Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of invention:
A TANNING COMPOSITION AND A METHOD THEREOF

Applicant:
Tata International Limited
A company Incorporated in India under the Companies Act, 1956
Having address:
Industrial Area, Agra-Mumbai Road, Dewas - 455001,
Madhya Pradesh, India

The following specification particularly describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[001] The present application does not claim priority from any patent application.

TECHNICAL FIELD
[002] The present disclosure in general relates to field of leather tanning agents. More particularly, the present disclosure relates to a tanning composition method for preparing a tanning composition used in leather industry.
BACKGROUND
[003] Generally, leather refers to crafted animal skin obtained by physical and chemical processing such as unhairing and tanning. Tanning plays an important role in whole leather processing process. Tanning processes generally include organic tanning, inorganic tanning or a combination of organic tanning and inorganic tanning, depending on the tanning agent employed during the tanning. The organic tanning method includes vegetable tanning, oil tanning and the like. The inorganic tanning method includes chrome tanning, aluminium tanning, zirconium tanning and the like. The combined tanning method comprises chrome-vegetable tanning method, chrome-aluminium tanning method and the like.
[004] Chrome tanning is a main stream approach of current leather industry and has been widely accepted by the tanning world due to its tanning properties. Chrome tanning agent (trivalent chromium salt) is represented by basic chromium sulfate, and is prepared by using aqueous solution of potassium dichromate (bichromate) or sodium dichromate and sulfuric acid as main raw materials which is suitable for tanning various leathers and furs.
[005] Though chrome tanning is widely adopted, however, chromium ions are toxic and are one of the main pollution sources of tannery wastewater which leads pollution to the environment. Further, wet leather which are tanned with chrome tanning agents are generally bluish and is referred to as wet blue leather. Therefore, trend in leather industry is changing from chrome tanned leather to chrome free tanning for which active research is going for identifying a much-needed chrome-free tanning agent.

SUMMARY
[006] Before the present composition and method for preparing a tanning composition is described, it is to be understood that this application is not limited to the particular composition, and methodologies described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosure. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the present application. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
[007] In one implementation, a method for preparing a tanning composition is disclosed. The method comprises of treating solid waste with a predefined quantity of mineral acid and water at a boiling temperature for obtaining a soluble hydrolyzate, filtering the soluble hydrolyzate and the soluble hydrolyzate contains hydrolysate of solid waste materials. The method further includes condensation polymerisation of the soluble hydrolyzate and Phenolic acid with urea and Formaldehyde or Glutaraldehyde for obtaining polymer product, adjusting pH of the of the polymer product and blending the polymer product with vegetable extract for obtaining the tanning composition.
[008] In another implementation, the hydrolyzate composition is disclosed. The composition comprises of a chemical compound having a predefined quantity of synthetic tanning agent containing hydrolysate of collagen, aldehydes, a predefined quantity of acrylics or a predefined quantity of sulphone. Each of the predefined quantity of synthetic tanning agent containing hydrolysate of collagen, aldehydes, the predefined quantity of acrylics or the predefined quantity of sulphone undergoes condensation polymerisation with organic acid, urea and formaldehyde or Glutaraldehyde. The condensation polymerisation is followed by blending of with one or more vegetable extracts and synthetic tanning agents.

BRIEF DESCRIPTION OF DRAWINGS
[009] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.
[0010] Figure 1 illustrates a flow diagram for a method 100 for preparing a tanning composition, in accordance with an embodiment of the present subject matter.
DETAILED DESCRIPTION
[0011] Some embodiments of the present disclosure, illustrating all its features, will now be discussed in detail. Herein, the conjunction “or” is not intended to be exclusive unless otherwise noted. For example, the phrase “or alternatively” is intended to be exclusive. Further, when used in connection with chemical substitution at a specific position, the conjunction “or” is intended to be exclusive. As used herein, the adjective “exemplary” is used simply to point to an example and is not meant to indicate preference. It must also be noted that as used herein and in the appended claims, the singular forms "a", "an" and "the" include plural references unless the context clearly dictates otherwise.
[0012] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure for preparing a tanning composition is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein.
[0013] Chrome tanning agent (trivalent chromium salt) is represented by basic chromium sulfate, and is prepared by using aqueous solution of potassium dichromate (bichromate) or sodium dichromate and sulfuric acid as main raw materials which is suitable for tanning various leathers and furs. However, chromium ions are toxic and are one of the main pollution sources of tannery wastewater which leads pollution to the environment.
[0014] The present subject matter overcomes the above-mentioned problem of tanning process. In order to address the above challenges, the present subject matter develops a tanning composition and a method for preparing the tanning composition from solid waste of leather industry. The tanning composition is chrome free tanning, thereby tanning process requires organic tannages including collagen hydrolyzate aldehyde, acrylic or sulphone condensate products. The process of preparing the composition requires hydrolysis tank, steam/heating arrangement, glass lined reactor, mixing tanks etc.
[0015] Referring now to the drawings, and more particularly to Figure 1, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0016] Referring now to Figure 1, a flow diagram illustrating a method 100 for preparing a tanning composition (a composition that is used for tanning and thus may also be referred as the tanning agent) is disclosed. The tanning composition comprises a chemical compound having hydrolyzate of solid waste which contains hydrolysate of collagen, and aldehydes, a predefined quantity of acrylics or a predefined quantity of sulphone. The hydrolyzate along with organic acid which is not limited to phenol sulphonic acid, Naphthalene sulphonic acid or sulphones either alone or in combination undergoes condensation polymerisation with urea and formaldehyde or Glutaraldehyde followed by pH adjustment.
[0017] At step 102, the method 100 includes treating solid waste with a predefined quantity of mineral acid at a boiling temperature for obtaining a soluble hydrolyzate. The solid waste is obtained from a leather industry. The solid waste may include and not limited to chrome free shaving dust or trimming and split waste of leather industry. The solid waste contains collagen, aldehydes, acrylics or sulphone. The mineral acid is selected in a range of 6 % to 12 %. The mineral acid may include and not limited to sulphuric acid, hydrochloric acid, nitric acid, formic acid or oxalic acid either alone or in a combination. A required quantity of water for hydrolysis may added with the mineral acid at the boiling temperatures and the hydrolysis can be performed in a hydrolysis tank. The solid waste is treated with the mineral acid in a steam/heating arrangement at the boiling temperature selected in a range of 80 degree Celsius to 120 degree Celsius for obtaining the soluble extract. The soluble extract materials comprise hydrolyzate of collagen and aldehydes or acrylics or sulphone or mixture of all.
[0018] At step 104, the method 100 includes filtering the soluble extract. The soluble extract contains hydrolyzate of solid waste and therefore the hydrolyzate is filtered.
[0019] At step 106, the method 100 includes performing condensation polymerisation of the soluble extract with organic acid, urea and formaldehyde or Glutaraldehyde. The polymerisation reaction includes and not limited to an organic acid, urea and Formaldehyde for obtaining polymer product. The organic acid is selected from sulphonic acid of phenol, naphthalene or sulphone or similar. The polymerisation is performed in a reactor.
[0020] At step 108, the method 100 includes adjusting pH of the polymer product. The pH of the polymer product is adjusted in a range of 4 to 7 with a base. The base may include and not limited to sodium hydroxide, sodium silicate, sodium bicarbonate and may include additives. The additives may include and not limited to sodium bisulphite, hexa meta phosphate or similar, either alone or in combination.
[0021] At step 110, the method 100 includes blending the polymer product with vegetable extracts and other synthetic tanning agents for obtaining the tanning composition. The vegetable extract is selected from natural polyphenols, and the natural polyphenols is selected from one of wattle, gambier, quebracho, or tara powder or similar material. The blending is performed in a mixing tank.
[0022] In an exemplary embodiment, the method 100 may be executed to facilitate application of the tanning composition for chrome free/chromed leather manufacturing. The proposed tanning composition is applied in a range of 6% to 15% of pelt weight.
[0023] The order in which the method 100 is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method 100 or alternate methods. Additionally, individual blocks may be deleted from the method 100 without departing from the scope of the subject matter described herein.
[0024] In an embodiment, a predefined quantity of tanning composition is applied on leather during leather making process. The predefined quantity of tanning composition may include a range of 6 % to 15%. The leather is preferably also chromium-free but product can be applied in chrome tanned leather also. In the context of the present embodiment, the term “chromium-free” means not tanned with chromium salts.
[0025] In an exemplary embodiment, 100 Kgs of chrome free solid waste (Shaving dust) from tannery Tata International Ltd. Dewas Madhya Pradesh, India has been taken. A required quantity of water for hydrolysis has been treated with mineral acid in this example sulphuric acid at boiling temperatures for six hours. Hydrolyzed materials have been filtered using Nylon cloth mixed with organic acid and polymerized with urea and formaldehyde to get a tanning composition. Neutralized and additives have been added into the tanning composition. The additives may include and not limited to sodium bisulphite, hexa metaphosphate or sodium tri phosphate. The tanning composition has been mixed with synthetic and vegetable tanning agents and has been applied in leather making recipe at an appropriate dose of 6 to 15%.
[0026] In another exemplary embodiment, 100 Kgs of chrome free solid waste (Split wastet) from tannery Tata International Ltd. Dewas Madhya Pradesh, India has been taken. A required quantity of water for hydrolysis has been treated with mineral acid at boiling temperatures for six hours. Hydrolyzed material has been filtered using Nylon cloth mixed with Naphthalene Sulphonic acid and polymerized with urea and formaldehyde to get a tanning composition. Neutralized and additives have been added including sodium bisulphite. The tanning composition has been mixed with synthetic and vegetable tanning agents and applied in leather making recipe at an appropriate dose of 6 to 15%.
[0027] Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, the advantages may include those provided by the following features.
[0028] Some embodiments of the present subject matter provide an effective tanning composition from solid waste of leather industry by using hydrolysate tanks, glass lined reactors, steam and mixing tank etc.
[0029] The proposed method using a tanning agent other than chromium.
[0030] Some embodiments of the present subject matter may provide the tanning composition with reduced cost of production and cost to develop, due to simplicity in the process of preparing the composition.
[0031] The proposed composition is a gainful product from complexed nature chrome free shaving dust, trimming and split waste of leather industry due to presence of organics like aldehydes, acrylics or sulphone condensate chemicals.
[0032] Some embodiments of the proposed composition and method 100 solves solid waste disposal problem of leather industry and thus the pollution may be reduced. Some embodiments of the proposed composition and method 100 reduces effluent load since major part is collagen hydrolyzate which is biodegradable.
[0033] The proposed composition and method 100 suppress the toxicity that can be caused by the use of heavy metal components in the processing of leather. The proposed composition and method 100 provide a preparing method of a tanning composition which can prevent environmental pollution problems by not leaving components that may cause water quality and soil contamination in the waste liquid after the processing process.
[0034] The proposed composition is less-toxic in nature in comparison to conventional tanning material and suitable for all kinds of raw materials.
[0035] The proposed composition provides an enhanced characteristic and improved quality of leather after tanning with the proposed composition.
[0036] Although an exemplary embodiment of the present embodiment has been described in detail, the scope of the present embodiment is not limited thereto but various modifications and improvements made by those skilled in the art using the basic concepts of the present embodiment defined in the appended claims also pertain to the scope of the present embodiment.

, Claims:
1. A method (100) for preparing a tanning composition, the method (100) comprising:
treating, solid waste with a predefined quantity of mineral acid at a boiling temperature for obtaining a soluble hydrolyzate;
filtering, the soluble hydrolyzate, wherein the soluble hydrolyzate contains hydrolysate of solid waste;
performing, condensation polymerisation of, the soluble hydrolyzate with organic acid comprises Phenol Sulphonic acid, Naphthalene sulphonic acid or sulphone and urea and formaldehyde or Glutaraldehyde for obtaining polymer product;
adjusting pH of the polymer product; and
blending, the polymer product with vegetable extracts and synthetic tanning agents for obtaining the tanning composition.
2. The method (100) as claimed in claim 1, wherein the solid waste is obtained from a leather industry and comprises chrome free shaving dust or trimming and split waste of leather industry, and wherein the solid waste contains collagen, aldehydes, acrylics or sulphone.
3. The method (100) as claimed in claim 1, wherein the predefined quantity of the mineral acid is selected in a range of 6 to 12 %, wherein the boiling temperature is selected in a range of 80 degree Celsius to 120 degree Celsius for obtaining the soluble extract.
4. The method (100) as claimed in claim 1, wherein the soluble extract materials comprise hydrolyzate of collagen and aldehydes or acrylics or sulphone or mixture of all.
5. The method (100) as claimed in claim 1, wherein the organic acid is selected from sulphonic acid of phenol, sulphonic acid of naphthalene or sulphone.
6. The method (100) as claimed in claim 1, wherein the pH is adjusted in a range of 4 to 7.
7. The method (100) as claimed in claim 1, wherein the vegetable extract is selected from natural polyphenols, and wherein the natural polyphenols is selected from one of wattle, gambier, quebracho, or tara powder.
8. A tanning composition, comprising:
a chemical compound having a predefined quantity of synthetic tanning agent containing hydrolysate of collagen, aldehydes, a predefined quantity of acrylics or a predefined quantity of sulphone, wherein each of the predefined quantity of synthetic tanning agent containing hydrolysate of collagen, aldehydes, a predefined quantity of acrylics or a predefined quantity of sulphone undergoes condensation polymerisation with organic acid, urea and formaldehyde or Glutaraldehyde, wherein the condensation polymerisation is followed by pH adjustment and addition of additives followed by blending with one or more vegetable extracts and synthetic tanning agents.