IMPROVEING THE

REPRODUCIBILITY IN DYEING
 POINTS TO DISCUSS
• REPRODUCIBILITY
• RIGHT FIRST TIME DYEING
• BLIND DYEING CONCEPT
• LAB TO LAB REPRODUCBILITY
• LAB TO BULK REPRODUCBILITY
• AND HOW IMORVE REPRODUCBILITY
Background
 What is reproducibility?

To perform something in well manners and with

accuracy again and again.
 Reproducibility in dyeing??

The ability to produce the same shade with

recipe ,at anytime, every time and all the
times is termed as reproducibility.
IMPORTANCE OF REPRODUCIBILTY IN DYEING

• Approaching better and accurate results

• Decreases the shade variation
• Saves time and cost
• Increases productivity
• Achieve customer satisfaction
How Reproducibility Is Improved?
Right First Time Concept

and

Blind dyeing Concept

 Right First Time Dyeing
• RFT is the level of precision and accuracy of
process.
• Means the work done at first instance must
have desired results.
• No re-working or adjustments
 Importance of RFT
RFT eliminates
• Reprocessing
• Striping
• Re-dyeing
• Re-shading
 What reprocessing means here??
• More use of dyes and chemicals.
• More use of water
• Loss of time and possibly deadlines
• Lesser production compared to production
capacity.
• More energy consumption
• More effluent discharge and pollution.
• Higher effluent treatment costs
• Low competitiveness
• Low image in the global market.
• To achieve the RFT the most popular approach
is “Blind Dyeing”.

Blind Dyeing
 Blind dyeing concept
It is the practice of carrying out an exhaust
dyeing, removing the batch from the, and
loading the next batch and only then
examining the first batch for shade , levelness
etc.
 Principle of Blind Dyeing

• No-addition dyeing concept

• Control of factors affecting dyeing

Practices done to achieve Reproducibility

Process Cost Productivity Profit

Bind dyeing(RFT) 100 100 100
Small addition 110 80 48
Large addition 135 64 -45
Strip or redye 206 48 -375
The factors effecting the Dyeing
Reproducibility
 EFFECT OF SUBSTARTE

• Quality of fiber
• Textile yarn
• Woven fabrics
• Quality of fabrics
• Fabric preparation
• Lot to lot variation
 Effect of process conditions
• Temperature
• pH
• Pickup
• Methods of conditioning
• washing
 Effect of machine & equipment
• Color measuring instruments
• Color data processing
• Basis of computer matching
• Spectrophotometer
 Effect of Dyestuff & Auxiliaries
• Dye recipe formulation
• Dyestuff variables
• Impact of Dyeing auxiliaries
 Effect of Water & Steam
• Water impurities
• Hardness in dye bath
• Bicarbonate in dye bath
 Three Key Areas
• A recipe should give the same shade every
time it is repeated in the lab
• A recipe developed in the lab should give the
same shade in the bulk dyeing as it gives in the
lab dyeing.
• A recipe should give the same shade, all the
time it is repeated in the bulk dyeing
 FACTORS EFFECTING DYEING
REPRODUCIBILITY
• Water supply
• Type of substrate
• Dye application method
• Liquor ratio
• pH of dye bath
• Time/temperature profile
• Method of accessing color
• Weight basis for recipe calculation
 TYPES REPRODUCIBILTY
• Lab-to-lab reproducibility
• Lab-to-bulk reproducibility
• Bulk-to-bulk reproducibility
 Lab to lab reproducibility
• High quality lab recipe must be developed that
can b reproduced in bulk and give subsequent
bulk continuity.
Three problems raise their heads here:
• Accuracy of lab dyeing
• Compatible lab dyeing methods that can
reproduced in bulk
• Choice of dyestuff
 Aids to improve lab accuracy
• Use of automated machinery
• Lab dyeing machines with sophisticated
controllers
• Using multi-product injection (MPI) facilities
• Formulation and standards must be held in
shade library.
• Color matching instruments must used.
 Lab Responsibility
The following task must be taken care by the
textile laboratory.
• Receiving inspection of textile goods and dyes.
• Control of water quality.
• Lying down of quantity criteria.
• Development of appropriate test methods.
• Selection of reasonable dyeing and finishing
methods
 Lab Responsibility
• Making of formulation for new articles and
shades.
• Production control.
• Correction of off-shade dyeing
• Testing of color fastness and technologies
properties.
• Determination of the cause of problems
 Lab to Bulk Reproducibility
• When bulk results are correlated with that of
lab results then lab to bulk reproducibility is
achieved.
• Good Lab to lab reproducibility attributes to
good lab to bulk reproducibility.
Factors concerned for Good Lab to Bulk
Reproducibility
 Dye Selection
Many factors are involved in dye selection.
Dyes must be:
• Compatible
• Robust
• Stable
• Chromopheric content
• Reactive content in case of reactive dyes
 Dye Selection
• Moisture content
• Absorption in solution
• Particle size of dye
• Meeting the specification
 Substrate Control
• The various factors in substrate specification
must be certified such as:
• Dyeability
• Quality of fibre , yarn and fabric
 Computer color matching
• This technology can be major aid in dye house
both in cost and speeding up the production.
• For this database must be updated regularly.
Requirements for lab to bulk reproducibility

• A laboratory procedure that reproduce bulk

results or can be correlated with them must
be available.
• Process details must be standardized.
• Accuracy of weighting and measuring must be
of higher order in both lab and bulk practice.
 Practical Approaches to achieve lab
to bulk reproducibility
• By optimizing lab conditions compatible with
the bulk.
• By playing with recipe.
 How to Optimize lab conditions?
• Following Lab conditions can be considered
for reactive dyeing:
• Pad pressure
• Padder speed
• Drying temperature
• Drying time
• Steaming temperature
• Steam time
 Summary
• Lab procedure must be reproduced or correlated
with bulk system.
• Dyeing process must be standardized.
• Accuracy of weighting and measuring at lab and
bulk scale.
• Dyestuff used should be compatible , robust and
stable when applied.
• Data base loaded onto computer should be
updated.
• Lab dyeing equipments with sophisticated and
multi product injection are availed.
• Standard operating procedure(SOP)
• Proper control of machine parameters.