Practical Textile 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 the 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.
The key factor which reflects the topic:
- Fabric behavior
- Dyes behavior
- Dyeing process
- 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 used 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 Dispersed 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
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Anticreae+Detergent Inject = To remove impurities
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Wash and Drain
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Detergent+Anticreasing agent+Oil remover+Peroxide stabilizer inject
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Caustic soda dossing 10min
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Run time 5min
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Rise temperature at 70 ⁰C
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Inject the Hydrogen peroxide
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Rise the temperature to 98 ⁰C
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Run time 60 min
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Cooling at 78 ⁰C
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Shade check = Check the whiteness and absorbency
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If ok drain
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Normal hot at 80 ⁰C
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Run time 10 min
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Inject Acetic acid = For neutralization of Soda
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Run time 5min
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Drain and wash for 5min
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Peroxide killer Inject run for 5min
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Drain and wash 10min
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Rise the temperature to 55 0c
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Control PH= 4.5 with acetic acid
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Inject Enzyme
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Run time 40min
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Check sample hairiness
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If ok then raise the temperature to 80 0c
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Run 5min
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Drain and wash the enzyme dust
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Start dyeing
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Leveling pH check= PH 5.5 – 6;
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Levelling Dosing 600c 5 minute
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Runtime 10 minute
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Color Dosing 25 minute
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Runtime 10 minute
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Salt dosing 10 minutes
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Runtime 10 minute
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Salt Sample Check and Fabric Quality check = The evenness of dyes
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If ok then
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1st Soda dosing 20 minutes (10%)
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Runtime 10 minute
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2nd Soda dosing 20 minutes (80%)
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Run time 15min
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Sample Check
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Shade ok and then drain (Rinse drain is better)
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Normal, not 80 0c run 10min
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Wash until clear the loose dyes are (Not more than 20min)
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Inject soaping agent
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Rise 90 0c and run 10min
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Check shade if the ok drain
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Wash clear
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Fixing agent dos 5min
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Runtime 10min
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Wash clear
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Softener dossing 7min
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Check softness if ok
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Unload and deliver to finishing
Special Note for reactive dyeing process:
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 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
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POLYESTER PART START
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Oxalic acid+Detergent Inject = To remove impurities and neutralization
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Run time 10min
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Drain and wash for 5min
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Acetic acid inject= For Control PH: 4.2 to 4.5
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Rice the temperature at 80⁰C
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Disperse dye stuff dossing 30min = For polyester part dying
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Rise the temperature80 ⁰C to 95⁰C Grade 1⁰C = Grade for better penetration
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Then rise temperature 95 ⁰C to 135 ⁰C Grade: 0.5 ⁰C
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Run for 45min
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Cooling at 135 ⁰C to 95 ⁰C grade: 1 ⁰C
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Then 95 ⁰C to 79 ⁰C directly.
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Check the sample = To achieve the required shade
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If the shade ok then drain the dye bath
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Normal hot at 80 ⁰C
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Run for 10min
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Wash for 10min
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Caustic soda dossing 8min at temperature 50 ⁰C
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Run for 5min
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Rise the temperature to 80 ⁰C
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Inject hydro’s = for removing the loose disperse dyes
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Rise the temperature to 90 ⁰C
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Run for 10min
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Cooling at 80 ⁰C and drain
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Normal not at 90 ⁰C for 10min
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Wash for 10min and drain
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Polyester softener
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Unload the fabric and delivery it to finishing
Special note for the dispersed dyeing process:
Here the underlined portion is so important and you should not avoid getting better fastness results.
One more thing after unloading the 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 1500 C
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.
Research Links:
FOR MORE INFO VISIT KNIT DYEING DETAILS
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