Post on 05-Apr-2018
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ECO-FRIENDLY
DYEING
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OUTLINE
Background
Textile Wet Processing
Desizing
Scouring
Bleach Clean Up
Cold Pad Batch Dyeing
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BACKGROUND
Increasing awareness for a cleaner and
greenerliving standards
Enforcement of stricter guidelines and rulingsfrom various associations and Governmentbodies
Challenges faced by Textile Dyeing
companies around the world alike
Matexs belief in being ecologically efficient
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DYEING
PROCESS
DesizingMebyoNHT
ScouringMebyoPT
Bleach
Clean UpMebyoHON
DyeingMegafix B-CPB Soaping
Finishing
Garment
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DESIZING
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DESIZING
Removal of starch used as size duringweaving to prevent unleveled dyeingand poor batch-to-batch reproducibility
Traditional Desizing Methods Acidic: Sulphuric or hydrochloric acid
Oxidative: Persulphate plus alkali or
bromite and alkaliThese treatments reduce the tensile strengthof the fabric.
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DESIZING
Desizing with biocatalyst
Advantages: LESS chemicals involved
ECO-FRIENDLY
EFFICIENT in wide rangetemperature
Specific, NO damage to cellulose
fibres BETTER strength retention
SOFTER fabric feel
SHORTER process time
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DESIZING
Mechanism:
Biocatalyst hydrolyzes -1,4-linkagesin starch
HYDROLYSIS
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DESIZING
Test for degree of desizing
Tegewa Scale
Tegewa Rating: 1 Tegewa Rating: 7
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SCOURING
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SCOURING
Removal of impurities such as
Waxes Hemicelluloses Pectins Mineral salts
from raw cotton during the early stages
of textile wet processing
Prepares fabric for subsequenttreatments Mercerizing Printing
Bleaching Finishing
Dyeing
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SCOURING
AlkalineScouring
Bioscouring
NeutralizationConventional
FabricInput
Washing DyeingNo Neutralization
At low alkalinity (pH 8.5)
In highly alkaline condition
Alternative
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SCOURING
Advantages of bioscouring:
ECO-FRIENDLY (less harshchemical caustic soda)
LESS rinse water needed
REDUCE effluent load REDUCE water consumption
SAVE energy
SAVE cost Fully RETAIN cellulose structure
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SCOURING
Wetting Test
Grey Fabric Treated Fabric
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SCOURING
100%20-45%COD
100%20-45%BOD
100%20-50%Total diss solids (TDS)
100%35-50%Rinse water
consumption
SameSameDye ability
SameSameBleach ability
+ 5 -10% points+ 1-5% pointsBrightness increase
< 1 second< 1 secondWettablility, drop test
4-10%
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140Total water required(tonne)
1:7Liquor ratio
$1.00Fabric cost per kg
(USD)
20Total fabricprocessed / day(tonne)
Basic Assumption
$66,360-Steam cost saving / year2 (USD)
$189.601$410.801Total steam cost / day (USD)
1226Total steam required (tonne)
85.71185.71Steam required / 1 tonne water(kg)
3065Temperature differential (oC)
6095Scouring Temperature (oC)
3030Base temperature (oC)
Energy cost
Bioscouring
AlkalineScouring
Energy Saving
1 Based on steam costUSD$15.80/tonne of steam2 Based on 300 working days peryear3 Based on 4% fabric weight lost4 Based on 1.5% fabric weight lost
Bioscouring
AlkalineScouring
Fabric Saving
$150,0000Weight lost cost saving / year2
(USD)
$300$800Total weight lost cost / day(USD)
30048003Total fabric weight lost / day (kg)
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BLEACH CLEAN UP
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BLEACH CLEAN
UP Removal of H2O2 residual to
ensure leveled dyeing
Bleach Clean Up Alternatives By rinsing only
By reducing agent
With biocatalyst
Bleaching Rinsing DyeingRinsingRinsing Rinsing
RinsingBleaching DyeingRinsingReducing
Agent
RinsingBleaching Biocatalyst
Dyeing
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BLEACH CLEAN
UP Advantages of using biocatalyst:
SAVE water No rinsing required. Can proceed in the same
bath with dyeing process
SAVE energy No more hot rinse, cold rinse, hot rinse
SAVE time As short as 10 min to complete the job!
SAFE H2O2 complete removal without affecting
dyestuff or textile materials
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BLEACH CLEAN
UP Bleach Clean Up with Biocatalyst
- Adjust pH asdesired forsubsequent dyeing
- Add biocatalyst
Bleaching
-Drain-Fill cold
BleachClean Up
Dyeing
- Checkperoxide level
5 10 15 20 25 30 35 40 45 50 55 600
20
40
60
80
100
Time (min)
TemperatureC
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BLEACH CLEAN
UPWater Usage in the Various Bleach Clean Up
Methods
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
Water Reductive Biocatalyst
NoofRinseBaths
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Process Time for the Various Bleach Clean Up
Methods
0
20
40
60
80
100
120
140
Water Reductive Biocatalyst
Minutes
Bleaching Rinsing H2O2 Removal
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COLD PAD BATCH
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COLD PAD BATCH
DYEING
A more environmentally sound and
higher quality dyeing method
Process steps:Padding Roll Batching
Washing Soaping Washing
Drying
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COLD PAD BATCH
DYEING Total volume of pad-trough
10 / 15 litres per metre of
width of fabric (example 2metres; volume 20 to 30litres)
Immersion time 1.5sec
Bath temperature 25 30C
Pick up 70 80%
Fabric speed such as thetime to completely renew
the trough should notexceed 10 minutes
Batching time: 8 16hrs
Dyes/AuxiliariesAlkali
4 volumes Batching Vessels1 volume
Mixing Vessel
Foulard with anautomatic level-adjustment
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COLD PAD BATCH
DYEING Advantages of Cold Pad Batch Dyeing:
Simplicity in process of dyestuff application Reduction in water consumption by 50 to
80%
Reduction in energy consumption by up to60%
Reduction in chemical costs, other thandyestuff, by up to 50% due to elimination of
salt and reduction of alkali requirements Reduction in labor costs by 40 to 60%
Minimum fabric abrasion
Excellent shade reproducibility from lot toSource: Cotton Inc 2003/TRI3007
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COLD PAD BATCH
DYEING Reactive dyestuff
A dye type that connect to the fiber through
chemical reactions (covalent bond)
HYDROLIZATION25%
FIXATION75%
R2-DYE-OH R2-DYE-Ocell
HYDROLIZATION
6%
FIXATION
19%
HO-DYE-OH HO-DYE-Ocell
TOTAL6% HYDROLIZATION
94% FIXATION
MONO REACTIVE
DYE-R
HYDROLIZATION25%
FIXATION75%
DYE-OH DYE-Ocell
TOTAL25% HYDROLIZATION
75% FIXATION
BIFUNCTIONAL REACTIVE
R1-DYE-R2
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COLD PAD BATCH
DYEING Megafix B-CPB
Belongs to Bifunctional Reactive DyesGroup
Low to medium substantivity, medium tohigh reactivity
Excellent build-up, high color yield andfixation
Good fastness
Good repeatibility
Good trichromic compatibility
Meet Oeko-Tex 100 requirement
CO C
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COLD PAD BATCH
DYEING Trichromatic
CompatibilityFrom theillustration &data values, itshows that the
trichromaticcolors arecompatible &they give thesimilar shade &tone throughoutfrom the 1stfabric to the 40thfabric.
COLD PAD BATCH
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COLD PAD BATCH
DYEING
1. Based on water & sewer cost of $2.58/1000 gals.2. Based on steam cost $4.38/1000 lbs. of steam. Pad-batch includes extra drying.3. Based on electric power cost of 5.0/kWh.
4. Based on sodium chloride at 4/lb.
Cost Comparison on Reactive Dyeing pre-bleached 100%Cotton ( Greenville, S.C. local currency)
Source: Cotton Inc 2003/TRI3007
77.8%$117.15$33.40$150.55
-Total (ExcludeDyestuff & Labor)
100%$40.0000$40.0041000 lbsSalt
50.0%$1.50$1.503< 30kWh
$3.00360 kWhElectricalConsumption
67.6%$39.77$19.0524,350 lbs$58.82213,430lbs
SteamConsumption
73.6%$35.88$12.8514,980gals
$48.73118,889gals
Waterconsumption
-1 : 1-15 : 1Liquor Ratio
-1000 lbs-1000 lbsBatch size
%
Saving
Total
saving
Pad-batch
cost
Pad-
Batch
Beck
Cost
BeckItem
COLD PAD BATCH
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COLD PAD BATCH
DYEING
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