The dyeing of nylon is a special case in textile trends. Nylon fabric is used as an alternative to silk or hemp. Nylon is a reported member of its synthetic family. The dyeing of nylon with acid dyes is the most used practice in the textile industry. Yes, we are on right track to knowing about knitting, dyeing, finishing with complete practical documentation. Here I am sharing my most recent practical experience on dyeing of nylon.
Discussing practical experiment for dyeing of nylon:
- Knitting and yarn parameter of nylon fabric
- Knitting flow chart
- Dyeing flow chart
- Dyeing process
- Finishing flow chart
- Finishing porcess
- 11 Testing report of nylon fabric
- Final comments
- All step description
Dyeing of nylon knit fabric (single jersey) with practical documentation
Here I am sharing the knitting dyeing process of nylon knit single jersey fabric with a recent experiment. If you use the parameter you will get the same result which I got.
Target Parameter of nylon fabric:
| Fabric type | Lycra Single Jersey |
| Composition | 856% poliamide+ 15% Elastone |
| Color Name /Pantone | Dark Gray |
| Shade % | 0.015 |
| Repaired Diameter | 150 CM (Open) |
| Required GSM | 180 |
| Special Note | The special fabric needs special care ph and fabric handleing |
Estimated target process flow chart of Nylon fabric:
Knitting of Nylon fabric:
Imported yarn parameter of nylon:
We imported yarn from a reputed company for this cotton tencil blend fabric. I am sharing the below parameter.
| Yarn count and Type | 100D/36F Nylon+30Dly |
| Yarn Composition | 100% Polyamide+100% Elastone |
| Yarn Brand | A Reported Company |
Knitting setting Parameter of Nylon fabric:
The setting parameter of knitting to get our target fabric is in the below table.
| Setting parameter | Setting |
|---|---|
| Machine Dia and Gauge | 30 & 28 |
| Total Needle | 2640 |
| Stitch length | 29 |
| Machine Brand | Fukuhara |
| Machine RPM | 19 |
Parameter after Knitting of cotton tencil blends fabric:
After completing knitting we get the fabric parameter are stated below table.
| Setting parameter | Resutent parameter |
|---|---|
| Grey fabric width(Dia) | 164 cm (Open) |
| Gray GSM | 280 |
Dyeing of Nylon Black with acid dyes:
Here we have completed knitting of this nylon fabric. Now we have the dye the fabric. We discussing below all the flow processes of dyeing which we have done for this batch.
Dyeing of nylon process flow Chart:
Short description of cotton fabric dyeing process flow chart:
I am giving here a short description for a better understanding of all the processes.
Batching:
Knitted fabric is collected from the knitting gray store and create a batch here. Batch means they prepared fabric in a dyeable format. Knitting is done in roll to roll. Here fabric creates a rope according to the loading capacity of the dyeing machine. A batch card is also created for storing all the knitting and dyeing process parameters.
Heat Setting for the 100% cotton Heavy single jersey knitted fabric with a practical example:
Heat setting is the process of a stenter machine to control the dimensional stability of the fabric. This process is added to control the mechanical deformation of a knitted fabric like crease mark, long mark, Fabric side twisting, etc. This process is not needed for all the fabric. It is not possible to state all the fabric types. I am giving only some of the fabric which is in my mind right now.
Heat set is done for the fabric which is given below table:
| Fabric Type need to heat set | GSM range |
|---|---|
| Elastone / lycra fabric | All gsm fabric |
| Single jercy fabric | 180 and above |
| Fleace / terry | 350 and above |
| 100% polyester fabric/ PC fabric | All gsm fabric |
| Special constructional fabric | All gsm fabric( Depends on target swatch) |
| All type CVC fabric | All GSM (Which need polyester part dyeing) |
| Tightly knitted fabric | All Gsm fabric |
Heat Setting parameter of this nylon fabric and result:
Temperature : 180’C
Over feed : 20%
Machine speed : 20
Padder pressure : 1st padder- 3, 2nd padder- 2
Ist batch liquid : Lubricant & oil remover
2nd Batch Liquid : Lubricant
Before GSM : 258
After GSM : 256
| Setting parameter name | Before heat set | Setting In stenter machine | After heat set |
| Fabric diameter | 132 | 160 | 155 |
Loading to dyeing machine:
It is the 4th step of the dyeing process. Lubricant is injected into the machine for avoiding friction between the machine and the fabric surface. Then load the fabric. Cycle time, Pump pressure, Reel speed, Nozzle pressure setting controls here.
Scouring and Bleaching:
Normally scouring and bleaching are two different processes in oven fabric. But for knitting fabric, is done in the same batch. For the dyeing of nylon, we use soda ash light, and hydrogen peroxide uses for scouring and bleaching here.
Dyeing:
An Acid dyeing process is used here. This is one of the best sensitive fabrics (nylon/polyamide). So that it needs special care to get better results. This is why we use a perfect dyeing process. The result of this fabric dyeing process is good to use. I am personally using this process in my factory for better results.
After-treatment:
In this stage, neutralization is done. Then the unfixed dyes are removed by a soaping agent. Better or high-temperature soaping will give you better fastness property. But here the dye shade% is low. So that no need to high soaping. Here core neutralizer is used to get better results. But we can also use only acetic acid for naturalization.
Special note For dyeing of nylon fabric :
Over sure about the PH of the dye bath and other stages, Need proper heat setting. Lubricant must have to inject before loading the fabric. The cycle time range will be 2min-3min (Not below 2min).
Dyeing of nylon fabric recipe:
Here I gave the chemical agent name. Because I am not sharing the original brand name. The dossing depends on the dyes and chemical suppliers.
| Chemical Name | G/L |
| Detergent | 2.00 |
| Oxalic acid | 0.5 |
| Anti-creasing agent | 2.00 |
| Sequestering agent | 1.00 |
| Peroxide stabilizer | 2.00 |
| Soda Ash light | 4.00 |
| H2O2 | 2.50 |
| Peroxide killer | 0.15 |
| Acid (Neutralizing) | 0.7 |
| Leveling agent Nylon | 2.00 |
| Anti-creasing agent | 2.00 |
| Nylon Black | 3.4% |
| Soaping Agent Of Nylon | 0.80 |
| Fixing agent (Nynon) | 1.0 |
| Nylon softener | 0.10 |
Dyeing process 100% cotton fabric step by step:
Color Name : Black
Batch quantity : 10kg
Dyeing Type : Acid Dyeing.
M:L : 1: 10
Enzyme Type : No
Cycle Time : 2.5 min
Special Note : Care full about PH and the process
Scouring & Bleaching
Detergent + Anti-creasing agent = Inject
Temp 40c*= Fabric Load
Soda ash light Dosing
Temperature 60c*20 Minute
Temperature 70c
Sequestering agent + H2O2 Dosing 5 Minute
Temp to 95’C & run 50 Minute
Cooling at 78’C
Sample check
If sample ok then Drain
Normal Hot 70*10
Peroxide killer 60*10 Minute
Drain
Naturalization with acid
Drain
Wash 10 min
Dyeing
Levelling (PH 4.50-5.0)
Dyes Dosing 10 minute Tempeture 400c
Tempeture Increase 980c/10c
Runtime 30 minute
Colling 800c/10c
Shade check
If ok then Bath Drop
Cold rinse 10 minute
Soaping agent (Nylon) 2g/l (pH5.00)
Tempeture 80*15 minute
Cold wash10 minute
Nylon fixing agent 2 g/l
Cold water
Softener (Nylon 1g/l) (pH 5.00-5.50)
Unload
Finishing Process of nylon dyed fabric:
Now we completed dyeing this fabric. Now we discuss the finishing process and parameter step by step below:
Finishing flow chart of nylon fabric:
Short Description of the flow process stages for better understanding:
Slitting:
After dyeing the fabric we get it as a tube format fabric. But we have to use an open stenter and compacting machine to get a better result. So that the fabric needs to open. This is why we use this machine to open this fabric.
Setting parameter And result:
| Machine speed | 40 |
| Padder Pressure | 1.5 |
| Fabric In Diameter | 30 Cm (Tube) |
| Fabric Out Diameter | 150 Cm ( open) |
Stenter of nyon dyed fabric:
We dry the fabric and control the diameter, GSM, and shrinkage. For this, we need to appropriate setting. I am giving the setting which I did for this batch
Setting parameter of stenter :
| Setting parameter | Setting |
|---|---|
| Speed | 14 |
| Diameter | 170 |
| Temperature | 100’C |
| Overfeed | 50% |
| Padder pressure | 3+2 |
| After stenter | Result |
| Fabric diameter | 150 |
| GSM | 175 |
Compacting nylon finishing fabric:
Full dia, gsm, and shrinkage is controlled here. Better appearance and looking are done here. The overall quality of dyeing is control here.
I am giving the parameter which I did for the subjective batch.
| Compacting Parameter | ||||
| Common Setting | Overfeed | 35% | ||
| Speed/RPM | 16 | |||
| Temp | 110 | |||
| Steam Pressure | 30 | |||
| Topic | Target | Before | setting | after |
| Dia | 150 | 150 | 155 | 148 |
| Gsm | 180 | 175 | 180 | |
| Shrinkage | ||||
| Tumble dry | Length | -3% | ||
| Width | -2% | |||
| Spirality | 2% |
Special Note: Wash GSM = 194
Now the fabric is sent to the testing lab for all the test reports.
11 Best testing report of Nylon fabric dyenig
How many Tests will be done on the fabric depends on the buyer’s requirement? This batch is done for development so that the basic testing is done here. We did the best need 11 tests.
| 1. Dimensional Stability to Washing |
| 2. Twisting / Spirality |
| 3. Bursting Strength |
| 4. Pilling Resistance |
| 5. Mass per unit area |
| 6. Color Fastness to Washing |
| 7. Color Fastness to Rubbing |
| 8. Color Fastness to Water |
| 9. Color Fastness to Perspiration |
| 10. Fiber Analysis |
| 11. PHValue of Aqueous Extract |
DATE: 07 August 2021
Applicant Address: Knitting and dyeing development, Practical Textile
Contract Name:
M.K. Islam
CEO of Practical Textile
admin@practicaltextile.com
Sample Details:
Sample Received : 06 August 2021,Time:03:00pm
Test Period : 06 August 2021 to 07 August 2021
Turn Around Time : 02 Days
Sample Description & Color Name :Color 001 Black
Fiber Declaration: Nylon + Elastane
Fabric Weight: 180 GSM
Followed Care Instruction:
Test Program: Package Test
Buyer Name: Practical Textile
Conclusion of Test Results:
| S.L No | Parameter | Test Method | Result (A) | Requirement | Page |
| 01 | Dimensional Stability to Washing | ISO 6330 | Pass | ±5% | 3 |
| 02 | Twisting / Spirality | Method: 2020 | Pass | 3% | 3 |
| 03 | Bursting Strength | ISO 13938-2:1999 | Pass | 300 kPa | 3 |
| 04 | Pilling Resistance | ISO 12945-2:2020 | Pass | 3 | 3 |
| 05 | Mass per unit area | EN 12127:1997 | Fail | ±3% | 3 |
| 06 | Color Fastness to Washing | ISO 105 C08: 2010 | Pass | C.C = 4 C.S = 4 | 4 |
| 07 | Color Fastness to Rubbing | ISO 105×12: 2016 | Pass | Dry = 4 Wet = 3 | 4 |
| 08 | Color Fastness to Water | ISO 105 E01: 2013 | Pass | C.C = 4 C.S = 4 | 4 |
| 09 | Color Fastness to Perspiration | ISO 105 E04: 2013 | Pass | C.C = 4 C.S = 4 | 4 |
| 10 | Fiber Analysis | ISO 1833:2011 | STR | ±3% | 5 |
| 11 | PHValue of Aqueous Extract | EN ISO 3071:2020 | Pass | 4.0-7.5 | 5 |
STR= See the test result.
TEST RESULTS
01. Dimensional Stability To Washing
Test Method: ISO 6330:2012
Test Condition: Normal Program, Machine Wash @40ºC, Line Dry, Used Domestic Washing Machine Miele @ 1400RPM, Washing Time 02.00 Hours, Ariel Reference Detergent Solution With 4.0 Kg Load.
| Sample (A) | After One Wash | |
| Direction | Result | Client Requirement |
| Length (avg) | -4.0% | ±5% |
| Width(avg) | -1.2% |
Remark: (+) Means extension and (-) means shrinkage
02. Spirality / Twisting
Test Method :
Test Condition: Normal Program, Machine Wash @40ºC, Line Dry, Used Domestic Washing Machine Miele @ 1400RPM, Washing Time 02.00 Hours, Ariel Reference Detergent Solution With 4.0 Kg Load.
| Sample (A) | Result | Client Requirement |
| Spirality | 0.0% | 3% |
03. Bursting Strength
Test Method: ISO 13938-2:2019,used 7.3 cm2 dia
Test Stage: As Received Stage
| Sample (A) | Result | Client Requirement |
| Average | Over 600 kPa | 300 kPa |
04. Pilling Resistance (Martindale Method)
Test Method: ISO 12945-2:2020,Loading Weight 155±1gm
Test Condition: As Received Stage
| Sample (A) | Result | Client Requirement |
| After 1000 cycle | ||
| Grade | 4 | 3 |
| Note : Fuzzy Effects were observed |
Visual Assessment
| Grade | Description |
| 5 | No Change |
| 4 | Slight Surface fuzzing and/or partially formed pills. |
| 3 | Moderate surface fuzzing and/or moderate pilling. Pills of varying size and density covering the specimen surface. |
| 2 | Distinct surface fuzzing and/or distinct pilling. Pills of varying size and density covering a large proportion of the specimen surface. |
| 1 | Dense surface fuzzing and/or severe pilling. Pills of varying size and density covering the whole of the specimen surface. |
05. Mass Per Unit Area
Test Method: EN 12127:1997, Modified.
Test Stage: As Received Stage
| Sample (A) | Result | Client Requirement |
| Average | 194.7 g/m2 | 180 g/m2(±3%) |
06. Color Fastness To Washing
Test Method: ISO 105 CO8: 2010
Test Condition: Temperature at 40 degree, Time 30 min, Detergent 4g/l ECE,1 gm/l Sodium Per borate and 0.15gm/l(100% Activity) TEAD With 25 Steel Balls
| Sample (A) | Result | Client Requirement |
| Color Change | 4 | 4 |
| Color staining | 4 | |
| -Acetate | 4-5 | |
| -Cotton | 4-5 | |
| -Nylon | 4-5 | |
| -Polyester | 4-5 | |
| -Acrylic | 4-5 | |
| -Wool | 4-5 |
07. Color Fastness To Rubbing
Test Method: ISO 105 X12 :2016
Test Stage: As Received Stage
| Sample (A) | Result | Client Requirement |
| Dry Rub | 4-5 | 4 |
| Wet Rub | 4-5 | 3 |
08. Color Fastness To Water
Test Method: ISO 105 E01:2013
Test Condition: Temperature at 37±2ºC, Time 4 hours.
| Sample (A) | Result | Client Requirement |
| Color Change | 4 | 4 |
| Color staining | 4 | |
| -Acetate | 4-5 | |
| -Cotton | 4-5 | |
| -Nylon | 4-5 | |
| -Polyester | 4-5 | |
| -Acrylic | 4-5 | |
| -Wool | 4-5 |
09. Color Fastness To Perspiration
Test Method: ISO 105 E04:2013
Test Condition: Temperature at 37±2ºC, Time 4 hours.
| Sample (A) | Result | Client Requirement | |
| Acid | Alkaline | ||
| Color Change | 4 | 4 | 4 |
| Color staining | 4 | ||
| -Acetate | 4-5 | 4-5 | |
| -Cotton | 4-5 | 4-5 | |
| -Nylon | 4-5 | 4-5 | |
| -Polyester | 4-5 | 4-5 | |
| -Acrylic | 4-5 | 4-5 | |
| -Wool | 4-5 | 4-5 |
10. Fiber Analysis
Test Method: ISO 1833:2011
Test Stage: As Received Stage
| Sample (A) | Result | Client Requirement |
| Identification of fibers Analyzed fibers | Nylon + Elastane | (+3% to -3%) |
| Nylon | 91.5% | / |
| Elastane | 8.5% | |
| Fiber Label Recommended | 92% Nylon 8% Elastane | |
| Note: Based On Moisture Regain Value According To Regulation ( EU ) No 1007/2011 |
11. PHValue of Aqueous Extract
(Test Method: EN ISO 3071:2020)
| SL. No. | Material Description | Result | Client Specification |
| A1 | Black Base Fabric | 6.11 | 4.0-7.5 |
| Note: Temperature of the Solution: 22⁰c Type of the Solution Used: 0.1M KCl Solution. |
Overall Comments of Nyon fabric knitting and dyeing process:
After analyzing all the test reports I can say that the GSM of the fabric is low. Normally we tolerate +/- 3%. Bet
Solution: There are many ways to solve the problem. During geat setting, We have to control the GSM.
Because: After wash and relaxed condition gsm will be excessively high. So that we have to careful during heat setting.
The video of the final finish fabric (Dyeing of nylon)
The video will show how the finish fabric is.
Conclusion:
I am sharing here my full dyeing of the nylon experiment. I discussed the full knitting and dying process with a flow chart. A complete practical Gide line is available here. Of course, everyone can ask me any process-related question in the comment section. I will answer the entire question. As a textile engineer, I think I can solve problems from my 10 years of practical experience.
Reference:
- https://en.wikipedia.org/wiki/Nylon#Production_of_nylon_fabric
- https://www.sciencedirect.com/science/article/abs/pii/S0379677921001454
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