Product Development in Technical Textiles: Protective Textiles

Dr Nandan Kumar (PhD)

High Performance Textiles Pvt. Ltd & Institute of Technical Textiles Pvt. Ltd

Sonipat, Haryana

 

1.Introduction

 

To be a successful group leader in the technical textiles industry, particularly in the field of protective textiles, two fundamental aspects must be mastered: managing the cost of raw materials and understanding the testing of developed products. These elements are essential for ensuring both the performance and commercial viability of the products. The cost of raw materials can be effectively optimized by blending different fibres, which helps achieve the desired protective properties without excessive cost. On the other hand, having a clear understanding and facility to test the developed product for various hazards is crucial for the development of products that meet industry standards and regulations. This approach will not only improve the testing of finished products but also enhance the quality assessment of raw materials used in the development process.

The product developed should have to meet the minimum required performance requirements to perform the specific tasks and it is confirmed by referring the standards such as EN 388/ ISO23388, EN 407/ISO23407,BS EN 1149, ISO 11611, ISO 11612 etc (1-10). The performance is determined by considering the work environment, for example, fabrics used in environments with high mechanical hazards, such as glass manufacturing or metalworking, must meet high cut, abrasion, and puncture resistance standards. On the other hand, workers exposed to thermal hazards, such as firefighters or welders, require fabrics that offer superior flame resistance, convective and radiant heat protection, and protection against molten metal splashes. For electrostatic protection, the performance requirements depend on the specific industry. In electronics manufacturing, fabrics must demonstrate low surface resistance and fast charge decay to prevent static buildup, while in oil and gas, where the risk of explosion is higher, electrostatic protection is even more critical (11-16).

1.1 Cost optimization through fibre blending

 

In protective textiles, blending different fibres is a key strategy for reducing costs while maintaining or improving performance. Fibres like para-aramid, modacrylic, FR viscose, and high-performance materials such as ultra-high-molecular-weight polyethylene (UHMwPE) and high-performance polyethylene (HPPE) are commonly used in various blends. Para- aramid, for example, is highly resistant to heat and abrasion, making it a popular choice for protective clothing. However, its cost can be a limiting factor. By blending para-aramid with fibers such as FR viscose, modacrylic, nylon, or reinforcing with materials like steel wire, glass, or basalt, manufacturers can create fabrics that not only meet but also exceed the required protection standards, all while being more cost-effective. This approach ensures that the final product is tailored to meet specific hazards without incurring excessive costs in raw materials. Common fibres are used in development of protective textiles are shown in figure

 

Over 16 years of exposure in the manufacturing of technical yarns at High Performance Textiles Pvt Ltd. Haryana, India, I’ve realised that having a good R&D lab in-house is very important for the credibility of products for both overseas and domestic market. Further, extending the idea, Institute of Technical Textiles Pvt Ltd is established which is equipped with the testing equipment, commonly required in the development of protective textiles. We have also established an in-house commercial pilot plant where fibers can be blended, spun into yarn, woven or knitted, and the finished fabrics can be tested for mechanical, thermal, and electrostatic properties—all in one facility, allowing for immediate results.

1.2 Testing & validation for protective textiles

 

To ensure that the fabrics meet the required safety standards, rigorous testing is performed for various types of hazards, including mechanical, thermal, and electrostatic hazards. The tests are conducted in accordance with international standards, which define the minimum performance requirements. The testing facility available at the Institute of Technical Textiles Pvt. Ltd (ITT), Sonipat is shown in figure 2.

 

 

Half charge decay tester

Figure 2 . Testing facility available at ITT, Sonipat

1.2.1 Protection against mechanical hazards

 

Mechanical hazards are one of the primary concerns in industries like construction, manufacturing, metalworking, glass handing industries where workers are exposed to sharp objects, punctures, and abrasions. Mechanical testing includes the following types:

 TDM Cut Resistance (ISO 13997): These standards determine the fabric’s ability to resist cutting by sharp objects. The ISO 13997 test method uses a sliding blade under controlled pressure to cut through the fabric;

 Tear Resistance (ISO 13937): These tests assess the fabric’s resistance to tearing under tension. Higher tear resistance is essential for ensuring that the protective clothing remains intact when subjected to forces that could otherwise tear the fabric. Tear testing can be performed on tear testing machine or Universal Testing Machine (UTM);

 Abrasion Resistance (ISO 12947, ASTM D3884): Abrasion testing evaluates how well a fabric can withstand wear and tear over time. Fabrics with higher abrasion resistance are essential in high-friction environments. Martindale abrasion testing machine and Taber abrasion testing machine can be employed for determining the resistance abrasion resistance of particular fabric, however, client’s requirement must be met by a mutual agreement while selecting the test apparatus and test method;

 Puncture Resistance (ISO 13996, ASTM F1342): Puncture test determine the force required to puncture the fabric using a specific probe. This test is critical for industries where workers are at risk of sharp objects penetrating their clothing such as gloves, sleeves or workwear. Specific kind of puncture tool is required for specific purpose such as hypodermic needle or spike;

 Impact testing (BS EN 13594, BS EN 1621): It refers to a series of standardized tests designed to evaluate the protective capabilities of personal protective equipment (PPE), particularly for motorcycle riders. The two standard- BS EN 13594 and BS EN 1621-pertain to different types of gear used by motorcyclists;

 BS EN 13594 specifies the requirements for protective gloves worn by motorcyclists. The standard includes impact testing to ensure gloves provide adequate protection in case of an accident;

 BS EN 1621 (Motorcyclists’ protective clothing against mechanical impact): It deals with standard that sets requirements for impact protectors worn in motorcycling gear, including back protectors, elbow protectors, knee protectors, and shoulder protectors. This standard focuses on protective armour built into the clothing, like jackets and pants, to absorb and dissipate impact energy during a fall or crash.

1.2.2 Protection against thermal hazards

 

Thermal hazards pose a significant risk to workers in industries such as firefighting, metalworking, and electrical utilities (17-19). The following tests are commonly used to evaluate a fabric’s thermal protection:

 Limited Flame Spread (ISO 15025, ASTM D6413): This test assesses the fabric’s resistance to ignition and the spread of flame when exposed to a small flame. It is essential for ensuring that protective clothing does not catch fire easily or burn quickly;

 Convective Heat Resistance (ISO 9151, ASTM F1939): Convective heat testing measures how well a fabric insulates against heat transfer via hot air or gases. This is especially important for industries where workers are exposed to high temperatures or flames;

 Radiant Heat Resistance (ISO 6942, ASTM F1939): Radiant heat testing evaluates the fabric’s ability to protect against radiant energy, which is often encountered in environments with open flames or intense heat sources, such as furnaces;

 Contact Heat Resistance (ISO 12127, ASTM F1060): Contact heat tests measure how long a fabric can protect against direct contact with hot surfaces. This is crucial for industries where workers may inadvertently touch hot machinery or materials;

 Molten Metal Splash Resistance (ISO 9185, ASTM F955, ISO 9150): Molten metal splash tests evaluate how well a fabric can protect against splashes of molten metal, such as aluminium or steel. This is essential for workers in foundries and metalworking industries. For small splashes of molten metal is required while determining the performance of gloves, sleeves and welder protective wear and the test is conducted in accordance with ISO 9150. Whereas, for gloves, sleeves and other workwear testing is conducted for protection against large splashes of molten metal in accordance with ISO 9185 or equivalent.

1.2.3. Protection agasint electrostatic hazards

 

In certain industries, such as electronics manufacturing, aerospace, and oil and gas, controlling electrostatic discharge (ESD) is critical. Electrostatic hazards can cause equipment malfunction or even ignite flammable materials. The following tests are used to evaluate electrostatic protection:

 Surface Resistance (EN 1149-1): Surface resistance testing measures the ability of a fabric to dissipate static electricity. Lower surface resistance indicates better static dissipation, reducing the risk of electrostatic discharge.

 Half Charge Decay Time (EN 1149-3): This test measures the time it takes for the static charge on a fabric to decay to half its original value. Faster decay times indicate better electrostatic discharge performance.

Conclusion

 

In summary, being a successful global leader in the technical textiles industry requires a deep understanding of both cost optimization and product testing. By blending different fibres, manufacturers can create protective fabrics that offer a balance of performance and affordability. Additionally, a thorough knowledge of testing methods for mechanical, thermal, and electrostatic hazards is essential for developing products that meet industry standards. Each test, whether for cut resistance, flame spread, or electrostatic discharge, ensures that the protective clothing will perform as expected in real-world conditions, safeguarding workers in hazardous environments.

References

 

1. Kumar, N. Process of manufacturing a thermally insulating roving yarn and a textile thereof, Patent number. 530446;
2. Kumar, N. A three-dimensional textile and a process of preparing the same, Patent number. 537362;
3. Kumar, N. A protective textile, Patent number 495294;
4. Dhyani, H., Sinha, S. K., & Kumar, N. (2021). Effect of repeated laundering on cut resistance performance of UHMWPE based protective clothing, Journal of Textile and Clothing Science;
5. Kumar, N. (2021). Recycling of metallic cut resistant yarns. Sustainable Growth in Textiles, 28;
6. Kumar, N., & Pawaskar, S. S. (2020). Technical Textiles for protection against Arc- flash fire : Savesplash. WEENTECH Proceedings in Energy;
7. N. Kumar, Development of Stab-Resistant Body Protector in India, TechTex India, BCH, April-June 2013;
8. J Jajpura, J Kaushik, A Bhardwaj, N. Kumar, Performance Study of E-glass Reinforced HPPE and Cotton Cut-Resistant Gloves with Repeated Laundering & Industrial Use, Man-Made Textiles in India, 303-309, September 2018;
9. Protection against Mechanical Hazards: HPT Flex Gloves & Fabrics, A. Katyal, N. Kumar, Asian Textile Journal, August 2019;
10. N. Kumar, Personal Protection: Protecting our Skilled Hands Against Heat & Mechanical Risks, Textech Communique, Vol 1, Issue 3, September 2012;
11. N. Kumar, Personal Protection: HPT Aracore Gloves for Protection Against Thermal & Mechanical Hazards, Man Made Textiles, India, August 2017;
12. N. Kumar & A Katyal, Technical Textiles for Protection Against Thermal Hazards EN 407- 2004, Indian Textile Journal, 51-55, April 2020;
13. S. Srivastava, N. Kumar, and C. Malvi, “Testing Cut-Resistance of Protective Textiles: ISO 13997 and ASTM F 2992,” Inst. Eng. Part E, Accepted, 2023.
14. S. Srivastava, N. Kumar, and C. S. Malvi, “Study of Multi-layered inherent flame retardant fabrics for protection against contact heat transmission as per ISO 12127-1,” in Fire Engineer, 2022, pp. 63–70.
15. S. Srivastava, N. Kumar, and C. S. Malvi, “Recycled para-aramid yarn for protection against thermal hazards,” TIWC, University of Huddersfield UK, 2023.
16. S. Srivastava, N. Kumar, and C. Malvi, “Protection against thermal & mechanical hazards using para-aramid/tungsten core yarn,” 2023, FTC, IIT Delhi.
17. Srivastava, S., Kumar, N., Kumar, A., Prasad, K., Mohan, A., Malvi, C. S., ‘Performance investigation of protective clothing against low pressure steam and molten aluminium’, IJFTR, Accepted, 2023.
18. S. Srivastava, N. Kumar, and C. S. Malvi, “Determining the performance of thermal protective gloves against the exposure of flame as per ISO 9151:2016,” Asian Tech. Text. J., vol. 17, no. 1, pp. 58–63, 2023.
19. S. Srivastava, N. Kumar, and C. S. Malvi, “सुरक्षात्मक दस्ताने का अग्नि व ताप के विरुद्ध व्यवहार का आकलन,” Vigyan Prakash, vol. 20, no. 1, pp. 29–37, 2022.