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Dyeing process

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What is dyeing process?

What is dyeing process?

Dyeing process is to put colors or color-designs by using dyestuffs onto yarn, woven, and knitted fabrics.
Many kind of chemicals are used in this process. For instance, dispersing or leveling agent to evenly dye the fiber, soaping agent to remove excess dyestuffs from the fiber, fixing agent to fix dyestuffs onto fabrics.
The type of dyestuffs, dye assistants, or method of improving color fastness will be different and be depending on the fibers.

Processing method

Package (Cone) dyeing machine

It is used for dyeing of yarns for woven or knitted fabric.
The yarn, wound up to core bobbin, goes to dyeing stage, followed by soaping and fixing stage in the same condition as scouring and bleaching.
The solution with chemicals alternate the circulation from in-side to out-side and out-side to in-side. The most important key is to treat inner side, middle side and outer side of cone equally. The chemicals are required to provide penetration and eveness property.

Recommended recipe for Polyester yarn:

Disperse dyes
x%o.w.f.
NICCA SUNSOLT series 【leveling/dipsersant】
0.5~1g/L
Acetic acid
0.3g/L
130°C×30min.

Recommended recipe for Cotton yarn:

Reactive dyes
x%o.w.f.
Glauber's salt (unhydride)
20~80g/L
Soda ash
5~25g/L
NEOCRYSTAL 200【leveler】
1g/L
TEXPORT D series
【in-bath quality improver】
1g/L
40~80°C×30~60min.

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Pressurized jet dyeing machine

Pressurized jet dyeing machine

It is used for dyeing process (dyeing, soaping, fixing) on synthetic wovens or kniited fabrics.
Applicable for raising up temperature above 130C, with the device of circulating fabric by spraying power with chemical solution from the nozzle. By the physical beatings on woven fabric makes it possible to remove more waxes or sizes from the fabric, which were sticking on the fabric from the previous continuous scouring process. These impurities may cause the stains or uneven dyeing. As for knits, there is normally no scouring process prior to dyeing stage. The oils on the fabric may degrade the dispersibility of dyes or cause uneveness from batch to batch due to various amount of oils on the fabric. The chemicals need to have enough emulsification power of waxes or sizes as well as no degradation of dyestuff dispersibility under high impurities existence.
Additional use of dyebath lubricant to minimize the fabric damage by frictions or wrinkles will be effective to enhance the quality.
Above mentioned chemicals should have all low foaming property for treating both wovens and knitted fabrics.

Recommended recipe for Polyester:

Disperse dyes
x%o.w.f.
NICCA SUNSOLT series 【disperse/leveler】
0.5~1g/L
Acetic acid
0.3g/L
TEXPORT DY-300F【dye bath lubricant】
0.3g/L
130°C×30min.

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Winch

Winch

It is mainly used for cotton knitted fabric for dyeing process (dyeing, soaping, fixing). There are both atmospheric and pressurizing types and the latter is applicable for polyester fabric.
The device is to use reel for circulating the fabric. Due to processing in rope form, it may cause creases so utilizing anti-crease agent (dye bath lubricant) is effective for its prevention.
The fabric stays in the chemical bath rather long with less tension so the fabric hand feel is soft.

Recommended recipe for Cotton:

Reactive dyes
x%o.w.f.
Glauber's salt (unhydrate)
20~80g/L
Soda ash
5~25g/L
NEOCRYSTAL 200【leveler】
1g/L
TEXPORT D series 【dye bath lubricant】
1g/L
40~80°C×30~60min.

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Drum (Paddle) dyeing machine

Drum (Paddle) dyeing machine

It is used for dyeing the garments such as pantyhose, tights, or inner wears.
There are both atmospheric and pressurizing type and the latter is applicable for polyester fabric.
The drum in the machine, having many holes, will be rotating for dyeing the garments. Propylene-made mesh bags are used for putting garment pieces for better handling.

Recommended recipe for Nylon pantyhose:

Acid dyes
x%o.w.f.
NEWBON SD series【leveler】
2g/L
TEXPORT PRN
【in-bath quality improver】
0~5g/L
Acid donner
1~2g/L
100°C×30min.

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Continuous washing machine

It is a washing off machine for continuously dyed or printed woven fabric.
Un-fixed dyes, residual sizes, or remained chemicals on the fabric will be washed off continuously by using several washing boxes.
Continuous winch, treated by rope form, or open-soaper, treated by open width are one of these machine. Chemicals require high anti-redeposition property and should watch for keeping the chemical concentration level equal.

Recommended recipe for Cotton fabric:

LIPOTOL RK series【soaping agent】
2g/L
90~95°C×30sec.

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