Académique Documents
Professionnel Documents
Culture Documents
Present textile market is buyers' market. The consumer dictates the term as far as the quality, quantity and
delivery schedule are concerned. To withstand such competition . the manufacturers/processo rs have to
adopt total quality management approach so th at not only they ge t the ~ond~ processed ri ght at the first time,
but quality is ensured. I ncreasing environmental polluti on a\l4areness has thrown new challenges before the
textile technocrats. The present paper reviews the new developments in the field of d yes manufactured,
methods of application and machinery used . It also takes into account the impact of advent of micro fibres and
specihc developments in processing of terry-towels, garments. etc. The future trend is also predicted based on
all the above factors.
Keywords: Dyei ng. Disperse dyes. Reacti ve dyes. Polyester fibre. Cellulosic fibre. Wool fibre , Silk fibre .
Dyeing machinery
1 Introduction
The globalization has widen the scope of the textile
business with the inevitable entry of international competition. The challenges and opportunities are increasing and the appropriate response has to be evoked.
in terms of technological advancement and on-time
delivery . Such "quality and quantity" supply has to
be done on the basis of right-first-time , right-everytime, quick response approach. While this is being
attempted, it is also incumbent to consider reduction
in energy and production cost. The challenges posed
by this decade revolve around the conservation of
environment, an issue which has aroused the attention at global level and will direct th!! future chemical
technological adva ncements predominantly.
The emergence of new materials such as polyester
microfibres, increasing applications of computer technology for recipe prediction as well as for expert
systems of dyeing and fini shing, and the increasing
use of microprocessor-based process monitoring
and control equipment will stimulate the fin e tuning
of our production efficiency and effectiveness as well
,\seconomy. The opportunities placed before us, of
course with a package of challenges, in post-GATT
period need to be exploited and it is the technological
advances which will be playing major role in shapin g
the destiny of thi s industry.
When one talks about technological advancements in dyeing process control it is natural tha t the
majority of these advances are concentrated on dyeing of woven fabric . However, d yeing of garment,
terry-towel, microfibre and hosiery or knit goods
2 Developments in Dyes
The technological developments in the dyestuff indu st ry are taking place from the point of view of:
42
Disperse dyes are used to colour polyester. Anthraquinone dyes have much lower colour values and are
more expensive although they give valuable bright
red, blue and turquoise shades whereas azo dyes offer
a full shade range and high colour values. With the
advent of jet dyeing and tHermosol application , the
search for new chromophores has led to the development ofbenzodifuranone dyes of high colour value,
brightness of shade, good substantivity and low thermomigration. Some of the new disperse dyes available are:
Resoline Brilliant Red F 3GS (Bayer) has good
fastness to dry heat fixation and high brilliance
which is required for fashion polyester and poly.ester/cotton sports and leisure wear.
'
BASF has introduced a new series of Pal ani! dyes
in its Palanil disperse range- Palanil Black G,
Red FFB, Navy Blue GN, Navy Blue-CF, Brilliant Blue BGFN and Brilliant Blue BGM-CF.
These dyes are available as low-dusting powders/
liquids .
Palanil Bue BGFN : Suitable for polyester blend
dyeing, it is insensitive to dyebath pH and reduct ion.
2.2 Reactive
O V,,'S
Zencca's Proc io n H-EXLexh a ust d yes (hifunctio na l) ha ve been engineered to produce hi gh performance le vel d ye in g, mi gration , diffu sio n a'nd
exceptional build-up pro perties.
Of the reactive d yes available toda y, new Rema zo l
EF d yes significantl y reduce waste in e fflu ent , cl a im s
Hoechst. These dyes
Require 33-70% less salt than conventional reactive d yes,
Prov ide higher fix a tion under low salt conditions
as compared to conventional reac ti ve dyes, and
Arc available in environrnental safe pack agin g
(low-du st powd ers or liquid s).
Rite Indu stri es Inc. ha s launch ed the Rite Reactive B se ries of d yes whi ch a llow to reduee the
amount of salt to be used in the d yein g with similar
advantages .
43
Durin g the d yeing of po lyester fibre. the conventional dyein g liquor contain s la rge a1Tlounts of di spersing agents a nd s urfactants which are used to ge t rea so na ble ra tes of d ye ing, ensuri ng levelness. Thi s leads
to an effluent loaded with dye and dis persing agent s
which is to be treated with an ever increasing cost. One
radically new a pproach is to use supe rcritical CO 2
med ium for dyeing P ET with disperse d yes 9 . Afte r the
dyeing o perati o n is conwlete, dry d ye powder, which
has no t been used up. deposits at the bottom . There is
no necessit y of dispersing agent or carrier. H oweve r.
thi s dyein g requires di sperse dyes of special structural
features. free from dispersing agents. Also. the cost of
eq uipmcnt an d pipings is hi gh. Bl~t the operational
costs are very low as compared to that in conventional
dyeing meth od (requires only 1/ 5th of the e ne rgy) .
There is also no requirement fo r red uction clearing
trea tment s, washings, dryin gs, etc., thereby saving
time a nd energy and providing protecti o n to environment. Thi s meth od loo ks to se t further the cause of
QR and hence QM .
Rece ntl y, H oec hst Mit s ubi shi Kase i (HMK) ha s
made poss ible the d ye ing of pol yes ter in an alkalinc
medium . thereby makin g the e ntire wet processi ng
simple and reproducible. The quality of dyed materials is also improved. In addition , the problems due to
the presence of pol yes ter oligomers in acidic d yei ng
conditions are also minimized 10.
The HMK system involves both alkali-resistant
d yes and a newl y developed stabilizer JPH95 for dyes
fo r alkaline conditions. The stabilizer has many functi o ns s uch as buffering the dyebath pH to around
9.0-9.5 during d yeing, stabilizing dyes. chelating metal io ns and dissolving oligomers. The small variation
in pH during the dyeing cycle promotes excell ent reproducibility.
3.2 Cellulosic Fibres
Man y ideas surround the concept of blind coloratio n, ranging from a simple no addition dyeing to the
management of all those factors that affect the coloration o fa textile, resulting in a right-first-time dyeing.
The latter definiti o n implies the total control of all
factors (including the human ones) that can influence
coloration and ca use a shade to deviate fro III the standa rd .
44
70-80%
> 90%
> 70 %
A comparison ofRCM of individual dyes will provide a measure of the compatibility of dyes when they
are used in combination. Dyes with simi lar performance and with substantivity, migration index, LDF,
and Tso values within the target specification will offer
robustness to small variations in processing condition s, shade reproducibility and level dyeing performance l2 .
Newer developments controlling add iti ona l paramete rs relati ng to the physical characteristics of the
substrate take into acco unt the influence of me chan ical and hydraulic forces exercised by the machine during the process l3 . The control eq uipment a ll ow the
hydraulic and mechanical action of the dyeing machine to be adjusted, not only for the entire process but
also for each period in the dyeing pcocess. This principle is utilized in the sync hron dyeing control system,
whic h sy nchronizes liquor circulation, fabric speed
and process cycle l 4 .
The a lk a li dosing process is becoming popular as a
rationalized dyeing method for reacti ve dyes 6 - s .
Many types of reactive dye can be used , but the optimum pH range will depend on the nature of the dye
employed . To control the rate of exhaustion, it is desirable to use a dye that reacts over a wide pH range so
that the conditions can easily be controlled during
dyeing. The Sumifix Supra range of dyes contain both
a vinyl su lphone group a nd a monochl o rotriazi ne react ive group. The y react with ce llul ose ove r a wide pH
range and are, therefore , suitab le for use in such opti mized dyeing processes I 5 .
Thesc d yes ha ve bee n ada p ted both fo r exhaust
d yeing and semi -continuous operations. Hi gh fixation, low substanti vity and good diffu sio n, effect ing
rapid and efTicient rcmoval of sma ll amounts of unfixcd dye, are the sa lient fea tures o f these dyes. To increase the fixation of d ye, the one of the most popular
alternat ive ene rgy sources which could he used is radio-frequency (RF) energy.
Heatin g of the batch with radio-frequency energy
during the batching stage grea!ly acce lerated the rate
of fixa ti on. Fixa tion leve ls ac hie ved usi ng opti mi zed
R F-assisted methods were approximately equival ent to those achieved in co nventional pad-batch dyeing l6 .
Dawson International , in 1978, patented a process
and the equipmen t design used for fixing dyes or chemicals with RF energyl6. The process involved continuous conveying of treated fibres through closely confin ed tube located between flat parallel e lectrodes.
By generating RF energy field within the tube, a se lf-seali ng pressure chamber was created by the formation of steam from the wetted fibres. The advantage
claimed was an increase in the reaction rate ofthe dye
on the fi bre.
The semi-continuo us pad-batch process using RF
energy has also been recognized as one o f the most
efficient methods ofapplying reactive dyes to cellulosics with exce ll ent reproducibility , leading to ri ghtfirst-time every time concept.
Laser fixation is a feasible low-heat trea tment method for fine-line dye fixation . A comparison of wash
fastness of ha nd-ironed and laser-treated specimens
showed that the specime ns treated with a n argon -i on
laser at 129C and 23YC maintained color significan tly bcttcr than thc specimens trcatcd with a lowcr lascr
heat (94C) and hand iron ( 190C). This was true for
10, 20 and 30 washes. A laser tempera! ure of 129C
was as effective in setting fibre reactive d ye in cotton as
was a laser temperature of 23C, ind ica ting that a
lower energy laser would be as useful in settin g dye as
higher power models 17 .
Electromagnetic hea ti ng produces d yei ngs of si milar shades to those obtained by conventional heating
when pressure and temperature conditions are kept
the sa me for both treatme nts. However, e lectrom agnetic heating allows smoother and more homogeneous boiling tha n docs conventional heating and can
be useful industria ll y 18 .
Lewis and eoworkers l 9 ca rri ed out fibre pretreatments a imed a t dyeing with reactive dyes under neut-
ral to sli ght Iy acid ic co nditi ons in the absence of elec trolytes. All of th ese' treatment s introduce cationic
(basic) resid ues in the form of quarternary, terti ary
and seco nd ary am ines.
One of the most co nveni ent pretreatments wa s to
apply polyamide epic hl o rohyd rin resin to the cellul osic fab ric usin g pad-dry syste m. Selection of highl y
reac tive d yes gave good co lo ur yield o n thi s type or
fabr ic a nd the fixation of dyes proceeded si mpl y by
ap pl ying them from a dyebath se t a t pH 5 a nd raising
the temperature to boil. Unfortunately. rin g dye ing
of tb e fibre a nd ya rn s was clearly evident and as a
result, li ght fas tness red uced by 1-2 points. These drawbac ks, howeve r, have bee n overco me by th e use or
low molecular we ight species a nd pretrea tin g the co tton fabric using a pad-th ermollxa ti on tec hnique .
Anot her adva nt age is th e need fo r sho rt er was hin golfp rocess to remove the unfi xed dye because of hi gh
level or dye -libre fixation ac hi eved.
In eo lo ura ti on of cellul osic fibres. vat dyes (including Indi go) and sulphur dyes ho ld a la rge part of th e
dyestuO' mark et. Vat dyes give exce ll ent fa stness,
whereas sulphur dyes a rc economical with good degree of fastness properties. The red uction process employed here req uires reducing age i1t s and it has ye t not
been possible to regenera te th ese co nven ti ona I agents, except in th e sta ndin g dyeba th procedure .
In recent inves tigations, an elec tro lytic process was
used to <lchi eve dye reel uction ~O. In eli rect electrolysis,
the dye itself has to be rcduced at the surface of th e
ca th ode, whil e in indirect elec tro lys is the reducing
power of the cat hode is transferred to the solution by a
soluble redo x sys tem (mediator) . This reversible redox system is continuously rege nera ted at th e cathode so th a t a renewal of th e reducing agent is achieved. Thi s tec hnique offers th e possibility of full dyebath recyeling, including the reuse o f reducin g agents.
Co tt on may readil y be modified by pret rea tment
with N-methylolacryla mide to introd uce penda ntacti va ted double bonds. These have been ex ploited in
two ways to imp rove the reacti ve dyeing o f co tton.
Firstly, by introducing a min o residues at these new
sites, excellent dyeings with reactive dyes can be achieved a t pH 5-7 in absence of an electro lyte, coupled
with a ve ry hi gh degree of fixation. Secondl y, it is
possi ble to dye th e cellul ose, modified o nl y with
N-meth ylo lac ryla mide, with dyes co nt aining pend ant aliphatic amino residues. In thi s case, it is necessary to dye in the presence oran elec trol yte under alkaline condi ti ons but ve ry hi gh colour yields are obtained, thank s to th e elimin a tion of th e hyd rolytic side
reactions nOrill all y associa ted wit h n:acti vc d yeing.
45
46
A ut o ma tion or the d yei ng process avoiding inco rrect a ddi ti o ns of dye so luti o n, auxiliaries a nd
che mical s: mo reove r, the re are no idl e times.
Reliabilit y of the process, because th e re is a lwa ys
an o ptimum reac ti o n medium a vailable for th e
d ye in g process.
- Increased repro duc ibilit y b y ex act rcpetiti on of
the d ye in g process.
Optimi za tion of the leve ln ess .
Cost sa vings by using caustic a s fixation alkali
in s tead of soda (e.g. in reac ti ve dyeing).
Cost sav in gs by usin g acid (acetic o r fo rmic ) in
woo l/ po lya mid e d ye in g.
- Simplilica tion of the rinsing a nd washing processes in reac ti ve d ye in g, owing to less h ydrol yzate
fo rmati o n during the d yei.ng process.
Ort e n it is possible to reduce th e d ye in g time.
M o re re li a bl e sho rt liquo r d yei ng, especially wit h
dark colours. By met erin g-in the d ye, the co nce ntra ti o n of d ye in the d ye bath is reduced so th a t no
agglo meration can occur.
Increasin g automation in application o f dyes to the
fibre substrate ha s been o ne mo re guid in g principle in
th e d eve lo pment of the machin e ry as d esc ribed ahove. One of th e typi ca l examples in exhaust d yein g is
ADC-200, a me tering device de ve lo ped by Hoec hs t
a nd ADCON. The process, mo re known a s Ra maza lautomat, me ters the supply o f a lkal i for the li xat io n
o f th e reac tive d yes a ut o ma ticall y and prog ressively
in order to o btain the hi ghest leve ln ess in sho rt es t
d ye in g time.
The eme rge nce or short liq uo r je ts fo r d ye ing cotto n and it s bl end s has bee n mark ed over recent yea rs.
Not only d ocs thi s process offe r the po ss ibilit y of
more eco no lllical d ye ing but it also reduces the load
inflect ed o n the en vironment to the tun e or 30% (rd.
29).
On-line con trol s in continuous d ye in g are ro und to
be elTective in improvin g th e cost ellicie ncy and rep roducibi!ity. Forexample, on- lin e liqu o r pi c k-up meas urement wit h level co rrecti o n and co ntro l e n:lblcs
precise calculation of the vo lume o f li qu o r Ileelled
and conseq ucntl y savin gs in the cost of dyes a nd auxi liaries. On-line colourimctry orthe p;ldJed rab ri c improves th e contro l over th e prod uc tio n process wit h
reliability and imp ro ved quality'o .
4, I J igg('r Dye ing
47
5 Garment Dyeing
. Whil st garment dyeing has an in-built lead time
advantage for producing comparatively sm'all tots,
the com bined effect of customers wanting larger lo t
sizes quicker and more reprod~cibility and the advances in response time made by the colouration routes
has driven development in gannent dyeing technology.
5. 1 Dyes
The component units of the contin.uous dyeing ranges are being modified from time to time to minimize
the possible imperfections in the final dyed product.
Development work regarding these component units
is still .in progress. The points which have been a nd
which will still be considered during such work include:
Co mposition and formation of pad rollers,
Pre-drying by infra -red radiation to avoid possible mi gration , with vertical fa bric passage , a nd
Well-designed and evenly impinging hot flue or
high-temperature dryers for thermoso l dyeing.
With the advent of synthetics and blends, the thermosol system is bound to achieve a very promising
position .
The most recent development from Gilwood (Fabrica tors) Co. Ltd, a British machine maker, is an oval,
double side-paddle machine for dyeing readymade
knitwear. Machine capacity ranges frum 150 to 6800
litres. Positive dye penetra tion is achieved by speci ally designed paddles fitted with synchronised dri ve
for enhanced liquor circulation . An innovati ve recirc ulation system delivers heated liquor simultane~u
sly to the two-paddle a rea, significantly improving
the overall temperature controp5.
48
The recent inn ova ti o n in convcntional drum dyeing machine is the one with liquor circu lation through
the drum centre. Thi s helps impart ing an extremel y
gentle treatment to the goods even at low liquor ratios. i.e. I :6. Thi s kind of machinery has the advantage
of dyeing all kind s of hosiery. The goods dyed can al so
be cent,:ifuged in the same machi ne which means in vestment costs ["or centrifugers a re a voided. The technica l advanta ges include:
Level dyei ng due to rapid liqu or interchange.
Reduced wate r eilluent and less steam and chemical co nsumption because of operations at low liqlI or rati os. and
- In-built hydroex traction " .
The newer machinery for garment dyeing are based
on the foll owin g feature s: (i) Low liq uor rati o, (ii)
Microprocessors- for improved lot-t o-I ot reprod ucibilit y, (iii) Hea t exc ha nge rs - for rapid heatin g
uJ1dcoo ling. (iv) !....int filte rs) (v) Ce ntrifugal hydroextrac tion , (vi) Ea sy sa mplin g with out droping dye
liq uor. (vii) Tilting- for ease of loading /unl oa din g,
(vi ii ) C ushi o ned suspension, (ix) Variable drum
speed, and (x) Automatic balancin g drum .
What is importa nt in garment dyeing is to achieve
level dyeing, with excellen t penetration in short dyeing cycle. The de ve lopments a rc thus directed towards these aspects .
6 M icrofibre Dyeing
The microfibres are the lates t entrant in textile marke t a nd ha ve inherent adva ntages for which their co nsumpti on is increasing day by da y. Howeve r, because
the microlibre has inc reased su rface a rea , th e rate of
dyeing is tremendo usly enhanced and it becomes essen ti al to co ntrol the dyeing of microfibres to avoid
uneven dyeing. The dyeings obtained a re also apparently lighter as compared to the ones with the norma l
denier pol yester yarn and it is difficult to ge t th e dee p
shades in microdenier varieties. The fast ness to washing. rubbing and li ght is inferior to th at of norm al
denier pol yes ter. This necessita tes the selection of
proper range of disperse dyes specially suited for microfi bres.
The Fo ron RD dyes of Sandoz seem to be perfo rming favo ura bl y. To improve th e li gh t fa stness of the
dyed microllbres, use ofFadex R F liquid is recommcnded since thi s acts as a kind of UV -abso rber. A number of dyes manufacturers are making the selection of
dyes from the pont of view o f their a ppl ica tion on
micro Ii bre fa bric .
7 D)leing of Hosiery/Knits
In dyeing of kn ilted fabri cs. co ld bran d as well as
hot brand reacti ve dyes and also the direc t dyes are
6
7
8
9
10
II
12
13
14
IS
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
49