Exhaust Dyeing

Indanthren dyes in exhaust dyeing
®
Indanthren dyes
in
exhaust dyeing
Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Content
Recommendations for dyeing yarn with vat dyes for the first time................................................................................................................................................ 3
Good levelness can be achieved in vat dyeings through.............................................................................................................................................................. 4
Advantages of cylindrical and conical packages .......................................................................................................................................................................... 5
Tube systems .............................................................................................................................................................................................................................. 6
Advantages and disadvantages of winding types......................................................................................................................................................................... 7
Winding density as a function of yarn thickness and type ............................................................................................................................................................ 8
Properties of pressed packages................................................................................................................................................................................................... 9
Effect of temperature on liquor flow rate .................................................................................................................................................................................... 10
Dye liquor flow rate for cellulosic yarns ...................................................................................................................................................................................... 11
Loss in weight of cotton ............................................................................................................................................................................................................. 12
Water requirements ................................................................................................................................................................................................................... 13
Water quality.............................................................................................................................................................................................................................. 14
Complexing capacity for CaCO3 ................................................................................................................................................................................................. 16
Rub fastness.............................................................................................................................................................................................................................. 17
Colour measurement units ......................................................................................................................................................................................................... 18
Reasons for a pretreatment ....................................................................................................................................................................................................... 20
Pretreatment of cotton yarn ....................................................................................................................................................................................................... 21
Prepigmentation process ........................................................................................................................................................................................................... 23
Leuco process ........................................................................................................................................................................................................................... 24
High temperature process.......................................................................................................................................................................................................... 25
Dye selection for the high temperature process ......................................................................................................................................................................... 26
®
Indanthren Brilliant Red LGG.................................................................................................................................................................................................... 27
Hank yarn dyeing with Indanthren dyes ..................................................................................................................................................................................... 28
Dyeing of PES/CEL with disperse / Indanthren dyes.................................................................................................................................................................. 29
Finishing of Indanthren dyeings ................................................................................................................................................................................................. 30
Obtaining a deeper shade in a fresh dyebath............................................................................................................................................................................. 33
Dye selection for cross-wound packages ................................................................................................................................................................................... 34
Auxiliaries recommendation for exhaust processes ................................................................................................................................................................... 36
RoDos process .......................................................................................................................................................................................................................... 42
Dyeing on the piece dyeing beam .............................................................................................................................................................................................. 49
Indanthren combination recommendations ................................................................................................................................................................................ 55
RAISA - computer program for the application of Indanthren dyes ............................................................................................................................................ 59
Note ........................................................................................................................................................................................................................................... 60

Recommendations for dyeing yarn with vat dyes for the first time
• Use dyes with good levelling properties

(Group A in our recommended list; see further below)
• Avoid dyeings > 6% (with brilliant green > 4 %).
• Avoid winding densities above 400 g/l and packages over

180 mm diameter.
• Pump output of the equipment should be 20-30 l/kg/min.
• Material to be dyed should be completely submerged in the

liquor (no short liquor).
• It should be possible to reverse the liquor flow.

Good levelness can be achieved in vat dyeings through
• Regular package structure.
• Pump performance that guarantees a liquor throughput of 20-30 l/kg/min.
• Intensive pretreatment: boiling-off or bleaching.
• Pigmentation and dyeing at high temperatures (80 - 90 °C).
• RoDos® process
• The addition of levelling auxiliaries (Peregal® P, Albigen® A).
• Optimum finishing of the dyeing.
• Use of dyes with good levelling-out properties.

Advantages of cylindrical and conical packages

Comparison: conical - cylindrical ð Preference for cylindrical package form
Reason:
Winding Exacter with constant radius.
Rounding off Not necessary as winding is exacter.
edges
Spacer No spacers needed for insertion systems; better sealing; up to 30 %
higher loading possible.
Loading the Simpler; no spacers;
dyeing machine Supply from winding dept. in blocks of 6.
Pressing Better utilization of available space and better seal between
packages.
Flow Smaller edge to middle difference;
better seal between packages.
Unwinding Easier unwinding, particularly with long packages.

Tube systems
Tubes Fibres Advantages Disadvantages
Biko Press PAC + WO Weight up to 3 kg; Winding not precise

yarn compression
AVA CO up to Nm 40/1 Weight up to 1.5 kg; Unwinding problems;

yarn compression no compression
Di CO up to Nm 100/1 Weight up to 1.5 kg; No compression

PES/CO no spacers
Multiflex CO + PES/CO Weight up to 1 kg; One-way tubes

Tube compression Spacers necessary
AC tubes CO up to Nm 50/1 Weight up to 1.5 kg; One-way tubes

tube compression;
no spacers
Metal Universal very durable; Expensive;

CO + PES/CO no staining PES/CO: inner layers may
become shiny

Advantages and disadvantages of winding types
Normal winding Precision winding

(constant angle) (changing angle)
Winding machine cost: low high

Package winding: stable unstable
Density: uniform not uniform
Unwinding performance: not so good good
Characteristic image zones: yes no

Winding density as a function of yarn thickness and type
Substrate Yarn thickness Winding density
Cotton up to Nm 40/1 ≈ 400 g/l

PES/Cotton Nm 50/1 ≈ 350 g/l
Linen ≈ 250 - 350 g/l

Viscose ≈ 350 g/l
Calculation of winding density: RAISA exhaust process

Properties of pressed packages
Winding thickness = Tube diameter
Winding density uncompressed = 330 g/l

20 % compressed ≈ 400 g/l
Package diameter max. 200 mm
Package weight 5“ tube ≈ 1400 g (tube 130 g)

6“ tube ≈ 1600 g (tube 150 g)

Effect of temperature on liquor flow rate

Example: Cotton, Nm 70/1, compressed packages, 1,450 g each
220 mm package diameter
420 g/l winding density
1.5 bar pressure drop
Pigmentation Dyeing Levelling
Liquor troughput, l/kg/min

100 50
Temperature, °C .
80 40
60 30
40 20
20 10
0 0
0 10 20 30 40 50 60
Time, min

Dye liquor flow rate for cellulosic yarns
Liquor throughput l / min / kg fabric
too low < 20

sufficient 20 - 25
good to very good 25 - 30
too high > 30
The above values take into account the usual leaks in the package column.
The true flow rate is therefore normally 10-30 % less, but nevertheless adequate.

Loss in weight of cotton
Boiling-off / Bleaching
4-6%
Bleaching + Mercerizing Dyeing of grey yarn

6 - 10 % 4-6%
Dyeing of pretreated
fabric
Possible gain after
dyeing
The loss in weight depends on the quality of the fibre.

Water requirements
The following amounts of water are required for 1 kg* of cellulosic yarn:
Vat dyeing Reactive dyeing

light dark light dark
Pretreatment: 3x 10 l 3x 10 l 3x 10 l 3x 10 l
Dyeing: 1x 10 l 1x 10 l 1x 10 l 1x 10 l
Finishing: 4x 10 l 8x 10 l 6x 10 l 8x 10 l
Total: 80 l 120 l 100 l 120 l
* Liquor ratio 10:1

Water quality
The process water for textile mills must meet the following minimum standard:
• Colourless / clear
• Free from vegetable and mineral impurities
• Free from iron and manganese compounds
• Soft
pH: 6-8
Hardness: max. 6 °Clark
Suspended matter: < 1 mg/l
Organic load: < 20 mg/l
Residue on ignition: < 50 mg/l
Iron: < 0.1 mg/l
Manganese: < 0.05 mg/l
Copper: < 0.01 mg/l
Nitrate: < 50 mg/l
Nitrite: < 5 mg/l
Free CO2: 0 if possible (risk of corrosion)

Possible problems with hardness

• Lower colour yield.
• Poor reproducibility of the dyeings.
• Dusting of the yarn, particularly when rewinding onto another bobbin.
• Poor fastness properties.
• Hard handle.
• Poor wettability.
• Deposits on the machines.
• Poor levelling-out properties, particularly with wound packages.
• Formation of spots.
These problems can be avoided by

. . . good pretreatment of the fabric.
. . . the use of Dekol® SAD, SN, Trilon® TA or TB in the dyeing process.
Of iron is present, Trilon® FE should be used too.

Complexing capacity for CaCO3
1 g . . . complexes . . . mg CaCO3* . . . °dH** . . . °Clark . . . °fH p.p.m. (USA)
Dekol® SAD 108 6.0 7.5 10.8 108
Dekol® SN 125 7.0 8.7 12.5 125
Lufibrol® DK 162 9.1 11.3 16.2 162
Trilon® TA Powder 353 19.8 24.7 35.3 353
Trilon® TA Liquid 176 9.9 12.3 17.6 176
Trilon® TB Powder 235 13.2 16.4 23.5 235
Trilon® TB Liquid 118 6.6 8.2 11.8 118
* at pH 11
** 1 °dH = 10 mg CaO / l water = 17.9 mg CaCO3 / l water

Rub fastness
• As the rub fastness depends very much on the substrate, the pattern card gives no data.
• If the dry rub fastness is good, it is normally not possible to improve the wet rub fastness.
• Staining through fibre abrasion and foreign bodies are not taken into account.
• Dark reactive dyeings often have better wet rub fastness than vat dyeings
(½ - 1 point).
Factors that affect the rub fastness:

û Material.
û Dye concentration.
û Water hardness.
û Improper finishing of the dyeing.
û Inadequate liquor flow rate.

Colour measurement units
NBS Cielab
Total colour difference: DE DE
Difference in lightness: DL DL
Difference in saturation: DS DC
(Brilliance, clarity)
Difference in shade: DT DH
Daylight: D 65
Incandescent light: A
Department store light: TL 84
Fluorescent tube light: F

Pretreatment

Reasons for a pretreatment
• Good rewetting of the fabric (e.g.: terry fabric).
• Brilliant shades.
• Heavy contamination in short liquors.
• High amounts of spin-finishing oils.
• Migration of impurities during drying in rapid dryers.
• Reproducibility of the dyeings.

Pretreatment of cotton yarn

Boiling-off Bleaching
2.0 g/l NaOH 100 % 4.0 ml/l hydrogen peroxide 50 %

1.0 g/l Lufibrol® DK 1.5 g/l NaOH 100 %
1.0 g/l Kieralon® CD or MFB 1.0 g/l Prestogen® D
1.0 g/l Kieralon® CD or MFB
Liquor ratio 10 : 1 Liquor ratio 10 : 1

Treatment time 30 min Treatment time 30 min
Temperature 95 °C Temperature 95 °C
rinse. Extraction, if required:

When the bleaching time is up, add to the liquor:
1,0 g/l Lufibrol® DK
and maintain at 95 °C for a further 10 min
rinse.

Dyeing
of
cross-wound
packages

Prepigmentation process (< 3 % Indanthren® dye)

100
Temperature, °C
• ‚
80
60
40
20
0 10 20 30 40 50 60
Time, min
• ‚
®
2 g/l Dekol SN ... ml/l caustic soda 38 °Bé
... % Indanthren dye ... g/l Hydrosulfite Conc. BASF
1 - 2 g/l Peregal® P (if necessary)
... g/l sodium nitrite or glucose (necessary for dyes
that are sensitive to overreduction)

Leuco process (> 3 % Indanthren® dye)

100
Temperature, °C
•
80
60
40
20
0 10 20 30 40 50 60
Time, min
•
2 g/l Dekol® SN
... % Indanthren dye
... ml/l caustic soda 38 °Bé
... g/l Hydrosulfite Conc. BASF
1-2 g/l Peregal® P (if necessary)
... g/l sodium nitrite or glucose (necessary for dyes that are sensitive to overreduction)

High temperature process (< 2 % Indanthren® dye*)

120
Temperature, °C
100
• ‚
80
60
40
0 10 20 30 40 50 60 70
Time, min
• 2 g/l Dekol® SN ‚ 3 ml/l caustic soda 38 °Bé

®
1 g/l Trilon TA Powder 3 g/l Hydrosulfite Conc. BASF
<2 % Indanthren dye *
4 g/l Rongal® 5242 or > 5 g/l Rongal HT
1-2 g/l Peregal® P (if necessary)
3 g/l Glucose (necessary for dyes that are sensitive to overreduction;
not necessary in case of Rongal 5242)
* See „Dye selection for the high temperature process“

Dye selection for the high temperature process

Indanthren® Shade Indanthren® Shade
Yellow 5GF unchanged Blue BC** unchanged
Golden Orange G* weaker Blue CLF weaker
Orange 3G duller, weaker Brilliant Green FFB weaker
Orange RRTS duller, weaker Olive Green B unchanged
Red FBB weaker Olive MW browner
Brilliant Violet RR much bluer Olive T browner
Brilliant Violet 3B bluer, weaker Brown BR yellower
Dark Blue BOA unchanged Brown RN yellower, weaker
Navy Blue BF greener Brown LBG yellower
Dark Blue DB** weaker Grey 5607 bluer, weaker
Dark Blue 5508** weaker Direct Black RBS unchanged
Navy Blue G redder Direct Black RB unchanged
Brilliant Blue RCL** unchanged Direct Black R unchanged
Blue RS** unchanged Direct Black 5589 unchanged
* At < 1% take account of fastness to light

** Sensitive to overreduction

®
Indanthren Brilliant Red LGG
70
Temperature, °C
60 •
50
40 ‚ ƒ
30
20
0 10 20 30 40 50 60
Time, min
• 2 g/l Dekol® SN ƒ 10 min suck off (vacuum),

1 g/l Trilon® TA Powder Oxidation: 5.0 ml/l hydrogen peroxide 50 %
... % Indanthren Brilliant Red LGG ®Colloisol * 0.5 g/l Setamol® WS
... g/l soda ash 5 min cold, 15 min at 60 °C,
... g/l Hydrosulfite Conc. BASF drop the bath,
cold rinse with overflow until clear,
‚ 25 g/l glaubers salt Soaping: see „Finishing of vat dyeings“
* Combination dyes see Combination recommendations „Brilliant Red“.

®
Hank yarn dyeing with Indanthren dyes
Dyeing Rinsing Oxidation Rinsing Soaping Rinsing
100
80
Temperature, °C
‚
60 • …
40
ƒ
20
„
0
0 20 40 60 80 100 120 140 160 180 200
Time, min
• 2 g/l Dekol® SN ‚ Cold rinse with overflow until pH 10.

1 g/l Trilon® TA Liquid
... % Indanthren dye ƒ Cold rinse without overflow
... g/l Hydrosulfite Conc. BASF „ 4 ml/l hydrogen peroxide 50 %
1-3 g/l Peregal® P (if necessary) 1 g/l Setamol® WS
3 g/l glucose (necessary for dyes
that are sensitive to overreduction) … 1 g/l Kieralon® B high conc.

®
Dyeing of PES/CEL with disperse / Indanthren dyes
140
120
Temperature, °C
100
80
‚
•
60
40
20
0 20 40 60 80 100 120 140
Time, min
• 1-2 g/l Dekol® SN ‚ ... ml/l caustic soda 38 °Bé

0.5 g/l Trilon® TA Powder ... g/l Hydrosulfite Conc. BASF
1.0 g/l Setamol® WS 1-2 g/l Peregal® P (if necessary)
... % disperse / Indanthren dye ... g/l sodium nitrite or glucose (necessary for
... ml/l acetic acid pH 4 - 5 dyes that are sensitive to overreduction)

®
Finishing of Indanthren dyeings (light shades, < 1 %)
Oxidation Soaping Rinsing Softening
100
Temperature, °C
80
60
‚
40
ƒ
•
20
0
0 10 20 30 40 50 60 70
Time, min
• ƒ
®
2 g/l Ludigol or hydrogen peroxide 50 % 2.0 g/l Basosoft® EUK
0.5 ml/l acetic acid 30 %
‚
1 g/l Kieralon® B high conc.

®
Finishing of Indanthren dyeings (medium shades, 1 - 3 %)
Reductive Oxidation Soapinng Rinsing Softening
100
clearing
Temperature, °C
80
ƒ
60
40
„
‚
20
•
0
0 10 20 30 40 50 60 70 80
Time, min
• 2 ml/l caustic soda 38 °Bé ƒ 1.0 g/l Kieralon® B high conc.
2 g/l Hydrosulfite Conc. BASF
1 g/l Setamol® WS „ 2.0 g/l Basosoft® EUK
0.5 ml/l acetic acid 30 %
‚ 2 ®
g/l Ludigol or hydrogen peroxide 50 %
0.5 g/l Setamol® WS

®
Finishing of Indanthren dyeings (dark shades, > 3 %)
Reductive Oxidation 1st soaping 2nd soaping Rinsing Softening
100
clearing
Temperature, °C
80
„
60
ƒ
40
…
‚
20
•
0
0 10 20 30 40 50 60 70 80 90
Time, min
• 2 ml/l caustic soda 38 °Bé ƒ 0.3 g/l Uniperol® O microperl

2 g/l Hydrosulfite Conc. BASF
1 g/l Setamol® WS „ 1.0 g/l Kieralon® B high conc.
‚ 2 g/l Ludigol® or hydrogen peroxide 50 % … 2.0 g/l Basosoft® EUK

0.5 g/l Setamol® WS 0.5 ml/l acetic acid 30 %

Obtaining a deeper shade in a fresh dyebath

Example:
In vat dyeing, 2.0 % dyeing
approx. 90 %* of the dye is fixed in the yarn = 1.8 % dye *
approx. 10 %* remains in the dye liquor, which is drained = 0.2 % dye *
To deepen a shade by 20% in a fresh dyebath requires:

10 %* to reestablish the original dye concentration = 0.2 % dye *
20 % to deepen the shade = 0.4 % dye
Quantity of dye required = 0.6 % dye
Basic premises for calculating the chemicals:

dye fixed in the yarn = 1.8 % dye *
dye remaining in the liquor = 0.2 % dye *
20 % to deepen the shade = 0.4 % dye
Dye quantity to be used in the calculation = 2.4 % dye
* Exact value depends on dye, depth of shade, dyeing temperature, liquor ratio and levelling auxiliary.

Dye selection for cross-wound packages

(Not high temperature process)
Group A Group B Group C
Pastel shades Light / medium shades Dark shades
(up to approx. 2 % Colloisol)
Indanthren® Indanthren® Indanthren®
Yellow 5GF / F3GC Golden Orange G* Brilliant Red LGG
Orange 3G Orange RRTS Navy Blue BF / TRR
Brilliant Orange GR Brilliant Violet RR / 3B Dark Blue BOA
Scarlet GG Navy Blue G Dark Blue DB** / 5508**
Red FBB Blue RS** / BC** / GC** Brown LBG
Rubine R Brilliant Blue RCL** Olive MW / T
Blue CLF Olive Green B Direct Black R / RB / 5589
Brilliant Green FFB Brown BR Black BB
Olive R Direct Black RBS
Brown RN / 5170
Grey 5607 + all dyes listed in + all dyes listed in
Group A Groups A + B
* At < 1 % take account of fastness to light ** Sensitive to overreduction

Dye selection for cross-wound packages

(Not high temperature process)
Group D
Shockoxidation
(remove liquor by suction)
is necessarily needed
Indanthren®
Brilliant Pink R
Brilliant Orange RK
Brilliant Red LGG ***
Red FGL ***
Red Violet RRN
Mainly used on
mercericed cotton yarn
or
viscose (embroidery yarn
*** Soda or soda/caustic soda method

Indanthren dyes in the exhaust process

General information
Yellow 5GF
Brilliant, pure shade. Higher standard to light fastness than vat yellow 2. Suitable for HT process. Little shade change during soaping. Fast to coloured
bleaching. Reduce pH to appr. 9 before oxidation, otherwise shade somewhat brownish. Combinations of green and a large amount of yellow are prone to
“green eating”. Phototropic. Not fast to mercerizing.
Yellow F3GC
Neutral yellow shade. Little shade change during soaping. Very good light fastness. Fast to coloured bleaching. Average chlorine fastness. Combinations of
green and a large amount of yellow are prone to “green eating”. The only yellow that is fast to mercerizing.
Yellow 3R
Very high light- and wet fastnesses. In deep shades also fast to weathering. Good combination dye for beige and brown shades. At exposure to light quite
rapid shade shift to brown (first break); resulting shade is very consistent.
Golden Yellow RK
High tinctorial strength, economic, Strong staining on PES (lemon yellow). Fast soaping. Less “green eating”. Use Brilliant Pink R or Red Violett RRN as
shading components.
Golden Orange G
Good levelling properties. Combination dye for khaki and olive shades. Suitable for HT process. Pronounced shade change during soaping. Fast to coloured
bleaching. Light fastness in pale shades may be a problem- use > 1%.
Orange 3G
Good levelling properties. Standard and shading dye. Little shade change during soaping. High standard of fastness. Fast to coloured bleaching.
Brillant Orange GR
High tinctorial strength and outstanding brilliant shade especially for warn clothes. Little change during soaping (redder). Very good compatibility with
Indanthren Scarlet GG Colloisol.
Orange RRTS
High colour strength. Economic. Not recommended for light shades, because of average levelling-out properties and moderate light fastness. Shading dye
for deep brown shades. Suitable for HT process. Little shade change during soaping. Protect vat from light. Fast to coloured bleaching. Good standard of wet
fastness. Shade change towards yellow during drying and ironing (reversible).
Scarlet GG
High all-over fastness. Standard and combination dye with high colour strength. Fast soaping.


General information
Brilliant Red LGG
Only suitable for yarn dyeing, not for rope dyeing, due to its low affinity.
Most brilliant vat red for deep red shades. Good levelling properties. Colour yield increased with soda or soda/caustic soda. Use Yellow 5GF, Red FBB and
Blue CLF as shading components. Not recommended as a shading component for pale shades, because of limited light fastness. Crosswound packages
must be preoxidized by suction extraction after dyeing. The dye must be oxidized with a large amount of peroxide at pH 7 – 9. Not recommended for
application in rope-dying machines. Low substantivity. Fast to coloured bleaching.
Red FGL
Colour yield increased with soda or soda/caustic soda. No overflow rinse or reductive clearing. Must be oxidized with a large amount of peroxide at pH 7 – 9.
Use Yellow 5GF, Red FBB and Blue CLF as shading components. The only weatherfast red of vat dyes. Some lack in wet fastness compared to other vat
red brands. Higher light fastness in pale shades than other vat reds.
Red FBB
Standard and combination dye. Good levelling properties. Suitable for HT process. Light shades should not be applied by the pigmentation process (pigment
affinity too high). Little shade change during soaping. High standard of fastness. Fast to coloured bleaching.
Brilliant Pink R
Sensitive against most auxiliaries, use only Setamol WS, Avolan IS or sulphonated castor oil (Monopolbrillantöl). No levelling agent! Dye at higher
temperatures (80 – 90°C). No overflow rinse or reductive clearing. Oxidation only with peroxide, appr. 10 ml/l 35% 38°Bé. Light tenderer. Use Golden Yellow
RK or Red Violett RRN as shading components.
Rubine R
Very high tinctorial strength. Pronounced shade change during soaping, therefore exact soaping conditions necessary. Best alternative for heavy red and
rubine shades.
Red Violet RRN
Sensitive against most auxiliaries, use only Setamol WS, Avolan IS or sulphonated castor oil (Monopolbrillantöl). No levelling agent! Dye at higher
temperatures (80 – 90°C). No overflow rinse or reductive clearing. Oxidation only with peroxide, appr. 10 ml/l 35% 38°Bé. Use Golden Yellow RK or Brilliant
Pink R as shading components.


General information
Brilliant Violet RR
Most brilliant violet dye. High colour strength. Average levelling-out properties in light shades. Apply with Peregal P. Becomes bluer as dyeing temperature
increases. Suitable for HT process (much bluer). Shade may change during soaping and drying. Fast to coloured bleaching. Use as a single dye for solid
shades only if there are no particular requirements with regard to fastness to water drops and ironing. Faster to mercerizing than Brilliant Violet 3B.
Brilliant Violet 3B
High colour strength. Can improve the chlorine fastness of Indanthren Blue BC when applied in combinations. Suitable for HT process (somewhat bluer).
Fast to coloured bleaching. Other properties similar to those of RR.
Navy Blue TRR
High colour strength. The only navy blue dye with good fastness to water drops and ironing. Retarded by dye-affinitive levelling and dispersing agents.
Becomes redder as dyeing temperature increases. Dry cleaning causes the dyeings to bleed out red.
Navy Blue BF
High colour strength. Economic. Apply with Peregal P. The only navy blue dye that covers dead cotton. Suitable for HT process (greener). Pronounced shade
change towards red during soaping. Fast to coloured bleaching. Limited fastness to water drops, ironing and mercerizing. Note shade change caused by
finishing (becomes redder).
Navy Blue G
Greenish navy blue. Good levelling properties. Mainly for medium shades. Suitable for HT process (redder). Shade change towards red during soaping and
on overdrying. Fast to coloured bleaching. High standard of fastness. Limited fastness to water drops and ironing.
Dark Blue BOA
High colour strength. Economic. Standard dye for dark blue shades. Apply with Peregal P. Suitable for HT process. Pronounced shade change towards red
during soaping. High standard of fastness. Limited fastness to water drops and ironing.
Dark Blue DB
High colour strength. Economic. Suitable for HT process but glucose necessary. Pronounced shade change towards red during soaping, but less than with
Dark Blue 5508. High standard of fastness.
Dark Blue 5508
High colour strength. Economic. Poorer levelling properties than Dark Blue DB. Suitable for HT process but glucose necessary. Pronounced shade change
towards red during soaping. Fast to coloured bleaching. High standard of fastness. Better cost-benefit ratio than Dark Blue DB.


General information
Brilliant Blue RCL
Clear, brilliant blue shade. Apply with plenty of caustic soda and not too much hydrosulfite. Use Blue CLF for pale shades, because of better levelling-out.
Sensitive to overreduction and overoxidation. Suitable for HT process but glucose necessary. Fast to coloured bleaching. Good fastness to chlorine. High
standard of fastness. Ideal for workwear.
Blue RS
High colour strength. Economic. Apply with plenty of caustic soda and not too much hydrosulfite. Good levelling properties. Suitable for HT process but
glucose necessary. High standard of fastness. Not fast to chlorine. Sensitive to overreduction and overoxidation.
Blue BC
Standard dye. High colour strength. Economic. Suitable for HT process but glucose necessary. Fast to coloured bleaching with peroxide. Limited fastness to
chlorine. Good general standard of fastness. Sensitive to overreduction and overoxidation.
Blue CLF
Top-quality product with a high standard of fastness. No overreduction or overoxidation. Outstanding levelling properties. As a combination dye, mainly for
pale to medium shades. Higher colour yield when soda is used as the alkali. Vat skinning. Low substantivity. Suitable for HT process. Little shade change
during soaping. Fast to coloured bleaching. Maximum chlorine fastness, but chlorine treatment at pH values below 9 partially destroys the dye.
Brilliant Green FFB
Standard dye for all green shades. Good levelling properties. Suitable for HT process. High standard of fastness. Fast to coloured bleaching. Limited
fastness to ironing (shade change towards blue on overdrying). Limited rub and wash fastness in deep shades (Olive Green B performs better). Limited light
fastness in combinations with a large amount of yellow.
Olive Green B
Standard dye for maximum fastness requirements. Stable in the HT process. Pronounced shade change during soaping. In green, olive and khaki shades,
improves the light fastness of the other dyes. Fast to weathering. Fast to coloured bleaching.
Olive MW
Standard dye for olive shades. Moderate levelling properties. Little shade change during soaping. Good coverage of dead cotton. Suitable for HT process
(browner). High standard of fastness. Fast to coloured bleaching.
Olive T
Standard dye for military and civilian uniforms. Moderate levelling properties (add Peregal P). Suitable for HT process (browner). Little shade change during
soaping. Fast to coloured bleaching. Outstanding fastness to light, water drops and ironing.


General information
Olive R
Good levelling properties. Mainly for pale to medium shades. Pronounced shade change during soaping. On military fabrics, IR reflectance is similar to
chlorophyll curve. Fast to coloured bleaching. Good light fastness. Limited fastness to water drops, ironing and mercerizing.
Brown BR
Standard dye. Moderate levelling-out properties in pastel shades. Suitable for HT process. Becomes yellower as temperature increases. Little shade change
during soaping. Fast to coloured bleaching. Fast to light and weathering.
Brown RN
Good levelling properties. Very good in combinations with other IW dyes. High standard of fastness. Fast to coloured bleaching.
Brown 5170
Ideal combination dye for beige, brown and olive shades. Good levelling properties. For pale to medium shades. Little shade change during soaping. Fast to
coloured bleaching. High light fastness. Fast to weathering. Average coverage of dead cotton.
Brown LBG
High colour strength. Economic. Use Peregal P for pale and medium shades. Little shade change during soaping. Outstanding fastness to light and
weathering. Good coverage of dead cotton. Fast to coloured bleaching with peroxide. Limited chlorine fastness.
Grey 5607
Ideal standard dye for pale to medium grey shades. Good levelling properties. Little shade change during soaping. Suitable for HT process (bluer). Fast to
coloured bleaching. Fast to chlorine.
Grey NC
For military textiles (IR values). Fast soaping. Excellent fastness property profile.
Direct Black RBS/RB
Homogeneous grey and black dyes. Economic medium and deep grey shades. Use Peregal P. Suitable for HT process. Fast to coloured bleaching with
peroxide. May stain accompanying material red during chlorine bleaching. Cover dead cotton. Limited fastness to light and water drops in pale shades.
Direct Black 5589/R
High colour strength. Economic. For black and deep grey shades. Suitable for HT process. Fast to coloured bleaching. Fast to washing, light and weathering.
Black BB
Economic deep black. Must be oxidized with strong oxidizing agent (hypochlorite or persulfate). Not suitable for coloured bleach goods and washables.
Stains accompanying material red.

Auxiliaries recommendation for exhaust processes

Lufibrol® DK
Pretreatment Dyeing Finishing Extracting agent with
Primasol NF ® ® dispersing and
Leophen M
complexing effect.
Deaerating wetting agent. Rapid wetting Wetting agent with deaerating and
at low temperatures. More foam formation foam-suppressing action. Not applicable
in fully softened water. in dyebaths with vat dyes. Trilon® TA
Form water-soluble com-
®
Kieralon CD / MFB ® plexes with the ions of alkaline
Prestogen D earths and heavy metals.
Low-foaming wetting agent Peroxide stabilizer with
and detergent with emulsifying dispersing effect.
and extracive action and Peregal® P
complexing effect. Improves the levelling-out
Dekol® SN
properties of vat dyes,
Dispersant (protective colloid) and chelating
generally without affecting
Hydrosulfit konz. BASF agent for all stages in dyeing textiles
the color yield.
Universal reducing agent. produced from cotton and ist blends.
Uniperol® O microperle
® ®
Rongal 5242 Albigen A Aftertreatment agent for a better
Liquid reducing agent. Insensitive to Rongal® HT Stripping and rub fastness. Removes depositions
the atmospheric oxygen. It is necessary Special reducing levelling agent. of dye pigments.
to use small amounts of Hydrosulfite agent for high
Conc. BASF to achieve complete vatting. temperature
processes. Kieralon® B high conc.
Soaping-off agent with good wetting and dispersing effect.
®
Ludigol
Oxidizing agent for high alkaline liquors Setamol® WS / BL Basosoft® EUK
too. Without fibre damage. Dye-dispersing agent. Liquid softener for all types of fibres.

®
RoDos process
... for optimum levelling of vat dyeings

Bath exhaustion rate
100
90
80
Bath exhaustion, %
70
60
50
40 too fast
30 optimum rate
20 too slow
10
0
Dyeing time

Bath exhaustion in vat dyeing (prepigmentation process)
100
90
80
Bath exhaustion, %
70
60
50
Pigmentation
40
Single addition of hydrosulfite
30 Metered hydrosulfite*
20
10
0
0 10 20 30 40 50 60
Dyeing time, min
* Metering of hydrosulfite is not recommended.

Redox potential, mV
2 % Indanthren® Olive T ®Colloisol
- 1000
- 900
- 800
- 700
- 600
- 500
- 400
- 300
- 200
40 °C 60 °C 80 °C
Hydrosulfite
Rongal® 5242
Bath exhaustion and redox potential in Indanthren dyeing

RoDos® process
80 °C 80 °C 60 °C
100 0
+ hydrosulfite
Redox potential, mV
80 -200
Bath exhaustion, %
End of metering
60 -400
40 -600
Pigmentation
20 -800
Start of NaOH/
®
Rongal 5242 metering
0 -1000
0 10 20 30 40 50 60 70
Time, min

RoDos® process
Slow reduction by metered addition
100 of NaOH/Rongal® 5242
Temperature, °C
• ‚ ƒ
80
Pigmentation Complete reduction and maintenance

60 of the redox potential by addition of
hydrosulfite
40
0 10 20 30 40 50 60 70
Time, min
• ‚
®
2 g/l Dekol SN 18 ml/l NaOH 38 °Bé
1 g/l Trilon® TA Powder 2 g/l Rongal® 5242 (depending on depth of shade)
... % Indanthren® dye add at a constant rate over 20 min
2 ml/l NaOH 38 °Bé
2 g/l Peregal® P ƒ
... ml/l NaOH 38 °Bé (final quantity, calculated with RAISA)
2-4 g/l Hydrosulfite Conc. BASF (depending on depth of shade)

Advantages of the RoDos® process
• Better levelness.
• Modern measurement and control technology can be used to monitor the

state of the vat (redox potential).
• Reduced wastewater burden as a result of lower hydrosulfite concentration.
• Rongal® 5242 protects against overreduction by hydrosulfite as long as the

quantity of hydrosulfite does not far exceed the quantity of Rongal 5242.
• Easy to meter Rongal 5242 as it is liquid, stable to the oxygen in air and
water and it is active only with enough quantity of caustic soda.

Dyeing on the piece dyeing beam

Winding the goods onto the beam
When winding goods onto a beam, the following points must be noted:
⇒ Tension of the goods
⇒ Thickness of the goods on the beam
⇒ Covering the perforations

Thickness of goods on the beam
The structure and density of the goods, and the diameter of the beam determine how
much can be wound onto the beam.
The following data can be taken as a guide
• Tightly woven fabrics:

Beam diameter in mm = batch size in m
• Open fabrics:
Beam diameter in mm x 2 = batch size in m
• Terry fabric and knitgoods:

Batch size depends on the diameter of the beam and the size
of the dyeing machine.

Coverage of the perforations

Open fabric: overlap = winding thickness
Tight-woven Ware: overlap = approx. 4 - 6 cm
Overlap too small:

Material
O O O O O O O O O O O O O O O
Beam
Overlap
Correct overlap:
Material
O O O O O OBeam
O O O O O O O O O
Overlap

Dye selection for piece dyeing

Group A Group B Group C
Pastel shades Light / medium shades Dark shades
(up to approx. 2 % Colloisol)
Indanthren® Indanthren® Indanthren®

Yellow 5GF / F3GC Golden Orange G* Navy Blue BF / TRR
Orange 3G Orange RRTS Dark Blue BOA
Brilliant Orange GR Brilliant Violet RR / 3B Dark Blue DB** / 5508**
Scarlet GG Navy Blue G Brown LBG
Red FBB Brilliant Blue RCL** Olive MW / T
Rubine R Blue RS** / BC** Direct Black R / RB / 5589
Blue CLF Olive Green B Black BB
Brilliant Green FFB Brown BR
Olive R Direct Black RBS
Brown RN / 5170
Grey 5607
+ all dyes listed in + all dyes listed in
Group A Groups A + B
* At < 1 % take account of fastness to light ** Sensitive to overreduction

®
Indanthren dyes
+ =
Combination recommendations
for exhaust dyeing

Indanthren® combination recommendations * ≥ 1% dye

Exhaust dyeing ** ≥ 2 % dye
Main dye *** Soda or soda/caustic soda
Shading dye
Yellow Orange Brilliant Red***

Yellow 5GF / F3GC Golden Orange G* Brilliant Red LGG (not for piece dyeing)
Orange 3G Orange 3G / RRTS* Yellow 5GF
Scarlet GG Brilliant Orange GR Red FGL (not for piece dyeing)
Red FBB Yellow 5GF / F3GC Red FBB
Brilliant Green FFB Red FBB Blue CLF
Brown RN Brown RN / 5170
Olive R Olive R
Red Violet Light blue

Red FBB / Rubin R Brilliant Violet RR Blue CLF
Yellow 5GF / F3GC Brilliant Violet 3B Red FBB
Orange 3G / RRTS* Red FBB Brilliant Green FFB
Scarlet GG Rubin R Olive R
Brilliant Orange GR Blue RS* Brown RN
Blue CLF / RS* / BC* Blue BC* Grey 5607
Brown RN / 5170 / BR* Blue CLF


Shading dye
Royal blue Grey blue Kingfisher, pigeon

Brilliant Blue RCL Grey 5607 Blue BC* / RS* / CLF
Blue RS* Red FBB Navy Blue G*
Blue BC* Navy Blue G* Red FBB
Red FBB Brilliant Violet 3B Brilliant Violet 3B
Brilliant Violet 3B Blue CLF / RS* / BC* Brilliant Green FFB
Brilliant Green FFB Brown RN / 5170 Olive Green B
Navy blue, Dark blue Green Beige

Dark Blue DB* / 5508* Brilliant Green FFB Brown RN / 5170
Navy Blue G* / BF* / TRR* Olive Green B* Yellow 5GF / F3GC
Scarlet GG Yellow 5GF / F3GC Orange 3G
Red FBB Orange 3G Scarlet GG
Rubin R Blue CLF / RS* / BC* Red FBB
Brilliant Green FFB Brown RN / 5170 Brilliant Green FFB
Olive Green B Olive R Olive R
Brown BR* Grey 5607
Direct Black RB


Shading dye
Olive Brown Grey, Light grey
Olive R / MW* / T** Brown RN / 5170 Grey 5607

Yellow 5GF / F3GC Brown BR* / LBG** Yellow 5GF / F3GC
Orange 3G Yellow 5GF / F3GC Orange 3G
Golden Orange G* Orange 3G / RRTS* Scarlet GG
Scarlet GG Golden Orange G* Red FBB
Red FBB Scarlet GG Navy Blue G*
Navy Blue G* Red FBB Blue CLF
Dark Blue DB* Blue RS* / BC* Brilliant Green FFB
Blue CLF / RS* / BC* Brilliant Green FFB Olive R
Brilliant Green FFB Olive Green B Brown RN / 5170
Olive Green B Olive R / MW*
Brown RN / 5170 Direct Black RB*
Brown BR* / LBG**


Shading dye
Dark grey Black Black

Direct Black RB Direct Black 5589 Black BB
Direct Black RBS Direct Black R / RB
Orange 3G Navy Blue G*
Orange RRTS* Navy Blue BF*
Red FBB Dark Blue DB*
Dark Blue DB* / 5508* Dark Blue 5508*
Blue RS* / BC* Olive Green B
Blue CLF Olive T
Olive Green B Brown BR* / LBG*
Olive R / MW* / T**
Brown 5170 / BR*

RAISA - computer program for the application of Indanthren® dyes

RAISA contents the following segments:
General informations Exhaust processes Continuous processes
Product information General
• Dyes • General
• Auxiliaries Combination recommendations
• Ecology • Combination recommendations
Process information Dye selection
• Continuous processes • Dye selection on fastness grounds R ecipe calculation and
• exhaust processes or technical criteria in processing A pplication technology for
Calculations Calculations I ndanthren dyes
• Dye calculation (g/l, %, g/kg) • Chemical calculation for S ytematically
• NaOH concentration - cross wound packages, hank yarn
A djusted
• Amounts of Trilon to use and beam
• Temperature conversion (°C, °F) - Overflow, jet, winch and
Fibre separation drum dyeig machines RAISA has been developed for
- Jig with / without metering of our customers in order to
Titration procedures
chemicals
• Caustic soda, soda ash provide information about our
• Package density
• Hydrosulfite dyes, auxiliaries and the
• Yarn count systems
• Rongal 5242 (dtex, den, Nm, Ne ...) different processes.
• Ludigol
Fault tracing
• Hydrogene peroxide There is also the possibility for
• Fault tracing
• Sodium hypochlorite different calculations.

Note
The information submitted in this publication is based on our current

knowledge and experience. In view of the many factors that may affect
processing and application, these data do not relieve processors from
the responsibility of carrying out their own tests and experiments;
neither do they imply any legally binding assurance of certain
properties or of suitability for a specific purpose. It is the
responsibility of those to whom we supply our products to
ensure that any proprietary rights and existing laws and
legislation are observed.
The following brand names are registered Trade Marks of DyStar :

Indanthren, Colloisol
The following brand names are registered Trade Marks of :

Albigen, Basosoft, Dekol, Kieralon, Ludigol, Lufibrol, Peregal, Prestogen, Primasol,
Rongal, Setamol, Trilon, Uniperol und Vitexol.

Exhaust Dyeing

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Exhaust Dyeing

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Indanthren dyes in exhaust dyeing

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

• Use dyes with good levelling properties

• Avoid dyeings > 6% (with brilliant green > 4 %).

• Avoid winding densities above 400 g/l and packages over

• Pump output of the equipment should be 20-30 l/kg/min.

• Material to be dyed should be completely submerged in the

• It should be possible to reverse the liquor flow.

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Good levelness can be achieved in vat dyeings through

• Regular package structure.

• Pump performance that guarantees a liquor throughput of 20-30 l/kg/min.

• Intensive pretreatment: boiling-off or bleaching.

• Pigmentation and dyeing at high temperatures (80 - 90 °C).

• The addition of levelling auxiliaries (Peregal® P, Albigen® A).

• Optimum finishing of the dyeing.

• Use of dyes with good levelling-out properties.

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Advantages of cylindrical and conical packages

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Biko Press PAC + WO Weight up to 3 kg; Winding not precise

AVA CO up to Nm 40/1 Weight up to 1.5 kg; Unwinding problems;

Di CO up to Nm 100/1 Weight up to 1.5 kg; No compression

Multiflex CO + PES/CO Weight up to 1 kg; One-way tubes

AC tubes CO up to Nm 50/1 Weight up to 1.5 kg; One-way tubes

Metal Universal very durable; Expensive;

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Advantages and disadvantages of winding types

Normal winding Precision winding

Winding machine cost: low high

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Winding density as a function of yarn thickness and type

Substrate Yarn thickness Winding density

Cotton up to Nm 40/1 ≈ 400 g/l

PES/Cotton Nm 50/1 ≈ 350 g/l

Linen ≈ 250 - 350 g/l

Calculation of winding density: RAISA exhaust process

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Properties of pressed packages

Winding thickness = Tube diameter

Winding density uncompressed = 330 g/l

Package diameter max. 200 mm

Package weight 5“ tube ≈ 1400 g (tube 130 g)

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Effect of temperature on liquor flow rate

Pigmentation Dyeing Levelling

Liquor troughput, l/kg/min

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Dye liquor flow rate for cellulosic yarns

Liquor throughput l / min / kg fabric

too low < 20

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Loss in weight of cotton

Bleaching + Mercerizing Dyeing of grey yarn

The loss in weight depends on the quality of the fibre.

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Vat dyeing Reactive dyeing

Total: 80 l 120 l 100 l 120 l

* Liquor ratio 10:1

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Possible problems with hardness