Sodium metasilicate based fiber opening for greener leather processing.

Growing environmental regulations propound the need for a transformation in the current practice of leather making. The conventional dehairing and fiber opening process results in high negative impact on the environment because of its uncleanliness. This process accounts for most of the biochemical oxygen demand and chemical oxygen demand in tannery wastewater and generation of H2S gas. Hence, this study explores the use of a biological material and a nontoxic chemical for performing the above process more cleanly. In this study, the dehairing and fiber opening processes has been designed using enzyme and sodium metasilicate. The amount of sodium metasilicate required for fiber opening is standardized through the removal of proteoglycan, increase in weight, and bulk properties of leathers. It has been found that the extent of opening up of fiber bundles is comparable to that of conventionally processed leathers using a 2% sodium metasilicate solution. This has been substantiated through scanning electron microscopic analysis and softness measurements. The presence of silica in the crust leather enhances the bulk properties of the leather. This has been confirmed from the energy dispersive X-ray analysis. Performance of the leathers is shown to be on par with conventionally processed leathers through physical and hand evaluation. The process also exhibits significant reduction in chemical oxygen demand and total solid loads by 55 and 24%, respectively. Further, this newly developed process seems to be economically beneficial.

Reversing the conventional leather processing sequence for cleaner leather production.

Conventional leather processing generally involves a combination of single and multistep processes that employs as well as expels various biological, inorganic, and organic materials. It involves nearly 14-15 steps and discharges a huge amount of pollutants. This is primarily due to the fact that conventional leather processing employs a "do-undo" process logic. In this study, the conventional leather processing steps have been reversed to overcome the problems associated with the conventional method. The charges of the skin matrix and of the chemicals and pH profiles of the process have been judiciously used for reversing the process steps. This reversed process eventually avoids several acidification and basification/neutralization steps used in conventional leather processing. The developed process has been validated through various analyses such as chromium content, shrinkage temperature, softness measurements, scanning electron microscopy, and physical testing of the leathers. Further, the performance of the leathers is shown to be on par with conventionally processed leathers through bulk property evaluation. The process enjoys a significant reduction in COD and TS by 53 and 79%, respectively. Water consumption and discharge is reduced by 65 and 64%, respectively. Also, the process benefits from significant reduction in chemicals, time, power, and cost compared to the conventional process.

Silicate enhanced enzymatic dehairing: a new lime-sulfide-free process for cowhides.

A conventional dehairing process with sodium sulfide and lime is a major source of the pollution from the tanning industry. In other words, conventional dehairing processes degrade the hair to the extent that it cannot be recovered; thus, these processes become a major contributor to wastewater pollution. In this study, an attempt has been made to develop a lime and sulfide-free dehairing process using a commercial enzyme formulation with the activation of a silicate salt. A dip and pile method of application has been standardized. The amount of enzyme and sodium metasilicate has also been optimized based on complete removal of hair. Enhancement of enzyme activity by the addition of silicate has been demonstrated through activity measurements. Hair removal is found to be complete using scanning electron microscope analysis. Strength and bulk properties of the experimental leathers are comparable to that of control leathers. The process enjoys a significant reduction in chemical oxygen demand (COD) and total solids (TS) by 53 and 26%, respectively. More importantly, the application of enzyme for dehairing results in an 8% area increase in the final leather. Also, the process is proven to be techno-economically feasible.

Natural leathers from natural materials: progressing toward a new arena in leather processing.

Globally, the leather industry is currently undergoing radical transformation due to pollution and discharge legislations. Thus, the leather industry is pressurized to look for cleaner options for processing the raw hides and skins. Conventional methods of pre-tanning, tanning and post-tanning processes are known to contribute more than 98% of the total pollution load from the leather processing. The conventional method of the tanning process involves the "do-undo" principle. Furthermore, the conventional methods employed in leather processing subject the skin/ hide to a wide variation in pH (2.8-13.0). This results in the emission of huge amounts of pollution loads such as BOD, COD, TDS, TS, sulfates, chlorides and chromium. In the approach illustrated here, the hair and flesh removal as well as fiber opening have been achieved using biocatalysts at pH 8.0, pickle-free natural tanning employing vegetable tannins, and post-tanning using environmentally friendly chemicals. Hence, this process involves dehairing, fiber opening, and pickle-free natural tanning followed by ecofriendly post-tanning. It has been found that the extent of hair removal and opening up of fiber bundles is comparable to that of conventionally processed leathers. This has been substantiated through scanning electron microscopic analysis and softness measurements. Performance of the leathers is shown to be on par with conventionally chrome-tanned leathers through physical and hand evaluation. The process also exhibits zero metal (chromium) discharge and significant reduction in BOD, COD, TDS, and TS loads by 83, 69, 96, and 96%, respectively. Furthermore, the developed process seems to be economically viable.