmarks on a scale that matters. If meaningful, transformative industrial change is to be made, then it calls for collaboration between denim industry stakeholders that goes beyond supplier-buyer relations and includes horizontal value chain collaboration of competing large and small denim brands. However collaboration between organizations, and especially between competitors, is highly complex and prone to failure. The research behind the Alliance for Responsible Denim project asked a central research question: how do competitors effectively collaborate together to create common, industry standards on resource use and benchmarks for improved ecological sustainability? To answer this question, we used a mixed-method, action research approach. The Alliance for Responsible Denim project mobilized and facilitated denim brands to collectively identify ways to reduce the use of water and chemicals in denim production and then aided them to implement these practices individually in their respective firms.
