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PROJECT : REACTION MECHANISM OF REACTIVE DYES IN ON CELLULOSE FIBER.

PROJECT : REACTION MECHANISM OF REACTIVE DYES IN ON CELLULOSE FIBER.

sheshir
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PROJECT : REACTION MECHANISM OF REACTIVE DYES IN ON CELLULOSE FIBER.

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  1. PROJECT REPORT ON REACTION MECHANISM OF REACTIVE DYES IN BENGAL HURRICANE GROUP ON CELLULOSE FIBER. BASIS OF BENGAL HURRICANE GROUP

  2. Prepared By : Prepared By : Mazadul Hasan sheshir ID: 2010000400008 13th Batch (session 2009-2013) Department : Wet Processing Technology Email: mazadulhasan@yahoo.com Blog : www. Textilelab.blogspot.com (visit) Southeast University Department Of Textile Engineering I/A 251,252 Tejgaon Dhaka Bangladesh ©right

  3. CONTENTS • Introduction • Raw Materials • Importance of The Survey • Reason of using Reactive dyes in major textile industry in Bangladesh • Methods of Dyeing & Printing Cotton Goods with Reactive Dyes • Technical Deficiency of Reactive Dyes, Causes and Remedies of Technical Deficiency • Conclusion

  4. Chapter 1 Acknowledgement Project Work is an academic function of the Pabna Textile Engineering College. Our teacher Md. Abdul Mannan, Principal, Pabna Textile Engineering College, gave us an opportunity to choose preferable mills for Project Work. I chose Bengal Hurricane Dyeing & printing (pvt.) Ltd. joyfully with the supervision of Mithun Biswas, Asst. Manager(production). During the Project with Bengal Hurricane Dyeing & printing (pvt.) Ltd. I worked in all the departments related with Dyes and Chemicals. Beside these, I learned about Dye Quality Control and Storage System,printing, Garments, Store & Inventory , finishing & specially dyeing. Our deepest appreciation goes to Mithun Biswas, Asst. Manager(production)Dyeing, Bengal Hurricane Dyeing & printing (pvt.) Ltd. to give us the opportunity to have project work at BENGAL HURRICAN GROUP. I would like to thank Engr. Md. Iqbal Mahamud (Head of the Factory), GM, Dyeing, Bengal Hurricane Dyeing & printing (pvt.) Ltd. for helping to know about the all aspects of BENGAL HURRICAN GROUP. I would also like to thank Tareq Ahmed(Deputy Manager),Md.Anwarul Islam(Deputy Manager), Md. Arif Rabbani Talukdar(Deputy Manager),Dyeing, Bengal Hurricane Dyeing & printing (pvt.) Ltd. for helping to know about the all aspects of BENGAL HURRICAN GROUP. Our gratitude also goes to all the employees of BENGAL HURRICAN GROUP for their sincere co-operation, support and valuable advice which they have provided us during the two months of training. Lastly I express my gratitude to our supervising teacher, the name that should be mentioned first, Shib Shankar Chakraborty, Head of the Dept. Wet Processing Technology for his valuable direction & supervision. However, I have prepared my Industrial Attachment overcoming all the difficulties & also the shortage of time. Here I would like to present the report. •

  5. Chapter:2 Application of reactive dyes in major textile industries in Bangladesh

  6. Application of Reactive dyes in major textile industries in Bangladesh

  7. Chapter:3 Project Abstract • The use of reactive for Dyed products has dramatically increased over the last 50 years. Reactive dyes are now used to produce multiple products. Reactive coloring components are inert into materials which are adhered to the base substrate by the application of soda ash which act as fixing agent. The main goal of our project is to provide information about the reason of using reactive dyestuff in major textile industry in Bangladesh, different methods using in our industry for cotton dyeing with reactive dyes, technical deficiency of reactive dyes during dyeing & causes and remedies of deficiency of reactive dyes. During reactive dyeing there is a rule of using different amount of soda ash with fixed amount of salt & auxiliaries. In case of dyeing of cotton with reactive dyes alkali pH should be correctly maintained as during dyeing more electrolytes required for exhaustion and alkali for fixation. However the rubbing fastness and hand feel properties of dyed fabric depends on the amount of soda ash. When we use fewer amounts of soda ash then hand feel is good but rubbing fastness is not good. And when we use more amounts of soda ash then rubbing fastness is good but hand feel is not good.

  8. Chapter 4 INTRODUCTION • With the evaluation of the wet processing industries the use of the reactive dyes in the most of the industries increases day by day. As a result to complete the project it is has become a part to discus about the evaluation or growth of the wet processing industries in Bangladesh. Now the number of the wet processing industries and finishing industries in Bangladesh is 193 which are totally export oriented according to the survey of the BTMA which has been provided into their we address. But the interesting matter is that with the growth of the textile wet processing mills the number of the employee is not increasing. This is because of to reduce the cost and increase the quality the modernization of the machine is also increasing which reduce the number of worker in wet processing industries. But what is the actual number of the worker in wet processing industries has not been found due to the lack of proper survey in this sector. Our project work was estimated as: APPLICATION OF REACTIVE DYES IN MAJOR TEXTILE IN BANGLADESH & DEFICIENCY OF REACTIVE DYE: The project work is interesting as well as lengthy but we must admit that we had to really work hard and it helps us a great deal to know about whole procedure of reactive dyeing on dyed fabric. Though reactive dyeing products exhibit intrinsic characteristics which make them suitable for multiple products application but reactive dye has it main problem with hydrolysis while dyeing as a result wastage of the reactive dye increase and it become difficult to match the proper • • • •

  9. The objects of project are: Knowing the source of textile raw materials of wet processing and cost. To mention the reasons of using reactive dyes in major textile industry. To study on the application of reactive dyes To learn about the technical deficiency of reactive dyeing. To study the causes and remedy of deficiency of reactive dyeing.

  10. Chapter 5 RAW MATERIALS Types of raw material • The basic raw materials used in wet processing industries are: • Fabric • Dyestuffs • Chemicals & auxiliaries. • • Raw material is a unique substance in any production oriented textile industry. It not only plays a vital role in case of continuous production & for high quality fabric but also it is related to the profit of the industry.

  11. Names & source Fabric: Different types of fabric treated in Bengal Hurricane Group pvt Ltd. dyeing section are namely dyeing section dyeing section • Single Jersey • Single jersey with Lycra attachment • Single Jersey with slub • Double Jersey • Polo pique • Back pique • Rib Fabric • Flat back Rib Interlock • Interlock with Lycra • Pique • Lacost • Lacost Lycra • Fleece • Tery Fleece • Waffle •Melange •

  12. Fibres dyed: By reactive dyes the following fibres can be dyed successfully: 1)Cotton, rayon, flax and other cellulosic fibres. 2)Polyamide and wool fibres. 3)Silk and acetate fibres It covers a wide range of color spectrum and includes shades varying from bright to heavy dark like, a. Violet b.Blue c. Green d.Red e. Black f. Yellow g.Etc.

  13. Trade names Some trade names of this dye are mentioned: Trade name Manufacturer Country Procion I.C.I U.K Ciba cron Ciba Switzerland Remazol Hoechst Germany Levafix Bayer Germany Reactone Geigy Switzerland Primazin BASF Germany Drimarine Sandoz Switzerland

  14. Popularity of reactive dye: Reactive are mostly used for dyeing cellulosic fibres. At past cellulosic fibres were dyed with direct and vat dyes, but after the introduction of reactive dyes there utility has become limited. Reactive dyes are superior to direct dye in the following aspects: i) Ability to procedure bright shades of wide range. ii) High leveling quality. iii)Good washing fastness. iv) Good light fastness. And it is superior to vat dyes in the following aspects: i) Simple dyeing method therefore one stage dyeing. ii) Low temperature dyeing (below 1000C) iii)Lower cost, i.e. cheaper. Again its dyeing process is fast and gives brighter shades than metallized azo dyes. For the above reasons reactive dyes are more popular.

  15. The general structure of reactive dye is: D-B-G-X. NH (bridging part) C Hetreocyclic ring N N - NH C Cl C N -N N- Chemical structure of reactive dyes Here, D= dye part or chromogen (color producing part) Dyes may be direct, acid, disperse, premetallised dye etc. B = bridging part. Bridging part may be –NH- group or –NR- group. G = reactive group bearing part. X= reactive group.

  16. Classification of reactive dyes: Reactive dyes may be classified in various ways as below: 1) On the basis of reactive group: a) Halogen (commonly chlorine) derivatives of nitrogen containing heterocycle, like 3 types- • Triazine group • Pyridimine group • Quinoxaline dyes Example: Triazine derivatives: procion, cibacron. Pyridimine derivatives: reactone Quinoxaline derivatives: levafix. b)Activated vinyl compound: • Vinyl sulphone • Vinyl acrylamide • Vinyl sulphonamide. Example: Vinyl sulphone: remazol Vinyl acrylamide: primazine Vinyl sulphonamide: levafix.

  17. Classification of reactive dyes: 2) On the basis of reactivity: a) Lower reactive dye: Here ph is maintained 12-12.5 by using NaOH in bath. b) Medium reactive dye: here pH is maintained 11-12 by using Na2CO3 in dye bath. c) Higher reactive dye: here pH is maintained 10-11 by using NaHCO3 in dye bath. 3) On the basis of dyeing temperature: a) Cold brand: These types of dyes contain reactive group of high reactivity. So dyeing can be done in lower temperature i.e. 320-600C. For example: PROCION M, LIVAFIX E. b) Medium brand: This type of dyes contains reactive groups of moderate reactivity. So dyeing is done in higher temperature than that of cold brand dyes i.e. in between 600-710C temperatures. For example, Remazol, Livafix are medium brand dyes. c) Hot brand: This type of dye contains reactive groups of least reactivity. So high temperature is required for dyeing i.e. 720-930 C temperature is required for dyeing. For example PRICION H, CIBACRON are hot brand dyes.

  18. The reactive rate of some compounds are mentioned below: COMPOUND Water Iso-propanol Ethanol Methanol Glucose C6H12O6 5.5 STRUCTURE H-OH CH3-CHOH-CH3 CH3-CH2-OH H-CH2-OH REACTIVE RATE 1.0 0.7 7.4 12.3 So from the above table it is obvious that secondary hydroxyl group is the beast reactive while primary one is the most reactive.

  19. Dyeing mechanism of reactive dye: The dyeing mechanism of material with reactive dye takes place in 3 stages:- 1.Exhaustion of dye in presence of electrolyte or dye absorption. 2.Fixation under the influence of alkali. 3.wash-off the unfixed dye from material surface. •Now they are mentioned below: 1.Dye absorption: When fibre is immersed in dye liquor, an electrolyte is added to assist the exhaustion of dye. Here NaCl is used as the electrolyte. This electrolyte neutralize the negative charge formed in the fibre surface and puts extra energy to increase dye absorption. So when the textile material is introduces to dye liquor the dye is exhausted on to the fibre.

  20. Dyeing mechanism of reactive dye: 2. Fixation: Fixation of dye means the reaction of reactive group of dye with terminal –OH or-NH2 group of fibre and thus forming strong covalent bond with the fibre and thus forming strong covalent bond with the fibre. This is an important phase, which is controlled by maintaining proper pH by adding alkali. The alkali used for this purpose depends on brand of dye and dyeing temperature. Here generally caustic soda, soda ash or NaHCO3 is used as alkali depending upon reactivity of dye. They create proper pH in dye bath and do as the dye-fixing agent. The reaction takes place in this stage is shown below:

  21. 3. Alkali 1. D-SO2-CH2-CH2-OSO3Na + OH-Cell D-SO2-CH2-CH2-O-Cell + NaHSO3 pH10-12.5 alkali 2. D-SO2-CH2-CH2-OSO3Na + OH-Wool D-SO2-CH2-CH2-O-Wool + NaHSO3 3. alkali pH10-12.5 3.Wash-off: As the dyeing is completed, a good wash must be applied to the material to remove extra and unfixed dyes from material surface. This is necessary for level dyeing and good wash-fastness. It is done by a series of hot wash, cold wash and soap solution wash.

  22. Application method of reactive dyes varies significantly with type of dyes, shade required, and available equipments in the mill. These are 3 application procedures available: 1. Discontinuous method- -Conventional method -Exhaust or constant temperature method -High temperature method -Hot critical method. 2. Cotinuous method- -Pad-steam method -Pad dry method - Pad thermofix method 3. Semi continuous method- - Pad roll method - Pad jig method - Pad batch method.

  23. Stripping of reactive dye: 1.Partial stripping: Partial stripping is obtained by treating the dyed fabric with dilute acetic acid or formic acid. Here temperature is raised to 70-100°C and treatment is continued until shade is removed by desired amount. After that a through washing is necessary to remove the product of hydrolysis. The amount of acid used is as below: - Glacial acetic acid : 5-10 parts With water :1000 parts Or Formic acid :2.5 to 10 parts With water :1000 parts Temperature : 70 - 100°C Time : until desired shade is obtained.

  24. 2. Full stripping: For complete stripping the goods are first treated with sodium hydrosulphite (hydrose) at boil then washed off and bleached with 1% sodium hypochlorite (NaOCl) at room temperature. This is carried out for 30 min. Na-hypochlorite : 1% at room temperature Na-hydrosulpite: at boil. Time : 30 min D-R-Cl + H-OH + H-Cl •Hydrolysis of activated vinyl compound containing dye, The recipe is as below: - D-R-OH D-F-CH2-CH2-OSO3H + H-OH D-F- CH2-CH2-OH + H2SO4 For preventing hydrolysis the following precautions are taken— 1.As hydrolysis increases with increasing temperature during dissolving and application temperature should not be more than 40°C. 1.Dye and alkali solution are prepared separately and mixed just before using. 2.Dye and alkali should not be kept for long time after mixing.

  25. Important factors for dyeing cellulosic fibre with cold brand reactive dye in batching process: The important factors are as follows: 1) pH of the dye bath: The optimum pH for fixing cold brand reactive dyes on cotton and viscose rayon depends on individual dyes, the temperature and time of dyeing. pH decreases with increasing temperature and time of dyeing. For most of the dyes the optimum pH is 10.8 to 11 at 20o to 25oC. Soda ash has been the best alkali for dyeing at 30oC for cotton, mercerized cotton and linen. Increased fixation (due to higher temperature) and increased dye bath stability and better reproducibility are the advantages of soda ash as the fixing agent. For viscose rayon the optimum pH is 10.3 at 20o to 25oC. 2) Amount of alkali: The amount of alkali used for fixing depends on the depth of shade dyed and the liquor ratio employed.Some quantities of alkali required for fixing the reactive dyes are given table 28. 3) Dyeing temperature: Since increase in temperature affects the rate of physical and chemical processes involved in dyeing, it is important in dyeing reactive dyes also. The affinity of the dye for the fibre decreases with increases in temperature and at the same time the rate of hydrolysis of the dye increases and adversely affects the fixation of color yield. However the rate of diffusion of the dye in the fibre increases with increased temperature. At temperatures lower than 20oc, the rate of fixation is very low. Hence for most of the dyes a temperature of 20o to 25oC is the recommended temperature while for some other dyeing at 50o to 60oC with sodium bicarbonate as the alkali gives maximum color value.

  26. Important factors for dyeing cellulosic fibre with cold brand reactive dye in batching process: 4) Electrolyte concentration: Since reactive dyes have low affinity for cellulose exhausting the dye bath by adding common salt or Glauber’s salt prior to fixation can increase the fixation. The amount of salt required producing adequate exhaustion decreases with decreasing liquor ratio. Thus for pale shade on cotton and viscose rayon 15 and 10 g/l of common salt used. The quantities may be increased to 30 and 20 to 30 g/l for medium and deep shades on these fibres. 5) Time of dyeing: Generally the dye may be added in two portions. The salt may also be added in two lots. The exhaustion takes place in 20 to 30 min. There is generally no advantage in extending the period beyond 30 min. The alkali is then added and the dyeing continued for 30 to 90 min. The depth of shade and reactivity of the dye decide the time of dyeing. For deeper shades larger times are required. 6) Liquor ratio: With decreased liquor ratio, both exhaustion and fixation take place to increased exert. However the rate of fixation of most of the dyes is not significantly affected. As the liquor ratio is decreased, the effectiveness of increasing salt addition also decreases. Hence lower amount of salt are sufficient to get optimum exhaustion. •

  27. Why low affinity reactive dyes are preferred for dyeing? If the reactivity of the dye is increased considerably, the rate of reaction with the fibre increases. There fore, the dyeing can be carried out in a short time. However in this case the rate of dye also increases, leading to deactivation of a part of the dye. This results in wastage of the dye. If on the other hand the reactivity of the dye is decreased, the extent of hydrolysis can be reduced considerably. However this results in the slower rate of reaction with the fibre also. The ultimate object of dyeing is to react as much of the dye ass possible with the fibre and minimize the hydrolysis of the dye. This is achieved in practice in two stages. The dyeing is first started from the aqueous medium under neutral conditions when the dye does not react either with the fibre or with water. Then gluber salt or common salt is added to exhaust the dye onto the fibre as much as possible. In this respect, this stage of dyeing (exhaustion) resembles the dyeing of direct dyes on cotton. Then the second step (that of fixation or reaction with the fibre) is carried out by adding the alkali (usually used soda ash). Since the exhausted dye is already on the fibre, it is more likely that the exhausted dye reacts with the fibre in preference to water. However the dye present in the dye bath (which contains a substantial amount of the reactive dye) can now react with water since it is under alkaline condition. It is already stated that the hydrolyzed dye cannot further react with the fibre but dye to the affinity forces; it is absorbed by the fibre and is retained in it. During the subsequent washing or soaping the substantivity held hydrolyzed dye gets stripped into the treatment of the dyeing with boiling soap or detergent solution removes almost all hydrolyzed dye. However if the affinity is very low, exhaustion of the dye bath prior to fixation cannot be achieved substantially. This results in a larger amount of the reactive dye remaining in the dye bath and getting hydrolyzed when alkali is added subsequently. If the dye has high affinity for cellulose like a direct dye, it becomes difficult to remove the hydrolyzed dye from the dyeing since it is also absorbed by and retained in the fibre by fairly strong affinity forces, through not as strong ass the covalent bond formed between the dye and the fibre. Hence in actual practice low affinity dyes are selected for converting in to reactive dyes. •

  28. Dyestuffs: Dye Brand name Bezactive Origin/source Bezema , Switzerland REACTIVE DYE Ciba Ciba , Switzerland Dychufix Hubei Hwalle dyestuff Ind.co. Kemafix Jaychem,India Levafix Dystar , Germany Procion Dystar, Germany Jackazol India Kemazol Jaychem,India Remazol Dyestar , Germany Solazol Solarfine , Taiwan Solacion Solarfine , Taiwan

  29. Chemicals: Brand name Novolube Jet Bluton BVB1 Cibacel DBC Cibafix ECO Cibafluid C SandocleanPCLF Permacol FA Novostone CR Cotton white T Cyclanon E Cyclanon ECO Jinlev RLF349 Eulysin S Felosan NOF Uvitex EBF Jinlev CL-225 Oxalic caid Palegal FA-8 Respumit BU Permacol SQ Na thiosulphate Uniperol O Uvitex EVF Uvitex 2B Mollan129 Acetic acid Reduction HCS Mollan130 Bluton 2B Type Anti creasing agent Violet tone brightener Sequestering agent Fixing agent Anticreasing agent Detergent Stabilizer Enzyme Redder tone brightener Fixing agent Reduction cleaning agent Dispersing agent pH buffer in PET dyeing Detergent Whitening agent Levelling agent for reactive dye Iron remover Levelling agent for disperse dye Antifoaming agent Sequestering agent Peroxide killer Washing agent for PET dyeing PET brightener Yellow tone brightener Soapinging agent pH controller Reduction cleaning agent Sequestering agent Whitening agent Source Techna,Italy CHT,Germany Ciba,India. Ciba ,Switz. Ciba ,Switz. Clarient,Germany Techna,Italy Techna,Italy CHT,Germany BASF,Germany BASF,Germany Geigy,Taiwan BASF,Germany CHT,Germany Ciba ,Switz. Geigy,Taiwan - BASF,Germany BASF,Germany Techna,Italy - BASF,Germany Ciba, Switz. Ciba ,Switz. Rota,dystar - Geigy,Taiwan Rota,dystar Ciba,India

  30. • Remark • The list is for the time of our industrial attachment. It varies according to the availability of the material & their price. • The price has not been supplied to us due to their secrecy act. • The annual requirement was not available & is a record of the procurement department.

  31. Chapter 6 IMPORTANCE OF THE SURVEY The main goal of our project is to provide information about the reason of using reactive dyestuff in major textile industry in Bangladesh, different methods using in our industry for cotton dyeing with reactive dyes, technical deficiency of reactive dyes during dyeing & causes and remedies of deficiency of reactive dyes. As these topics are very sensitive for dyeing industries, it is very much important to make a survey. It will be very helpful not only for our studying period but also for our future career. This survey also has these importances: 1. To mention the reason of using reactive dyes in major textile industry. 2. To study on the application of reactive dyes. 3. To learn about the technical deficiency of reactive dyeing. 4. To study the causes and remedy of deficiency of reactive dyeing.

  32. Chapter 7 Reason of using Reactive Dyes in Major Textile Industries in Bangladesh Maximum textile industries in Bangladesh are based on cotton knit fabric and reactive dyes are easily applicable to cellulose fibres. Other associated reason as follows: 1. Reactive dyes are soluble in water. 2. They have very good light fastness with rating about 6. 3. The dyes have very stable electron arrangement and can protect the degrading effect of ultra-violet ray. 4. Textile materials dyed with reactive dyes have very good wash fastness with rating about 4-5 due to strong covalent bonds formed between fibre polymer and reactive group of dye. 5. Reactive dyes give brighter shades and have moderate rubbing fastness. 6. Dyeing method of reactive dye is easy. It requires less time and low temperature for dyeing. 7. Reactive dyes are comparatively cheap. 8. Fixation occurs in alkaline condition. 9. Reactive dyes have good perspiration fastness with rating 4-5. 10. It has a wide range of shade

  33. Chapter 8 Methods of Dyeing Cotton Goods with Reactive Dyes REACTIVE DYE : Reactive dye react with the fibres mainly react with cellulose fibres e.g. cotton, jute, bast fibres, viscose, flax. It can be applied to protein fibres e.g. wool & silk. Reactive dye contains reactive group and this reactive group makes covalent bonds with the fibres and becomes the part of the fibre. The general formula of reactive dye as follows: D-X-Y Here D->Chromophore of dye post X->Bridge Y->Functional group D-X-Y + Fibre ->D-X-Y-Fibre Covalent bond Reactive dyes water soluble D-F + Cell-OH ->Dye-F-O-cell D-F + H-OH ->Dye-F-OH Hydrolysis Influencing factors: 1. PH 2. Temperature. Properties: 3. Conc. of electrolyte. 1. Anionic in nature. 4. Time. 2. Soluble in water. 3. Form strong covalent bond 5. Liquor ratio. 4. Better wet & light fastness. 5. Have better substantivity. 6. Dyeing is carried out at alkaline condition.

  34. REACTIVE DYEING FOR SENSITIVE SHADE AT 60oC Dyeing: Anticreasing Agent (.5 g/l) Leveling Agent (1 g/l) A. Acid ( .2 g/l) Dyes (According to Shade %) G. Salt (According to Shade %) Soda Ash (According to Shade %) 60min at 60OC, Neutralization (Dyeing): A. Acid (1 g/l) 10min at 40-50OC, Soaping: Soaping Agent (.5 g/l) Dyeing curve: Sequestering Agent Color Dosing 600C Leveling Agent Linear (30min) 500C 10min 50min Bath drain 350C 20min 30min 10min 10min 350C Cold PH +Hardness Check Salt (15min) 1 g/l Soda Rest Soda wash (30min) (60min)

  35.   Process steps: Dyeing: Anticreasing Agent (.5 g/l) Leveling Agent (1 g/l) A. Acid ( .2 g/l) Dyes (According to Shade %) G. Salt (According to Shade %) HOT BRAND REACTIVE DYEING: DYEING AT 92oC: Soda Ash (According to Shade %) 60min at 80OC, PH = Above8 (Always) Neutralization (Dyeing): A. Acid (1 g/l) A. Acid (.5 g/l) Softener (1.5 g/l) 10min at 40- 50OC, Soaping: Soaping Agent (.5 g/l) 20min at 70- 80OC, Fixing & Softening: Fixing Agent (.5 g/l) 15min at 40OC, 20min at 40OC, Bath Drain

  36. 800C 40min Dyeing curve: 50min Sequestering Agent Color Dosing 600C Leveling Agent Linear (30min) 500C 10min Bath Drain 350C 20min 30min 10min 10min 350C Cold wash PH +Hardness Check Salt (15min) 1 g/l Soda Rest Soda (30min) (60min) N.B: The temperature increase at the grade 10C/min because it’s an important matter to avoid the shade variation in dyeing

  37. DARK COLOR DYEING WITH REACTIVE  DYE AT 600C     Anticreasing Agent (1.5 g/l) Leveling Agent (1 g/l) A. Acid (.2 g/l) Dyes (According to Shade %) G. Salt (According to Shade %) Soda Ash (According to Shade %) 60min at 60OC, Dyeing: 60min at 60OC, Neutralization (Dyeing): A. Acid (1 g/l) 10min at 40-50OC,   10min at 40-50OC, Soaping: Soaping Agent (.5 g/l) 20min at 70-80OC, 20min at 70-80OC, Fixing & Softening: Fixing Agent (.5 g/l) 15min at 40OC, 15min at 40OC, 15min at 40OC, A. Acid (.5 g/l) Softener (1.5 g/l) 20min at 40OC, 20min at 40OC, Bath Drain

  38. Dyeing procedure for dark shade Felosan NOF/Wetting agent = 0.5g/l Kappazon H53NEU/Stabilizer (H2O2) = 0.5 g/l Anticreasing agent = 1.0 g/l [Only for S/J] ↓ 60oC x 5' Caustic → 2 g/l ↓ 60oC x 15' Hydrogen peroxide → 2.5 g/l [Dosing 10'] ↓ (60oC - 80oc) Temperature rise up to 105oC ↓ 30' Acetic acid → 1.0 g/l H2O2 killer → 0.5 g/l ↓ 60oC x 10' Acetic acid → 0.8 g/l (To control pH = 4.5-5.5) Enzyme → 1.5 g/l ↓ 55oC x 45' - 60' Kappaquest FE / Sequestering Agent → 0.35 g/l ↓ 90oC x 5' Sarabid LDR → 0.5 g/l (leveling agent) ↓ 60oC x 5' Gluber Salt (Runtime → 10') ↓ 60oC x 10' ↓ Dye stuff  ↓ 60oC x 35' Runtime 20' Soda ash ↓ 60oC x 40' Runtime 60' Bath drop after shade matching ↓ Hot rinse ↓ 60oC x 10' Soaping ↓ 80o - 95oC x 10' Cold rinse ↓ 45oC x 10' Neutralize (Acetic acid = 0.5 g/l) ↓ 45oC x 10' Fixing ↓ 40oC x 15' Softening ↓ Unload

  39. Dyeing Procedure for White ↓ Felosan NOF/wetting agent → 0.5 g/l Kappazon H53NEU /Stabilizer → 0.5 g/l Anticreasing agent → 1.0 g/l [Only for S/J] Caustic → 3 g/l ↓ 60oC x 15' Hydrogen peroxide → 10.0 g/l ↓ 60oC x 10' Syno white 4BK/Optical brightener (60o → 80oC) ↓ 105o x 60' Acetic acid → 1.0 g/l ↓ NT x 10' Acetic acid → 0.8 g/l [To Control PH- 4.5 - 5.5] Enzyme → 1.5 g/l ↓ 55oC x 45' - 60' Sequestering agent → 0.5 g/l 90oC x 5' ↓ Acetic acid → 0.35 g/l Softener → 1.5 g/l 40oC x 10' ↓ N. Hot ↓ Unload

  40. Dyeing procedure for Light/Medium Shade ↓ Felosan NOF/Wetting agent → 0.5 g/l Kappazon H53NEU /Stabilizer (H2O2) → 0.5 g/l Anticreasing → 1.0 g/l [Only for S/J] ↓ 60oC x 5' Caustic → 2 g/l ↓ 60oC x 15' Hydrogen peroxide → 2.5 g/l ↓ (60o - 80oC) Temperature rise up to 105oC ↓ 30' Acetic acid → 1 g/l H2O2 Killer → 0.5 g/l ↓ 60oC x 10' Acetic acid → 0.8 g/l [To Control PH- 4.5 - 5.5] Enzyme → 1.5 g/l ↓ 55oC x 45' Sequestering agent / Kappaquest FE → 0.35 g/l ↓ 90oC x 5' Sarabid LDR → 0.5 g/l (leveling agent) • ↓ Anticreasing agent → 0.5 g/l [ For S/J] ↓ 60o x 5' Dye stuff ↓ 60oC x 35' → Runtime → 20' Glauber Salt ↓ 60o x 10' → Runtime → 20' Soda ash ↓ 60o x 40' → Runtime → 60' Bath drop after shade matching ↓ Hot rinse ↓ 60o x 10' Soaping ↓ 80o - 90oC x 10' Cold rinse ↓ 45o x 10' Neutralize ↓ 45o x 10' Softening ↓ Unload NOTE: - During Bleaching we maintain gradian to rise temperature from  80o - 105oC as  1.5o/min and cooling from 105oC - 80oC as 2o/min. For S/J  or low GSM. Fabric. 

  41. Dyeing procedure for S/J Light / Medium Color ↓ Kappazon H53NEU /H2O2 Stabilizer = 0.5 g/l Anticreasing agent = 1.0 g/l ↓ 60o x 5' Caustic = 2 g/l ↓ 60oC x 15' [Dossing] Hydrogen peroxide (H2O2) = 2.5 g/l ↓ (60o - 80oC) Temp rise up to 105oC & Run - 30' ↓ Acetic acid = 1.0 g/l H2O2 killer / Kappaquest FE = 0.5 g/l ↓ 60oC x 10' Acetic acid = 0.8 g/l [To control PH - 4.5 - 5.5') Enzyme = 1.5 g/l ↓ 55oC x 45' - 60' Sequestering agent = 0.35 g/l ↓ 90oC x 5' Sarabid LDR /Levelling agent = 0.5 g/l Anticreasing - 0.5 g/l • ↓ Felosan NOF/ Wetting agent = 0.5 g/l 60o x 5' Dye stuff ↓ Glauber Salt ↓ Soda ash ↓ Bath drop after shade matching ↓ 60o x 35' - Run time - 20' Dosing - 60o x 10' - run time - 20' 60 x 40' Hot rinse - 10' x 60oC ↓ Soaping ↓ 80o - 90oC x 10' Neutralization / Acetic acid ↓ 45oC x 10 Cold rinse - 45o x 10' ↓ Softening ↓ Unload

  42. Migration Dyeing procedure for dark, medium & light shade Anticreasing → 1.0 g/l [Only for S/J] ↓ 60oC x 5' Caustic → 2 g/l ↓ 60oC x 15' Hydrogen peroxide → 2.5 g/l ↓ (60oC - 80oC) Temperature rise up to 105oC ↓ 105oC x 30' Acetic acid → 1.0 g/l Kappaquest FE /H2O2 killer → 0.5 g/l ↓ 60oC x 10' Acetic acid → 0.8 g/l [To control PH = 4.5 - 5.5'] Enzyme → 1.5 g/l ↓ 55oC x 45' - 60' Sequestering agent → 0.35 ↓ 90oC x 5' Sarabid LDR → 0.5 g/l Anticreasing agent → 0.5 g/l [for S/J] ↓ Felosan NOF/wetting agent → 0.5 g/l Kappazon H53NEU /stabilizer (H2O2) → 0.5 g/l ↓ Glauber Salt [Run time 10'] ↓ 60o x10' Temperature rise up to 80oC [ Run time→ 20'] ↓ 80oC x 20' cooling to 60oC ↓ soda ash ↓ 60oC x 40' → Run time → 60' Bath drop after shade matching ↓ Hot rinse ↓ Soaping ↓ Cold rinse ↓ Neutralize ↓ Fixing [ For medium & dark shade] ↓ 40 o x 10' Softening ↓ Unload 60o x 10' 80oC - 95oC x 10' 40o x 10' 45 o x 10' Dye stuff ↓ 60oC x 35' → Run time - 20'

  43. Sample (Dyeing) RECIPE SAMPLE COLOR SATAZOL YELLOW 3RS=1.649% SATAZOL RED 3BS =O.912% SATAZOL BLACK NNT=8.47% BLACK KIRA.YELLOW HB=1.4% KIRA. RED HB =2.0% KIRA. RED SP2B=6.64% RED KIRA.YELLOW HB=0.47% KIRA. RED HB =3.8% KIRA. BLUE HB =0.86% MERUN KIRA.YELLOW RR=0.188% KIRA. RED RR =0.29% KIRA. BLUE RR =1.26% DK-BLUE SETA. RED 3BS =0.078% SOLA.RED SP2B=0.02% PINK SATAZOL YELLOW 3RS=0.385% SATAZOL RED 3BS =O.049% SATAZOL BLUE BB=1.64% DK- TURGISH

  44. Sample (Dyeing) COLOR RECIPE SAMPLE CLASSIC BLUE SATAZOL YELLOW 3RS=0.013% SATAZOL RED 3BS =O.066% SATAZOL BLUE SETR =0.62% GOLD RUST SATAZOL YELLOW 3RS=3.14% SATAZOL BLUE BB =O.004% SATAZOL BLUE BB =0.40% VIO-LET SATAZOL RED 3RS =0.65% SATAZOL RED 3BS =O.48% BZ. BLUE VW =1.40% TURGISH E/B BLUE RSPL =2.1% R/M T. BLUE G =0.6% LIGHT YELLOW SETA. YELLOW 3BS=0.048% RM. YELLOW 3GL =0.076% NATURAL BEZ.YELLOW SLF=0.154% BEZ.RED SLF =0.05% BEZ.BLUE SLF =0.132% DEEP LILAC E/B. YELLOW-4GL=0.008% RED 3BSN =1.1% BE. BLUE VRN =1.14%

  45. Printing of cotton fabric with reactive dyes (block and screen printing method), combination shade. Introduction: By the term textile printing we mean the localized application of dyes or pigment and chemical by any method, which can produce particular effect of color on the fabric according to the design. In this practical we print cotton fabric with cold brand reactive dyes in block and screen-printing methods in combination method. A dye, which is capable of reacting chemically with a substrate to form a covalent dye substrate linkage, is known as reactive dye. The dye contains a reactive group and this reactive group makes covalent bond with the fibre polymer and act as an integral part of fibre. Reactive dyes forms covalent bond with fibre polymer and thus attach itself with fibre. It is now a day mostly used for dyeing and printing of cotton yarn and fabric. It is a cationic dye. Cold brand reactive dyes have higher reactivity.  Block printing method is the oldest printing method.  It is used mostly in sarees,  handkerchiefs etc. in this printing method we use blocks of different designs. In screen printing a very little screen made by glass fibre is used. There are many types of screen-printing, but we have done in our experiment was hand screen- printing. Hand screen-printing is mostly used for sarees to 14-16 colors in on pattern can be produced at a time.

  46. Style of printing: Direct style. Method of printing: Block and screen-printing method. Sample: One piece of square size bleached, scoured cotton fabric (small) and One piece of square size bleached, scoured cotton fabric(bigger) Combination color: Total Dyes = 1.8gm Blue = 0.6gm Red = 0.6gm Yellow = 0.6gm Recipe: Dye: Total Dyes = 1.8gm CIBA CRON RED = 0.6gm CIBA CRON BLUE = 0.6gm CIBA CRON YELLOW = 0.6gm Urea = 8gm Thickener = 70gm Alkali = 8gm Additional water = as required.

  47. Preparation of thickener: 1)16 gm of starch and 200cc water are taken in bowl. 2)Heat is applied and solution is stirred continuously until a thick viscose solution is obtained. 3)By continuous stirring and boiling a specific viscosity is obtained. 4)The heat application is stopped otherwise viscosity falls down. So temperature is maintained strictly.

  48. Preparation of printing paste: 1)At first we take required amount of dyestuffs in a bath. 2)Then little amount of water is added into the bath for mixing these dyes. And start stirring for mixing the three types of dye. 3)Then required amount of urea is added into the dye bath. 4)After then required amount of thickener is added 5)Then continuous stirring is done for few minutes for mixing all the ingredients of print paste. 6)After mixing finally required amount of alkali is added to the dye bath and mix them with the help of stirring. •

  49. Printing process: • Block printing method: 1)The fabric, which will be printed, is placed on the printing table. 2)The printing paste is put on the tray box. 3)The block is selected and it is touched with print paste. 4)Then block is pressed upon the sample fabric. 5)After pressing the block on the sample fabric the block is put off from the fabric. 6)Finally we get the printed fabric of required dyes. •

  50. Screen-printing method: 1)The fabric is placed on the printing table of flat screen- printing machine. The table is made of soft by laying on it. 2)Then the screen is placed on the sample fabric. 3)The printing paste is taken on the screen perforation. 4)Thus we can find the printed fabric with a smooth wooden strike the paste is spread over the screen with slight pressure. 5)So that the dye particles can penetrate through the screen perforation. 6)Thus we get printed fabric. •

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