Practical Textile A common way to finish cotton yarn is with Mercerization, which uses a very alkaline solution of Sodium Hydroxide. This treatment is done at the right tension and temperature, which improves the fabric’s shine, ability to take in color, and strength, among other things. During the process, the fiber’s physical structure changes in several ways, which changes its mechanical properties.
Mercerized cellulose is mostly just cellulose that has been watered. It still has the same chemical and physical properties, but the way it is made is different. The method has been used for a while and is becoming more well-known. If you’re looking to mercerized fabric dyeing process for knitted fabric, follow our step-by-step guide for optimal results.
Types Mercerized fabric dyeing process
The mercerized fabric dyeing process is a special dyeing process. Here two types of mercerization fabric dyeing processes are available.
- One is yearn mercerized fabric process
- Another is the Grey mercerized fabric dyeing process
Now we discuss both mercerized fabric dyeing processes. Here the fabric is knitted with mercerized yarn. So that fabric is like bleached fabric. Here I share my experience with this process. I have applied many processes for this fabric and fixed a process. By which we can avoid Unveng dyeing, Running shade and Dye spot, Caustic spot, etc.
Difference between the dyeing process of the yarn and gray mercerized:
Yarn Mercerized= Scouring and bleaching done on the yarn dyeing section.
Grey Mercerized= Scouring and bleaching done on knit dyeing section.
With Diagram a Mercerized (Yarn) Fabric Dyeing Process for Knitted Fabric Explained:
Process step by step are given below:
Acid+ Sequestering agent + anti creasing agent = Inject
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Fabric Load
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Temperature 70⁰C
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Run time 10 minute
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Drain
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Wash for 10 min
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Detergent +Anticreasing agent= Inject
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Soda dosing 5 minute
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Temperature 80⁰C
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Runtime=20 minute
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Check Absorbency
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Normal Hot Acid
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No Enzyme
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Control Ph=5-6
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Leveling dosing at 60⁰C
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Runtime: 5 minute
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Color dosing 30 minutes (Linear)
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Runtime 10 minute
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Steam Up 80⁰C (Grade=2⁰C/min)
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Runtime 5 Minute
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1st Salt 1/3 Dosing 5 minute
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Runtime 5 minute
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2nd salt 2/3 dosing 5 minute
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Runtime 5 minute
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Full Salt dosing 5 minute
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Runtime 5 minute
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Colling 60⁰C (Grade=2⁰C/min)
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Salt Sample check
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1st Time 10% Soda dosing 15 minutes (70% Progressive dossing)
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Runtime 10 minute
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2nd time 20% Soda dosing 15 minute
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Runtime 10 minute
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Full Soda dosing 10 minute
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Runtime: 10min
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Shade check
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Drain if the shade is ok
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Wash for 10 min
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Normal hot at 80⁰C
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Runtime: 10min
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Drain
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Wash for 10min
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Then soaping agent injects
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Rise temperature 80⁰C (According to shade)
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If shade is ok then Drain
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Wash and clean the water
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Fixing
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Softener (Should not use for navy or black color)
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Unload
The process of mercerizing (yarn) and dyeing knitted fabric involves several steps. First, the fabric is loaded and treated with acid, sequestering, and anti-creasing agents. It is then washed and treated with detergent and soda dosing, followed by a hot acid treatment. The fabric is then treated with color dosing, steamed, and subjected to a salt sample check. If the shade is okay, the fabric is washed again and treated with a soaping agent. The fabric is then rinsed and subjected to fixing and softening processes, before being unloaded. The entire process takes several hours and requires careful monitoring at each stage.
With Diagram a Mercerized (Grey) Fabric Dyeing Process for Knitted Fabric Explained:
Loading hot
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Full Scouring and Bleaching
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No Enzyme
⇓
Control Ph=5-6
⇓
Leveling dosing at 60⁰C
⇓
Runtime: 5 minute
⇓
Color dosing 30 minutes (Linear)
⇓
Runtime 10 minute
⇓
Steam Up 80⁰C (Grade=2⁰C/min)
⇓
Runtime 5 Minute
⇓
1st Salt 1/3 Dosing 5 minute
⇓
Runtime 5 minute
⇓
2nd salt 2/3 dosing 5 minute
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Runtime 5 minute
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Full Salt dosing 5 minute
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Runtime 5 minute
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Colling 60⁰C (Grade=2⁰C/min)
⇓
Salt Sample check
⇓
1st Time 10% Soda dosing 15 minutes (70% Progressive dossing)
⇓
Runtime 10 minute
⇓
2nd time 20% Soda dosing 15 minute
⇓
Runtime 10 minute
⇓
Full Soda dosing 10 minute
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Runtime: 10min
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Shade check
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Drain if the shade is ok
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Wash for 10 min
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Normal hot at 80⁰C
⇓
Runtime: 10min
⇓
Drain
⇓
Wash for 10min
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Then soaping agent injects
⇓
Rise temperature 80⁰C (According to shade)
⇓
If shade is ok then Drain
⇓
Wash and clean the water
⇓
Fixing
⇓
Softener (Should not use for navy or black color)
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Unload
The process for mercerized grey fabric dyeing for knitted fabric starts with loading the fabric into a hot environment, followed by full scouring and bleaching without enzyme. The pH is controlled at 5-6, and leveling dosing is done at 60⁰C for 5 minutes. Next, color dosing is performed for 30 minutes linearly, followed by steaming up to 80⁰C at a rate of 2⁰C/min for 5 minutes.
Salting is done in three stages, with the first stage dosing for 1/3 of the total salt, and subsequent stages dosing 2/3 and then the full amount. Cooling is done at a rate of 2⁰C/min to 60⁰C, and a salt sample check is performed. Soda dosing is done three times, with the first and second times dosing 10% and 20%, respectively, and the third time dosing full soda for 10 minutes.
A shade check is done, and if satisfactory, the fabric is drained, washed twice, and a soaping agent is injected. If the shade is ok, the fabric is drained, washed, and fixed. Finally, the softener is added except for navy or black color, and the fabric is unloaded.
Conclusion:
The mercerized fabric dyeing process is a special way to dye cotton fabric that makes it stronger. There are two ways to color mercerized fabric: by dying the yarn or by dying the fabric grey. Both processes have several steps, such as scrubbing, bleaching, adding color, salting, and softening, and each step needs to be carefully watched for the best results.
Research link:
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- Knitted Fabric Quality Control Parameters
- Fleece Fabric || Dyeing, Finishing, and Testing Of 100% Cotton Fleece Fabric With A Complete Practical Experiment
- Single Jersey Fabric Yarn Count And Gsm Chart
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