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UNHAIRING and LIMING
Loosening (depilation) or unhairing may be considered as an extension
of soaking. Its purpose
is to separate the two
structural proteins keratin and collagen.The
aim of unhairing (depilation) and liming is to
remove
the hair,
epidermis and
to some degree the inter-fibrillary proteins,
and to prepare the hide for removal of loose flesh and fat by the fleshing
process.
Unhairing:
Methods of hair removing can be
divided into two groups:
1) methods based on destruction or modification
of the epidermis tissue surrounding the hair, so that it can be loosened
and removed
2) methods in which hair itself is attacked
and its structure is destroyed (use of alkali Ca(OH)2 or NaOH
and Na2S).
-sweating :
The earliest method was "sweating" and may
still be used if the wool is of much greater value
than the skins. Soaked skins are hung up in
dark humid rooms (22-27 0C), bacteria attack keratin cells of
hair and epidermis, until wool is loose. The wool
is
then "pulled" and sorted and the skins
are rinsed and thrown in lime liquor to stop further putrefaction.
The
pulled wool is hydroextracted to remove water and dried to 16 % moisture
in which condition it is marketed.
Cathepsins contained in the lysosomes of the cells of the skin are
also participating in this process. For autolytic unhairing an optimal
pH is about 4. In this 'lysosomal' unhairing probably proteins and gycosaminoglycans
are equally attacked. In the products separated from the skin, hydroxyproline
is found in some amounts, equivalent to 0.3% of skin collagen. This may
be result of attacking of collagen-containing 'lining of the hair pocket.
A development of sweating process is enzyme unhairing.
-enzyme unhairing:
sweating is an uncontrolled enzyme process. Enzyme unhairing is a controlled
process. Enzyme preparations that preferentially
attack the keratin cells at base of hair roots or epidermis are available.
Enzymes are specific in their action and are active within a narrow range
of temperature and pH. Since optimum temperature for unhairing enzymes
are close to those for bacterial growth, it is essential to use some disinfectant
to prevent bacterial putrefaction.
Enzymatic processes may give some difficulties
in a tannery. Enzyme attack may be
very vigorous, too much protein may
be removed from the skin and collagen may be partly
decomposed. The resultant hides
are then thin and stiff.
If the enzyme action is too weak, insufficient amount
of protein will be digested, and additional operations necessary,
like eg. Alkali swelling of hides before pickling(after liming). The
enzymatically unhaired hides as a rule have to be tanned and dyed in a
different way than hides processed by other techniques.
According to Felicjaniak, who invested in detail the unhairing activity
of pancreatic enzymes, there is a distinct difference in unhairing and
proteolytic action of those enzymes. To increase
unhairing activity, the pelt has to be prepared by applying an inorganic
chemical before enzyme is used. The compounds giving optimal results are
ammonium chloride, thiocyanate, sodium thiosulphate and some others.
These substances increase the unhairing activity when used in 1% per pelt
weight. Sodiumthiosulphate increases proteolytic(not unhairing) activity
of the enzyme. Optimal unhairing activity was reached
at pH 8-9 (somewhat higher than optimal proteolytic activity pHopt=7.5).
Soaked skins are paddled or drained in a water float 28-300C
with 1-2 % of specific enzyme preparation at pH 8-9 for ~4 hours. Bacterial
contamination may be prevented by adding 0.2 % sodium chlorite.
-paint unhairing:
The washed or soaked skins are piled to drain off surplus water and then
painted, or sprayed on the flesh side with a "paint"
which may be made from approximately 50 parts hydrated lime, 50 parts water
and 5-2- parts sodium sulphide (fused). The
sodium sulphide and lime dissolves in the water and penetrate through the
corium and dissolve the keratin cells which enclose the hair roots. The
process may take 5-12 hours depending on thickness
of the skin, tightness of fiber structure, and amount of fat and flesh
left on the skin. Green
fleshing before painting can be good.
Green fleshing is a method of giving some mechanical
action. May be done by hand by scraping the flesh with a curved knife on
a wooden beam or by a fleshing machine. Apart from the squeezing action
loose fat, flesh or muscle tissue is removed, aiding entry of water from
the flesh side. It also flattens and stretches the skin and has a cleaning
action.
Advantages of the process:
-strong alkali (lime) and sodium sulphide prevent
putrefaction therefore give better skins than sweating.
-with reasonable control, hair loosening is reliable.
-unhairing is quicker and owing to shortage of
water in painted skins, the strong alkali cannot cause undue swelling,
buckling and distortion of the skin.
-the amount of paint can be varied over the area of the skin, giving
more to thicker backbone and less to thinner, loose flanks and bellies.
Disadvantages of the process:
-requires more labour
-wool yield is less (owing to the
disintigration of wool roots)
lime and sodium sulphide damage hair and wool,
causing a harsness to the touch or weakening of strength and eventually
complete disintigration. This action is a function of sulphide concentration.
Variations of the process:
Sodium sulphide + water à caustic soda + sodium hydrosulphide
too much sodium sulphide may weaken the skin
as it produces caustic soda in water. Adding wetting agents does
not improve penetration unless used in large quantities (excessive spread
down the wool shaft, with loss of wool or quality). On
greasy skin, excessive soluble lime produce lime soaps which give water
resistance to the skin and may result in poor tan.
The painted skins are usually given a modified liming after unhairing,
to remove unwanted protein and prepare them for fleshing or splitting.
Alternative materials:
Sodium hydrosulphide when used instead
of sodium sulphide gives no alkaline swelling, does not weaken the skin,
causes less damage to the wool. The penetration power is not as good as
sodium sulphide, especially on greasy skins.
Calcium hydrosulphide is even milder and
gives very good wool and skins.
Arsenic sulphide was popular(before the
above chemicals were introduced), poisonous.
If sharpened lime is used, pH is higher
than in the absence of alkali, but the swelling is greater, despite the
fact that the pH is higher than that of maximum swelling due to
( i) an increased breakdown of structural restrains
( ii)replacement of divalent calcium ions by
monovalent sodium ions.
When Na2S is used for depilation the
swelling effect is the same as that for NaOH, since H2S is a
very weak acid.
When calciumhydrosulphide is used, the
depilatory process can take place without any additional swelling. The
tanner can vary independently depilatory and swelling effects.
Liming:
The major chemical modification of collagen during
liming is the hydrolysis of some of the amido groups attached to aspartic
and glutamic acid residues.
-CONH2 + HOH -> -COOH + NH3
(pH decrease)
as the carboxyl group can ionize:
-COOH -> COO- + H+
more potential negatively charged centers are introduced so that the
isoelectric pH of collagen is invariably reduced by liming.
A small portion of arginine residues is also converted to ornithine
and urea.
-CH2CH2CH2NH-C=NH -> -CH2CH2CH2NH2
+ CO(NH2)2
I
NH2
Apart from these reactions, some modifications of covalent cross-links
may occur, especially of ester type, which are thought to join chains together.
The total effect is that
liming produces a pelt which
swells more at all pH values than does native, unlimed skin. Forces of
swelling lead to a general loosening
of the fiber- network layer and to the splitting of larger collagen fibers.
In normal tannery liming, apart from breakage of a few peptide main
chains by hydrolysis, the fibrils swell
and not show any marked changes in their general appearance. However
they are cleaner, as interfibrillary
material (mostly globular proteins and mucopolysaccharides)
is removed. Thus liming
helps to prepare a clean system of fibrils.
Liming may be enhanced by duration process, raising
temperature,and raising pH of liquor.
Unhairing and liming may be carried out at the
same time by immersing the hides and skins completely in lime and
water mixtures, often with the addition of other chemicals called sharpeners.
Liming process may be carried out without lime in certain cases, e.g.,
with greasy skins the lime is replaced by other alkali such as caustic
soda.
Straight lime liquors:
Water dissolves a relatively small amount of lime. And lime is unusual
because less dissolves with increasing temperature. Approximately 1/8 parts
lime per 100 parts water gives a clear solution.
The alkali solution causes the collagen fiber
of the corium to swell by absorbing more water. The hair and epidermis
swell to a lesser extent, and the interfibrillary proteins become more
soluble and are loosened from the structure.
These effects occur with all soluble alkalis and the
stronger the alkalinity, the greater the effect. As lime has a limited
solubility compared with other alkalis, it is considered safe for hides
and skins.
Under very alkali conditions, some of the young
keratin decomposes to produce sulphur compounds, these, in conjuction with
lime, accelerate the break-down of further keratin. Thus, the lime causes
unhairing and the more keratin break-down impurities it contains, the more
rapidly it unhairs. This is why old lime liquors
are more effective for unhairing.
All these reactions are accelerated
by increase in time, temperature
and high alkalinity.
The alkali also modifies and breaks down the collagen fibre of the
skin, but much more slowly than the keratin. Therefore, if skins are limed
too long they suffer from thinness, looseness and weakness.
For skins that have already been unhaired:
straight lime liquors of 2 parts lime per 100 parts water are used. The
skins are immersed in about 5-6 times their weight of this liquor (in paddles
or slowly revolving drums-agitated), for 12-60 hours at 13-18 C.
This quantity of lime is in excess of that needed to get the necessary
alkalinity (pH 12-13) plus the lime chemically fixed to the hide. The surplus
may be spent by adsorption on grease, loose protein or by carbonation.
It also makes handling the slippery hides easier. However this excess lime
often requires expensive effluent treatment.
One Pit Liming system:
Hides are laid or suspended in a pit in a similar lime solution. The
undissolved lime tends to settle to the bottom of the pit and therefore
not available for dissolving to maintain the 1/8 % solution. It may be
agitated by moving the frame the hides are suspended from or by rocking
a scraper arm moving along the pit bottom.
After 1-2 days in this liquor to allow the lime to start swelling the
hides uniformly
and gradually, 1/8 - ¼ % sodium
sulphide may be added. This is a sharpener
that speeds up the process:
- by producing sodium hydrosulphide, which very
quickly attacks the keratin, giving hair loosening;
- by producing caustic soda, which increases
the alkalinity and therefore the rate of swelling.
On the third or fourth day, in the case of ox hides, a further similar
addition of sulphide may be made to finish the process. If too much sulphide
is added too quickly, however, rapid unhairing results, but this is accompanied
by excessive swelling of the surfaces of the hide, while the interior is
unswollen.
The used liquor may be drained away but as it has become stronger in
unhairing power and less alkaline, it has good properties for starting
the liming of the next pack of hides.
According to old technologists 'art of tanning'
was the knowledge how to mix the fresh and used lime liquors. In fresh
liquor swelling is stronger and opening up weaker, old liquors (often infected
by microorganisms) are better hair looseners. A similar effect may be obtained
by adding methyl amine to lime liquor.
The "modified one pit" or the "three pit" system may be used.
Modified One Pit
system:
About half of the previously used lime liquor is left in the pit, which
is then topped up with water. 1 % lime is added and the goods limed in
this as before, except that the time and the amount of sodium sulphide
added may be reduced.
Three Pit system:
This system is more thorough development of the same idea, the pack
of hides being placed succesively in three pits for 2-3 days each.
A) The first pit contains a twice used lime liquor.
B) The second pit contains a once-used lime liquor with an addition
of ½ % lime and ¼ % sodium sulphide.
C) The third pit contains a fresh liquor of 2% lime and
¼ % sodium sulphide.
All these percentages are based on the volume of the water. This is
called a "counter current" system, the hides moving from pit to pit one
way, whilst the oldest liquor A is run away and replaced with a fresh liquor
C.
disadvantage: laborious
One liquor system more common (can controlled more accurately).
Drum Unhairing:
When the hair is of little value and the hides
are of a quality which will not suffer from the process, they may be drummed
in a relatively strong sodium sulphide solution,
for example: 300 % water on hide wt. At 16 C, 2-5 % sodium sulphide (fused),
12 % salt.
After 6 hours the hair and epidermis are reduced to a pulp (lapa),
which can be washed off, and the hides are well swollen. The salts limit
the swelling, which may also be reduced by replacing part of sodium sulphide
with sodium hydrosulphide.
1 % lime is often added to the sulphide solution .
NO LIME TREATMENTS are favored for thinner skins(hair, sheep,goat).
Advantages are absence of lime soap formation which may cause uneven tanning
and dyeing.
Hair or wool may be previously removed by a "lime free" sulphide paint.
Usually sulphide or hydrosulphide is used adjusted to pH 12.6-13 at a liquor
concentration of about 0.2 % caustic soda. As the temperature increases
to 28-30 C less swelling occurs giving a finer flatter grain and although
hydrolysis of the skin occurs this is slower and can be controlled by time(6-8
hours).
Sharpening Agents:
sodium sulphide- speeds up unhairing and
alkaline swelling
sodium hydrosulphide and arsenic
sulphide-speeds up unhairing only(not alkaline swelling)
caustic soda-sodium hydroxide-causes increased
swelling only.
Sodium carbonate-mild alkali, reacts with
lime to give caustic soda.
Ammonia- has a gentle swelling action
on the skin, particular in early stages. It is formed naturally in old
lime liquor.
Amines-dimethyl amines are added to lime
liquors, having a gentle swelling action and helping hair removal.
Salt:
at low concentration (below 2 % ) it increases the swelling or plumping
action of the lime liquors, but at high concentration it tends to decrease
the swelling or plumping and to give a softer, spongier type of leather.
Temperature:
temperature control is important. An increase from 16-27 C in the liming
temperature will halve the time required for loosening the hair; more significantly,
it will double the rate of solution of collagen. Normally temperatures
10-16 are used in Europe but some modern processes go higher.
Limed skin should never be unduly exposed to
the air, as carbondioxide in the air may convert the lime to hard, insoluble
calcium carbonate.
Use of amines in
lime liquors:
In recycling lime liquors, aliphatic amines were found to be in increasing
amounts with time and enhance unhairing. Perhaps the unhairing effect is
due to their properties as reductors. They bleach pelts which may be explained
by a reduction process. Unhairing by dimethylamine sulfate(DMAS) in alkali
(NaOH) was found to satisfactory and two significant remarks were done:
1)DMAS may be used for unhairing as main component (suitable for purposes
where hair saving is required).
2) NaOH was successfully used.
3) Further observations of sulfideless unhairing have led(Somerville)
to the conclusions that it is possible to apply short liquors (1:2)in unhairing
without sulfides and a (1:1) liquor in case of liquors containing 3% NaOH,
1% Na2SO4, 0.5% NaSH, 1%DMAS calculated on hide weight.
Operation time 24 hours.
Lyotropic agents act by structure making of the solution, they contribute
to the dissolving of the protein. Urea and NaCl affect hide in the same
way. Unhairing affect is a property of compounds dissolving protein molecule
through transferring H-bonds stabilizing protein molecules on the solute
molecules thus forming protein-solute bonds.
Thermal unhairing(scalding): used for
pigskins. Epidermis is more sensitive to thermal decomposition than other
layers and short time scalding doesn't influence collagen. Pigskin is passed
very quickly between rollers, one of them heated to 160-200 C, contact
time is 0.05-1.0 s. In this process the grain proteins are denatured, however
denaturation is a very shallow, and nubuck skin is obtained without buffing.
Denaturated layer dissolves very easily or may be seaparated spontaneously.
Oxidative unhairing(Rosenbusch):
5 NaClO2 + 4 HCl -> 4 ClO2 + 5 NaCl + 2 H2O
4 keratin-S-S-keratin + 10 ClO2 + 4 H2O -> 8
keratin-SO3H + Cl2
Chlorine dioxide reacts with keratin and splits disulfide bonds. Glycolic
acid is used to maintain pH 3.0-3.5, t<40 C, time:24 hours.
When the process is finished excess ClO2 decomposed by use
of sodiumthiosulfate, inorder to prevent oxidizing of chrome tanning agents(later).
This process replacing all the beamhose operations: degreasing,pickling
and alumpretanning by binding of chlorine to collagen, has some disadvantages,
therefore not used in industry.
1)has to be carried in acidic medium. All the materials used in construction
of machines in the beamhouse need to be replaced by acid resistant ones.
2)expensive
3)toxic gases are formed
4)leathers obtained are stiff and spready.
Measurements used
in control processes:
In many processing the quantity of chemicals
to be used are based on the percentages on skin weight. It is always necessary
to check whether this is dry skin weight or wet skin weight. It
is often specified "limed weight", "shaved weight", "crust dry weight",
where these refer to the weight of the leather passing through these processes,
which may have caused it to absorb more water, or cut away some of its
thickness, or reduced its weight by drying.
Leather is normally sold on the basis of a price
per unit weight or per unit area.
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