Development of Novel Formaldehyde-Free Melamine Resin for Retanning of Leather and Reduced Effluent Discharge in Water

The objective of this study was to develop a novel melamine-based resin suitable for producing formaldehyde-free leather with improved retanning properties. The resin was prepared by optimized condensation of melamine, glyoxal and metanilic acid. The novel resin was compared with a commercial resin against different parameters. Functional group analysis of the polymer structure and the route of synthesis was verified with the help of FT-IR spectroscopy. A Leica metallurgical microscope coupled with a CCD camera was used for SEM analysis. The results revealed that the mechanical and organoleptic properties of the novel resin were better than those of the commercial melamine resin. Tensile strength, tear strength and percentage elongation of leather were increased by 17.43%, 10.41% and 8.62%, respectively, in the direction parallel to the backbone, while the increases in these parameters were 15.17%, 9.79% and 6.0%, respectively, in the direction perpendicular to the backbone at the same dose. We observed a 100% reduction in free formaldehyde content in retanned leather as well as in effluent produced by the novel melamine resin. Pollution load study of effluent showed reductions in chemical oxygen demand, total suspended solids and total dissolved solids by 9.21%, 5.60% and 6.97%, respectively, for the novel melamine resin, reflecting its improved exhaustion. The fiber structure of the leather produced by the novel melamine resin was more orderly arranged, showing its improved retanning. These results prove that the novel melamine resin is an effective retanning agent suitable for producing formaldehyde-free leather with a reduction in effluent pollution load. This work introduces an alternative to formaldehyde for amino resins to address its carcinogenic effects.