1.SUBMITTED TO: SUBMITTED BY:DR. M.L.GULRAJANI ASHISH DUA(2012TTF2406) IIT DELHIashisdua@gmail.com 1

2. Classification of the methods fordyeing of P/C blend Exhaust dyeing method or batch dyeing method- This is again classified in the following three groups- a. Two bath dyeing b. One bath one step dyeing C. One bath two step dyeing methodThermosol Dyeing method - It is again classified in to two groups- a. Continuous dyeing- b. Pad batch process (semi-continuous) Note-In continuous dyeing process may be single bath ordouble bath.2 3. EXHAUST DYEING- Two bath dyeing This is the process in which we have to dyed first polyesterpart in the HTHP beam dyeing machine or HTHP jetdyeing machine and the cotton part is dyed in the jiggermachine. Batch process Machine used for dyeing of polyester part-i) HTHP Beam dyeing machine( First commercializedHTHP machine) ii) HTHP jet dyeing machine Machine used for dyeing of cotton part- Jigger dyeing machine 3 4. 4 5. PROCESS ROUTE P/C BLENDDYEING-5 6. MACHINE FOR POLYESTER DYEING- HTHP beam dyeing machine- No need to explain the whole process of dyeing in beam dyeingmachine. Only some important points we will discuss about it- Advantages & features: Loading and unloading of the fabric is easy and time of dyeing isshort. Dyeing in open width form. Most suitable for those fabrics that might crease, extend orabrade when dyed in machines where the fabric is in motion. Not appropriate for compact fabrics De-aeration is essential to avoid paler dyed spots. A wetting agent helps to eliminate air bubbles within the fabricroll.6 7. Recipe used HTHP dyeing Disperse dye- X%(depends upon the shade) Dispersing agent-1g/l Sequestering agent-1-2g/l(If required) Defoamers -.5 to 1g/l Levelling agent-.5 to 1 g/l Wetting agent- .5g/l Acetic acid-enough to get ph=5-6 7 8. Flow of the liquor usually in the in-to-out direction,but it can be reversed. Out-to-in flow can compressthe material causing flattening and glazing, particularlyon the inner layers.Material stationary and liquor is moving.Batching is very important, during batching tensionshould be uniform and optimum.M:Lratio is 1:10Both cloth and yarn can be dyed on this machine8 9. HTHP BEAM DYEING MACHINE-9 10. Disadvantages of beam dyeingmachine- Fabric of different width can not be dyed together on asingle beam. The dyed fabric may be display moir effect if it istightly due to shrinkage. Uneven dyeing may occur if the beam is fully loaded,as the dye liquor has penetrate several layers of fabric. 10 11. JET DYEING MACHINE-11 12. JET DYEING MACHINES- 12 13. HTHP jet dyeing machine The jet dyeing machine is an extension of the HPHT winchdyeing machine. Jet dyeing machine developed byBURLINGTON Industries and first machine developed in1963 by Gaston country Machine co. of U.S.AFeatures: Both material and liquor is moving. Dyeing in rope form. Fabric speed usually 200-250mt/min The jet dyeing can usually operated up to 1400c under highpressure and having capacity capable of dyeing 100 to 150kg of fabric at a time 13 14. Chemicals added Acids Buffers Sequestering agent Anticrease agent Defoamers Levelling agent 14 15. DEVELOPMENT IN JET DYEINGMACHINE- Soft flow jet- slow motion of fabric. Suitable for knittedfabric Super jet dyeing machine- M:L is 1:1 Aerodynamic jet dyeing machine Jet created by mixture of air + water M:L is 1:1 , drain out at a 130c Multi-nozzle sot flow jet dyeing machine 15 16. Advantages of jet dyeing machine: Fabric of two different width can be dyed at a time sothat two lots can be combined together for dyeing. No special batching device is required for winding thefabric as in beam dyeing. There is no flattening effect or uneven dyeing on thefabric as in beam dyeing 16 17. Disadvantages: There is possibility of entanglement of light-weight fabricduring dyeing. Loose fibres removed from the fabric may get redepositedon the fabric surface as well as on the interior of the jetdyeing vessel, this problem does not arise in beam dyeing. Yarn can not be dyed in a jet dyeing machine whereas it canbe dyed in a beam dyeing machine. PROBLEMS-1.Foaming problem 2.Oligomers problem 3.Rope marks17 18. Machine used for cottondyeing-Jigger dyeing machine Open jigger or closed jigger dyeing machine- Closed jigger specially for vat dyeing. Liquor is stationary and fabric is moving. 500 t0 1000 meter of fabric is processed in onetime. M:L ratio in jigger dyeing machine is about 1:5. Usually take 10 min. for each passage 18 19. One bath two step dyeing- One-bath dyeing processes ,using both the dyes suchas following in the same dye bath. 1. Disperse and vat dyes. 2. Disperse and reactive dyes. 3. Disperse and direct dyes.19 20. DISPERSE/REACTIVE DYEINGSYSTEM- 20 21. Disperse/vat dyeing system- Typical dyeing recipeDisperse dye-X%Vat dye-Y%Dispersing agent-.5-1%wetting agent-.5-1%pH 4-5 with acetic acid (30%) Procedure-Prepare the bath with dispersing agent,wetting agent and acetic acid + treatment for 10-15minat 50-60c then + disperse and vat + dye for 10-15min +raise temp up to 130c in 60-90 min.21 22. Procedure continued- After PET part dyeing cool to 80c for proper levellingthen add NaOH & Na2S2O 4 + dyeing 15min + coolingto 60c + dyeing for 30 min. for better exhaustionRinse with cold water + oxidation with H2O2 for 15minat 50c + Rinsing with cold water + Soap at 95 C for 25min using 2 g/l Lissapol D + Hot and cold rinse andthen final wash off. Only vat dyes which are stable up to 130c can be usedfor this process. 22 23. One bath two step dyeing method- All vat dyes may be used for the one bath hightemperature process provided that the dyes are finelydivided enough. The IK vat dyes are not preferred becausethe dye liquor requires to be cooled to about 300c in orderto obtain full colour yield. Therefore when IK dyes are to beused it is preferable to dye by the two-bath process. Typical dyeing recipe- Disperse dye-X% Vat dye-Y% Dispersing agent-0.5-1% Wetting agent-0.5-1% Ph-4-5(attained with 1-2 ml/l of 30% acetic acid)23 24. Oxidation and soaping- Oxidation and soaping can be be achievedsimultaneously using the following recipe: Hydrogen peroxide(35%) 1-2 ml Anionic detergent -.5-1g/l Ph-9-10 First treat the material for 10-15 min. at 500c withhydrogen peroxide. Then the anionic detergent andraise the temperature to 950c. Soap for 10-15 min. 24 25. Disperse/Vat dyeing system Method is used when selected vat dyes severely. It stainPET component during high temp dyeing. Vat dye is added at 80c after PET part dyeing rather thanadding at the start with disperse dye. Except it the whole process is same as the dyeing in onebath one step. DISPERSE/REACTIVE SYSTEM- Same as one step dyeingexcept the addition of reactive dye at 80c. This process is used for the reactive dyes which are notstable up to 130c, due to which they can not be used in onestep process 25 26. Thermosol Dyeing method- A) continious dyeing.B) pad batch process.Advantages of Thermosol dyeing- Continuous process so it gives higher production. Dye utilization is excellent. Dye can be used afterward. No carrier is required. Fabric is processed in open width form so natural feel offabric do not get disturbed. No crease formation. Lower energy is required than batch. No extra heat setting is required26 27. Disperse/vat dye system-PDPS method( continiousmethod) 27 28. ONE BATH ONE STEP THERMOSOLDYEING WITH DISPERSE ANDREACTIVE DYES.28 29. CHEMICAL RECIPE & PROCEDURE. Chemical recipe- Disperse dye-x g/l Reactive dye-y g/l Sodium bicarbonate or soda ash-5-20g/l Urea-100-200g/l Migration inhibitor-10-20 g/l Wetting agent- 1-2g/l PROCESS-pad-dry-thermosol-cool-wash. 29 30. Padding- Padding Temp-20-300 c Liquor pick up-60-80% ii) DRYING- First partial drying in infrared pre dryer and then fully drying. Partial drying is done to avoid migration of dyes. Drying is done at 120c. iii) THERMOFIXATION It is done at 180-220c, 30-45sec It is the fixation step. iv) PADDING- Padding bath contain NaOH + Na2S2O4 V) STEAMING- During this vat dye penetrated inside the cotton part. Thenoxidation, soaping and finally washing.30 31. One bath one step dyeing process-Disperse/Reactive dyes. Padding in the second step is done using NaCl + NaOH H- brand reactive dye is used. Fixation is done during steaming with saturated steam (102c) for 30-60 sec. Then washing ,soaping and again washing. Recipe-Disperse dye-x g/l Reactive dye-yg/l Sodium bicarbonate or soda ash-5-20g/l Urea-100-200g/l Migration inhibitor-10-20 g/l Wetting agent- 1-2g/l. 31 32. Dye