Defects in Dyeing with Reactive Dyes

Defect: Colors are not fast to washing, Abrasion;Staining in the fabric when transporting
from place to the other, water marks on the fabric
Remedy : Wash the fabric with soap and soda ash at right temperature. Adding sequestering
agent will yield good results. Treating with Ammonia will also give good results.
Defects in the fabric due to Printing- Need to take out full color
Remedy: Treat the dyed fabric with Sodium Hydrosuphite with 5-10 gm Sodium Hydrosulphite
at 75 deg C for 30-45 minutes. Add 5-7 gms Caustic Soda for even removal of colors. The color
becomes light yellow or brown after removal. Wash it thoroughly with soap.
The color can also be removed by solution of Sodium Hypochlorite. Treat the fabric with a
sodium hypochlorite solution ( 3-5 gms Chlorine) for 20-30 minutes. Keep the pH between 9-10.
The fabric is treated with Acetic acid after removal of color to remove chlorine and to neutralise
the fabric.
The fabric can be redyed after removal of color
Defect: Bleeding in colors during washing, abrasion
Remedy: Boil the fabric with caustic, Treat the fabric with Hydrogen Peroxide ( 5-10 gpl, 60-70
deg C) to make the color fast.
Defect: The fabric has been dyed in darker shade, uneven dyeing
Remedy: To take out color from the fabric treat it with caustic for 45-60 min at 70 deg C.
Thereafter treat the fabric with 10-20 gpl Acetic Acid for 40-60 min at 80-85 deg C.
Defect: Uneven dyeing, marks of water, marks of colors
Remedy: Wash the fabric in soap and redye in a darker shade
Defect : The fabric has become stiff and rough after dyeing
Remedy: Finish after adding right softner
Defect: Color staining of fabric, uneven dyeing
Remedy: Redye the fabric in darker shade.
Defect: Color staining in fabrics of darker shade, uneven undyeing
Remedy: Dye the fabric in Sulphur black
Caution: Please treat a small length fabric to check the effectiveness and any harmful
effects before commencing a full treatment.
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Common Causes of Dyeing Defects:
It is important that the general precautions should be followed while dyeing a textile material. It is always helpful
to keep a record of all the conditions (including temperature, time, conc of color, chemicals, material to liquor
ratio) in order to get an even shade in each batch. In general the following are the common causes of dyeing
defects across all the categories of dyes:
1. The material is not well prepared for dyeing and printing
a. Material having dead fibres or other defective fibres
b. Left over of Chemicals after bleaching etc.
c. Material not properly desized
d. Material not properly mercerised.
e. Absorbancy of the fabric not proper
f. Sticking of insoluble material on the fibres
g. Impurities are not removed properly
h. Uneven heat treatment.
2.Water Quality not Proper
a. More Hardness of water
b. Water has metal ions such as iron.
c. pH of water not proper
d. Water having more chlorine
3. Due to Shortcomings in making Dyeing Solution
a. Improper weight ratio of colors, material and chemicals.
b. Improper material to water ratio
3. Improper filtering of concentrated colors.
4. Due to Shortcomings in the dye machinery
a. Coming out of Dye liquor during dyeing
b. Defective instruments controlling temperature, pressure speed etc.

fJIGGER DYEING
thE Fabric is wound around one of the rollers; during dyeing the fabric is passed through the dye
bath and rewind on to the second roller.
When all First the fabric is passed through the dye bath the direction of movement is reversed,
this would be repeated until the dyeing is completed. During dyeing tension is imparted in
length of the fabric.
Suitable for delicate fabrics & light wt. Fabric.
Low liquors ratios (1:2 to 1:6) the consumption of chemicals and energy is low.
Knitted and stretch woven fabrics cannot be used
Machine Details
Machine make: Swastik (India)
Number of operator: 1 operator per 2 machines
Total number of machines: 13
Production: 20,000 m/ 13 machines/ day
Speed of the machine: 60 m/min
Roller pressure: 70 75 Kg/cm
Maximum Temperature: 80 C
SCM Textile Processing Mills in Erode.
PROCESS FLOW
SAMPLING (COMPUTER ART DESIGN)
STRIKE OFF FOR SAMPLING (SMALL SCREEN DEVELOPMENT)
PARTY SAMPLE APPROVAL
BLD (BRIGHT LIGHT DUPLICATE)
ROTARY SCREEN EXPOSING
PRINTING
SCREEN PRINTING
The respective screens are mounted on the roROTARY tary heads
Selected squeegees are inserted and connected to the respective colour pumps
The fabric to be printed is fed to the blanket and gets printed by the respective screens in
continuous manner
The printed fabric is conveyed through dryer and plaited
Machine details:
Machine make: Stomac
Machine width: 70 inch
Numbers of colours possible: 12
Numbers of operators: 1 operator and 4 assistants per machine
Printing speed: up to 80 meters/minute

PRINTING
Pigment printing is one of the simplest direct styles, which is applicable to all class fibres
Since the pigments are insoluble colouring PIGMENT matters, they are physically applied by
means of binders.
DISCHARGE PRINTING
Discharge prints are fabrics that are dyed a solid colour prior to printing.
The design is applied by screen or roller with a chemical a reducing agent which removes the
colour of the originally dyed fabric.
Cotton Dyeing:
Temperature: 60-80 degrees
Pressure: atmospheric pressure
pH: 10.8 11.4
Dye: Reactive dyes
Time: 45-75 min
Polyester Dyeing:
Temperature: 130 degrees
Pressure: 2kg/cm2
pH: 4 - 5
Dye: disperse dye
Time: 2 hours
Bleaching
Checking pH (process before pH =5.5-6)
Dyeing (pH = 7-9)
Shade checking
Soaping (95 degree Celsius for 15-30 minutes)
pH stabilization + finishing

Machine Details
Machine make: THIES
Number of operator: 1operator and 1 assistant per machine
Total number of machines: 7
Capacity: 1080 kg/batch