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Dyeing Process basically discusses what you do with the dyes. There are today available latest and state-of-the-art dyeing methods that effectively colour the various substrates. This is a very critical operation carried out in the Dye houses in a series of steps. The pages here gives precious information regarding the various dyeing processes in different industries.
Dyeing Process » Continuous Dyeing Process
Batch Dyeing Process Continuous Dyeing Process Semi-continuous Dyeing Process Pigment Dyeing Process

The working of a continuous dyeing process is described here. The textile substrates are feeded continuously into a dye range. The speeds can vary between 50 to 250 meters per minute. According to Industry estimates Continuous dyeing is a popular dyeing method and accounts for around 60% of total yardage of the products that are dyed.

A Continuous dyeing process typically consists the following. Dye application, dye fixation with heat or chemicals and finally washing. Continuous dyeing has been found to be most suitable for woven fabrics. Mostly continuous dye ranges are designed for dyeing blends of polyester and cotton. The step of padding plays a key role in the operation of continuous dyeing. Sometimes Nylon carpets are also dyed in continuous processes, but the design ranges for them is unlike that for flat fabrics. Warps are also dyed in continuous process. Very good examples of such warp dyeing are long chain warp dyeing and slasher dyeing using indigo.

A continuous dye range has been found useful and economically sustainable for dyeing long runs of a given shade. One important factor that separates continuous dyeing from batch dyeing is the tolerance factor for color variation. That is more for continuous dyeing as compared to batch dyeing. This is so because of two reasons a) the speed of the process. b) presence of a large number of process variables which affects dye application. The process that is illustrated below is designed for dyeing of blended fabric of polyester and cotton.

Continuous Dyeing ProcessContinuous Dyeing Process

Some of the popular methods in continuous dyeing process are Pad-steam, Wet-steam, thermosol dyeing, TAK dyeing, space dyeing, and pad-steam dyeing long chain warp dyeing etc.

Optimizing the Continuous dyeing Process

Continuous and to some extent semi-continuous dyeing processes both are less prone to water consumption than batch dyeing, but results in high concentration of residues. If some strict control measures are taken up it is possible to reduce this losses of concentrated liquor. The following steps may prove useful.
  • Applying low add-on liquor application systems along with minimising of volume capacity of the dip through when pad dyeing techniques are in operation.

  • Adoption of latest dispensing systems, where the chemicals get dispensed on-line as separate streams. They gets mixed only at the moment just before the delivery to the applicator.

  • Using any of the following systems for dosing of the padding liquor. Important to know that it should be strictly according to the measurement of the pick up:
    • A proper measurement of the dyeing liquor quantity consumption in comparison to the processed fabric. The resulting values thus obtained are processed automatically and applied in preparing the next comparable batch.

    • Application of the technique of rapid batch dyeing. Here the dyestuff solution is prepared just in time, with steps that are based on on-line measurement of the pick up. This proves better than those dyestuff that is kept prepared already for the whole batch before the commencement of the dyeing batch.

  • To increase washing efficiency based on the proven principles like reduction of carry-over and counter-current washing.

What gives Carpet its vibrant colour?

Vibrant Color
The carpets that you see in different colour and hues is dyed by a continuous dyeing. A continuous dye range for carpet typically consist of a steamer and a dye applicator. Generally acid dyes are used. Carpet manufacturers are very adept in application of dye for producing special color effects on their product. As a result of this, many variations of dye applicators exist. Under normal circumstances, a very high liquor ratio is must to produce good quality dyeing of carpet. Typically, application method is used to meter the dye solution into the carpet. Patterned effects are produced when the stream of dye that is metered onto the carpet are momentarily interrupted. Streams of variety color dyes are applied in different patterns to create those special effects.


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