Which Dyeing Process Produces The Most Colorfast Fabric?

Today I am discussing “Which Dyeing Process Produces The Most Colorfast Fabric?”. Yes, it is a most important and technical question in the dyeing industry. The dyeing process depends on the behavior of dyes and the selection of dyes depends on the fabric properties. Colorfastness depends on the bonding of dyes and fabric. So we have to select the dyes and their dyeing process which will create good bonding between the dye and fabric.

which-dyeing-process-produces-the-most-colorfast-fabric

The key factor which reflects the topic:

  1. Fabric behavior
  2. Dyes behavior
  3. Dyeing process
  4. Colorfastness

Fabric Behavior:

There are different types of fabric is available according to their fiber properties. Such as Polyester, cotton, wool, silk, and many more. The most using fiber is polyester and cotton. So that we are selecting only two

Cotton fabric and polyester fabric

Dyes behavior:

There are many types of dyes that are invented in the present world. Such as reactive dyes, Disperse dyes, Acid dyes, vat dyes, natural dyes, mordant dyes, basic dyes, sulfur dyes, azoic dyes, and many more. 

All the different dyes are used for different types of fiber. According to their fastness property, reactive dyes are the best for cotton fabric and disperse dyes are the best for polyester fabric. 

So we can say that

The reactive dyeing process can produce the best cotton colorfast fabric.

The Disperse dyeing process can produce the best polyester colorfast fabric.

Dyeing process:

The dyeing process is so important to get the best colorfast fabric. I am sharing the best reactive and Disperse dyeing process which I personally applied in my factory. These are stated below:

Reactive dyeing process:

Reactive dyeing creates a bonding between the fiber and dye molecule.

Load the fabric

Anticreae+Detergent Inject = For remove impurities

Wash and Drain

Detergent+Anticreasing agent+Oil remover+Peroxide stabilizer inject

Caustic soda dossing 10min

Run time 5min

Rise temperature at 70 ⁰C

Inject the Hydrogen peroxide

Rise the temperature 98 ⁰C

Run time 60 min

Cooling at 78 ⁰C

Shade check = Check the whiteness and absorbency

If ok drain

Normal hot at 80 ⁰C

Run time 10 min

Inject Acetic acid = For neutralization of Soda

Run time 5min

Drain and wash for 5min

Peroxide killer Inject run for 5min

Drain and wash 10min

Rise the temperature at 55 0c

Control PH= 4.5 with acetic acid

Inject Enzyme

Run time 40min

Check sample hairiness

If ok then raise the temperature at 80 0c

Run 5min

Drain and wash the enzyme dust

Start dyeing

Leveling pH check= PH 5.5 – 6;

Levelling Dosing 600c 5 minute

Runtime 10 minute

Color Dosing 25 minute

Runtime 10 minute

Salt dosing 10 minutes

Runtime 10 minute

Salt Sample Check and Fabric Quality check = The evenness of dyes

If ok then

1st Soda dosing 20 minutes (10%)

Runtime 10 minute

2nd Soda dosing 20 minutes (80%)

Run time 15min

Sample Check

Shade ok and then drain (Rinse drain is better)

Normal, not 80 0c run 10min

Wash until clear the loose dyes (Not more than 20min)

Inject soaping agent

Rise 90 0c and run 10min

Check shade if the ok drain

Wash clear

Fixing agent dos 5min

Runtime 10min

Wash clear

Softener dossing 7min

Check softness if ok

Unload and deliver to finishing

Special Note for reactive dyeing porcess:

In the reactive dyeing process, I underlined some steps which are the main key factor to get the best colorfast fabric. Soaping, washing, and fixing is the main key point. So that you should not change anything here to get better results.

I have a 100% applied experiment with a colorfastness report. You may check by clicking here.

Disperse dyeing process:

Disperse is a thermodynamic process. Here the temperature is so important factor. The process steps are below:

Load the fabric

POLYESTER PART START

Oxalic acid+Detergent Inject = For remove impurities and neutralization

Run time 10min

Drain and wash for 5min

Acetic acid inject= For Control PH: 4.2 to 4.5

Rice the temperature at 80⁰C

Disperse dye stuff dossing 30min = For polyester part dying

Rise the temperature80 ⁰C to 95⁰C Grade 1⁰C = Grade for better penetration

Then rise temperature 95 ⁰C to 135 ⁰C Grade: 0.5 ⁰C

Run for 45min

Cooling at 135 ⁰C to 95 ⁰C grade: 1 ⁰C

Then 95 ⁰C to 79 ⁰C directly.

Check the sample = To achieve the required shade

If the shade ok then drain the dye bath

Normal hot at 80 ⁰C

Run for 10min

Wash for 10min

Caustic soda dossing 8min at temperature 50 ⁰C

Run for 5min

Rise the temperature at 80 ⁰C

Inject hydro’s = for removing the loose disperse dyes

Rise the temperature at 90 ⁰C

Run for 10min

Cooling at 80 ⁰C and drain

Normal not at 90 ⁰C for 10min

Wash for 10min and drain

Polyester softener

Unload fabric and delivery to finishing

Special note for disperse dyeing process: 

Here the underlined portion is so important and you should not avoid getting better fastness results.

One more thing after unloading fabric you have to use a low-temperature (Not above 100 degrees) finish process. If you rise above 100 degrees it can migrate color which will affect directly the color fastness property.

I have a 100% applied experiment with a colorfastness report. You may check by clicking here.

Colorfastness property:

This property represents the durability of color. That means how long lasts the color is. This is measured by different ISO-certified methods. It depends on the requirement of users. Most using  colorfastness methods and types are stated below:

1. Color Fastness to Washing

2. Colorfastness to rubbing 

3. Colorfastness to water

4. Colorfastness to Perspiration

5. Colorfastness to Light

6. Colorfastness to Hotpress

Color Fastness to Washing

Test Method: BS EN ISO 105 CO6-A1S:2010 

Test Condition: Temperature at 40 degrees, Time 30 min, Detergent 4g/l ECE With 10 Steel Balls 

Colorfastness to rubbing 

Test Method: ISO 105 X12:2016 

Colorfastness to water

Test Method: BS EN ISO 105 E01:2013 

Test Condition: Temperature at 37±2ºC, Time 4 hours. 

Colorfastness to Perspiration

Test Method: BS EN ISO 105 E04:2013 

Test Condition: Temperature at 37±2 degrees, Time 4 hours. 

Colorfastness to Light

Test Method: BS EN ISO 105 B02:2014, Air Cool Xenon, Arc Lamp. 

Colorfastness to Hotpress

Test Method: BS EN ISO 105X11:1994* 

Test Condition: Temperature at 150C

Final word for the topic Which Dyeing Process Produces The Most Colorfast Fabric:

The final word for the question “Which Dyeing Process Produces The Most Colorfast Fabric?”  is 

The reactive dyeing process can produce the best cotton colorfast fabric.

The Disperse dyeing process can produce the best polyester colorfast fabric.

You can get some more information from the below link:

https://en.wikipedia.org/wiki/Dye#Natural_and_synthetic_dyes

you may read some other article:

ANY CONFUSION JUST ASK HERE

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