Exhaust Dyeing
Exhaust Dyeing
Exhaust Dyeing
®
Indanthren dyes
in
exhaust dyeing
Content
Recommendations for dyeing yarn with vat dyes for the first time................................................................................................................................................ 3
Good levelness can be achieved in vat dyeings through.............................................................................................................................................................. 4
Advantages of cylindrical and conical packages .......................................................................................................................................................................... 5
Tube systems .............................................................................................................................................................................................................................. 6
Advantages and disadvantages of winding types......................................................................................................................................................................... 7
Winding density as a function of yarn thickness and type ............................................................................................................................................................ 8
Properties of pressed packages................................................................................................................................................................................................... 9
Effect of temperature on liquor flow rate .................................................................................................................................................................................... 10
Dye liquor flow rate for cellulosic yarns ...................................................................................................................................................................................... 11
Loss in weight of cotton ............................................................................................................................................................................................................. 12
Water requirements ................................................................................................................................................................................................................... 13
Water quality.............................................................................................................................................................................................................................. 14
Complexing capacity for CaCO3 ................................................................................................................................................................................................. 16
Rub fastness.............................................................................................................................................................................................................................. 17
Colour measurement units ......................................................................................................................................................................................................... 18
Reasons for a pretreatment ....................................................................................................................................................................................................... 20
Pretreatment of cotton yarn ....................................................................................................................................................................................................... 21
Prepigmentation process ........................................................................................................................................................................................................... 23
Leuco process ........................................................................................................................................................................................................................... 24
High temperature process.......................................................................................................................................................................................................... 25
Dye selection for the high temperature process ......................................................................................................................................................................... 26
®
Indanthren Brilliant Red LGG.................................................................................................................................................................................................... 27
Hank yarn dyeing with Indanthren dyes ..................................................................................................................................................................................... 28
Dyeing of PES/CEL with disperse / Indanthren dyes.................................................................................................................................................................. 29
Finishing of Indanthren dyeings ................................................................................................................................................................................................. 30
Obtaining a deeper shade in a fresh dyebath............................................................................................................................................................................. 33
Dye selection for cross-wound packages ................................................................................................................................................................................... 34
Auxiliaries recommendation for exhaust processes ................................................................................................................................................................... 36
RoDos process .......................................................................................................................................................................................................................... 42
Dyeing on the piece dyeing beam .............................................................................................................................................................................................. 49
Indanthren combination recommendations ................................................................................................................................................................................ 55
RAISA - computer program for the application of Indanthren dyes ............................................................................................................................................ 59
Note ........................................................................................................................................................................................................................................... 60
Recommendations for dyeing yarn with vat dyes for the first time
• RoDos® process
Tube systems
Tubes Fibres Advantages Disadvantages
80 40
60 30
40 20
20 10
0 0
0 10 20 30 40 50 60
Time, min
The above values take into account the usual leaks in the package column.
The true flow rate is therefore normally 10-30 % less, but nevertheless adequate.
Boiling-off / Bleaching
4-6%
Dyeing of pretreated
fabric
Possible gain after
dyeing
Water requirements
The following amounts of water are required for 1 kg* of cellulosic yarn:
Pretreatment: 3x 10 l 3x 10 l 3x 10 l 3x 10 l
Dyeing: 1x 10 l 1x 10 l 1x 10 l 1x 10 l
Finishing: 4x 10 l 8x 10 l 6x 10 l 8x 10 l
Water quality
The process water for textile mills must meet the following minimum standard:
• Colourless / clear
• Free from vegetable and mineral impurities
• Free from iron and manganese compounds
• Soft
pH: 6-8
Hardness: max. 6 °Clark
Suspended matter: < 1 mg/l
Organic load: < 20 mg/l
Residue on ignition: < 50 mg/l
Iron: < 0.1 mg/l
Manganese: < 0.05 mg/l
Copper: < 0.01 mg/l
Nitrate: < 50 mg/l
Nitrite: < 5 mg/l
Free CO2: 0 if possible (risk of corrosion)
* at pH 11
** 1 °dH = 10 mg CaO / l water = 17.9 mg CaCO3 / l water
Rub fastness
• As the rub fastness depends very much on the substrate, the pattern card gives no data.
• If the dry rub fastness is good, it is normally not possible to improve the wet rub fastness.
• Staining through fibre abrasion and foreign bodies are not taken into account.
• Dark reactive dyeings often have better wet rub fastness than vat dyeings
(½ - 1 point).
NBS Cielab
Total colour difference: DE DE
Difference in lightness: DL DL
Difference in saturation: DS DC
(Brilliance, clarity)
Difference in shade: DT DH
Daylight: D 65
Incandescent light: A
Department store light: TL 84
Fluorescent tube light: F
Pretreatment
• Brilliant shades.
rinse.
Dyeing
of
cross-wound
packages
• ‚
80
60
40
20
0 10 20 30 40 50 60
Time, min
• ‚
®
2 g/l Dekol SN ... ml/l caustic soda 38 °Bé
... % Indanthren dye ... g/l Hydrosulfite Conc. BASF
1 - 2 g/l Peregal® P (if necessary)
... g/l sodium nitrite or glucose (necessary for dyes
that are sensitive to overreduction)
•
80
60
40
20
0 10 20 30 40 50 60
Time, min
•
2 g/l Dekol® SN
... % Indanthren dye
... ml/l caustic soda 38 °Bé
... g/l Hydrosulfite Conc. BASF
1-2 g/l Peregal® P (if necessary)
... g/l sodium nitrite or glucose (necessary for dyes that are sensitive to overreduction)
100
• ‚
80
60
40
0 10 20 30 40 50 60 70
Time, min
60 •
50
40 ‚ ƒ
30
20
0 10 20 30 40 50 60
Time, min
80
Temperature, °C
‚
60 • …
40
ƒ
20
„
0
0 20 40 60 80 100 120 140 160 180 200
Time, min
120
Temperature, °C
100
80
‚
•
60
40
20
0 20 40 60 80 100 120 140
Time, min
80
60
‚
40
ƒ
•
20
0
0 10 20 30 40 50 60 70
Time, min
• ƒ
®
2 g/l Ludigol or hydrogen peroxide 50 % 2.0 g/l Basosoft® EUK
0.5 ml/l acetic acid 30 %
‚
1 g/l Kieralon® B high conc.
80
ƒ
60
40
„
‚
20
•
0
0 10 20 30 40 50 60 70 80
Time, min
• 2 ml/l caustic soda 38 °Bé ƒ 1.0 g/l Kieralon® B high conc.
2 g/l Hydrosulfite Conc. BASF
1 g/l Setamol® WS „ 2.0 g/l Basosoft® EUK
0.5 ml/l acetic acid 30 %
‚ 2 ®
g/l Ludigol or hydrogen peroxide 50 %
0.5 g/l Setamol® WS
80
„
60
ƒ
40
…
‚
20
•
0
0 10 20 30 40 50 60 70 80 90
Time, min
* Exact value depends on dye, depth of shade, dyeing temperature, liquor ratio and levelling auxiliary.
Indanthren®
Brilliant Pink R
Brilliant Orange RK
Brilliant Red LGG ***
Red FGL ***
Red Violet RRN
Mainly used on
mercericed cotton yarn
or
viscose (embroidery yarn
Uniperol® O microperle
® ®
Rongal 5242 Albigen A Aftertreatment agent for a better
Liquid reducing agent. Insensitive to Rongal® HT Stripping and rub fastness. Removes depositions
the atmospheric oxygen. It is necessary Special reducing levelling agent. of dye pigments.
to use small amounts of Hydrosulfite agent for high
Conc. BASF to achieve complete vatting. temperature
processes. Kieralon® B high conc.
Soaping-off agent with good wetting and dispersing effect.
®
Ludigol
Oxidizing agent for high alkaline liquors Setamol® WS / BL Basosoft® EUK
too. Without fibre damage. Dye-dispersing agent. Liquid softener for all types of fibres.
®
RoDos process
100
90
80
Bath exhaustion, %
70
60
50
40 too fast
30 optimum rate
20 too slow
10
0
Dyeing time
100
90
80
Bath exhaustion, %
70
60
50
Pigmentation
40
Single addition of hydrosulfite
30 Metered hydrosulfite*
20
10
0
0 10 20 30 40 50 60
Dyeing time, min
Redox potential, mV
2 % Indanthren® Olive T ®Colloisol
- 1000
- 900
- 800
- 700
- 600
- 500
- 400
- 300
- 200
40 °C 60 °C 80 °C
Hydrosulfite
Rongal® 5242
Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH
Indanthren dyes in exhaust dyeing
80 °C 80 °C 60 °C
100 0
+ hydrosulfite
Redox potential, mV
80 -200
Bath exhaustion, %
End of metering
60 -400
40 -600
Pigmentation
20 -800
Start of NaOH/
®
Rongal 5242 metering
0 -1000
0 10 20 30 40 50 60 70
Time, min
RoDos® process
Slow reduction by metered addition
100 of NaOH/Rongal® 5242
Temperature, °C
• ‚ ƒ
80
• ‚
®
2 g/l Dekol SN 18 ml/l NaOH 38 °Bé
1 g/l Trilon® TA Powder 2 g/l Rongal® 5242 (depending on depth of shade)
... % Indanthren® dye add at a constant rate over 20 min
2 ml/l NaOH 38 °Bé
2 g/l Peregal® P ƒ
... ml/l NaOH 38 °Bé (final quantity, calculated with RAISA)
2-4 g/l Hydrosulfite Conc. BASF (depending on depth of shade)
• Better levelness.
• Easy to meter Rongal 5242 as it is liquid, stable to the oxygen in air and
water and it is active only with enough quantity of caustic soda.
When winding goods onto a beam, the following points must be noted:
The structure and density of the goods, and the diameter of the beam determine how
much can be wound onto the beam.
The following data can be taken as a guide
• Open fabrics:
Beam diameter in mm x 2 = batch size in m
O O O O O O O O O O O O O O O
O O O O O O O O O O O O O O O
Beam
O O O O O O O O O O O O O O O
Overlap
Correct overlap:
Material
O O O O O O O O O O O O O O O
O O O O O OBeam
O O O O O O O O O
O O O O O O O O O O O O O O O
Overlap
®
Indanthren dyes
+ =
Combination recommendations
for exhaust dyeing
Note