CPB Seminar CHT

CPB DYEING
Introduction
CPB DYEING
Padding with dye Batching and storring Washing off

and alkaline solution
2 01.05.2018 Kurt Speckle, Technical Service Dyestuffs

CPB DYEING
• cold dye fixation – energy savings

• highest fixing rate > 80% - much lower waste
• flexible in batch size, much better compared to
exhaust
• water saving app. 50 %
• no salt in effluent
• most times higher fabric quality, no biopolish
• higher productivity
• higher reproducibility

CPB DYEING
• reliability of production process
• efficiency

CPB DYEING

IMPORTANT PARAMETER
PROCESS WATER
MATERIAL
WASHING OFF
DWELLING DYESTUFF
MACHINE ALKALI
AUXILIARIES
COLD PAD BATCH DYEING
WITH BEZAKTIV DYES
Fabric requirements for CPB
IMPORTANT PARAMETER
PROCESS WATER
MATERIAL
WASHING OFF
DWELLING AUXILIARIES
ALKALI MACHINE
DYESTUFF
2 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs
REQUIREMENTS FOR THE PROCESSING WATER
• Clear, odourless
• Without chlorine
• Neutral pH (pH values should be checked using a pH meter)
• Water hardness below 90 ppm CaCO3 total max. 5°dH – German / 6.25 - U.K. / 5.2 - U.S.A. / 8.95 - French
• Low conductivity (no electrolyte)
• No copper, manganese, iron, nitrate etc.
• No solid substances in the water
• The water should be free of Carbon Dioxide (CO2), as its long-term presence may result in
machine corrosion.

REQUIREMENTS FOR THE PROCESSING WATER
These list indicates the minimum standards which a Textile Dyehouse water supply should meet. To
achieve these levels it may be necessary to pre treat the water ‘in-house’ before it is used for wet
processing or dyeing.

IMPORTANT PARAMETER - MATERIAL
Because to the chemical and physical conditions of the pretreatment work, the properties of
the fabric are changed.
It’s important to have uniformity from batch to batch.
Requirements for a uniform dyeing is a uniform pretreatment.
Well pretreated is half dyed!

To ensure optimum results with cold pad batch dyeing the fabric should be:
• Free of size

Mixed indicator 5
IMPORTANT PARAMETER – MATERIAL
SIZE / DESIZING sized desized
TEGEWA violet scale PVA

Polyvinylalcohol
Starch sized Starch desized
Polyester
iodine solution at a concentration Polyacrylate

c(I2) = 0.0025 mol/l (= 0.005 N)
9 = completly 6 = sufficient for
desized reactive dyeing Polyvinyl acetate

• Free of size
• Free of pectins, waxes, accompanying substances, mineral oil
• Good wettability

WETTABILITY
TEGEWA Drop-Test Capillary rise test
good bad
good bad
2 sec. 35 sec.

• Free of size, pectins, waxes, accompanying substances, mineral oil
• Neutral pH

PH–VALUE
Morapex Merck pH-Indicator pH scale
pH 3 pH 6,5 pH 8
equal pH over the entire width and length

• Neutral pH
• No residual peroxide

IMPORTANT PARAMETER – MATERIAL –
RESIDUALS OF HYDROGEN PEROXID Without With
CHT-CATALASE BF CHT-CATALASE BF

• Neutral pH
• No residual non-ionic surfactants

NO RESIDUAL NON-IONIC SURFACTANTS
Without product
+ 0,1 g/l non-ionic surfactant
+ 0.1 g/l non ionic surfactant

+ SARABID LDR

• Neutral pH
• Equal degree of mercerization

DEGREE OF CAUSTIFICATION AND MERCERISATION
Red-Green Test Baryt number
not causticized

100 g/l NaOH 100 %
Well mercerized yarns:

barite numbers between 150 and 160
150 g/l NaOH 100 %
Well mercerized woven fabrics:
barite numbers between 120 and 150.
200 g/l NaOH 100 %

• Neutral pH
• Equal degree of whiteness

DEGREE OF WHITENESS
Dyeing on a fabric with a not uniform/equal degree of whiteness
75 85
Degree of whiteness Berger
• Neutral pH
• If emerized, should be free of dust / powder

EMERIZED FABRICS
Free of dust / powder

• Neutral pH
• Same residual humidity and temperature over the entire width and lenght
• Should have no tension differences in the fabric

PREDRYING, FABRIC TEMPERATURE & RESIDUAL HUMIDITY
• Avoid overdrying
• Uniform weight per g/m2
• Small diferences in tension
• Do not dye the fabric immediately after the stenter / cane drier

• Neutral pH
• Storage
IMPORTANT PARAMETER – MATERIAL – STORAGE
In generally the goods should be stored:
• Dry
• Without big temperature fluctuations
• No expose to the direct sunlight
• Protect the fabric against impurity and damage

• Neutral pH
• Storage
THANK YOU FOR YOUR ATTENTION!

DYEING AUXILIARIES
COLD PAD BATCH
Auxiliaries for
• CPB dyeing
− Wetting agent COLORCONTIN VGP
− Alkaline system Si-CONTROL KKV / HEPTOL SF4
− Other auxiliaries – KOLLASOL CDS / SARABID LDR
• Washing after CPB dyeing COTOBLANC SEL
• Improving rubbing fastness REVOFIX WET
2 01.05.2018 Markus Boehme. TS dyeing aux.

COLORCONTIN VGP - WETTING AGENT
Requirements
for wetting
agent Better penetration of dyeing liquors in case of dense fabric
constructions
No wetting
COLORCONTIN
agent
VGP 2g/l

WETTING / DEARATING EFFECT

COLORCONTIN VGP - WETTING / DEAERATING EFFECT
Sinking test Sinking

preparing liquor with aux. , adding „beam“ to liquor time
No auxiliary -
KOLLASOL CDS 2g/l < 3sec
competitors product 2g/l 3-5 sec
COLORCONTIN VGP 2g/l < 3sec

Why do you need a
wetting agent when we
have good pretreatment
? • Good wetting by pretreatment
Shade differences (tailing, LCR) within batch
• Differences in pretreatment:
Different wetting within batch
Different grade of desizing
• Fabric not cooled:

Different temperature/humidity
of fabric within batch

TRIAL ON REDUCING TAILING / LISTING –
OVER-DRIED FABRIC
sample Over-dried conditioned
residual moisture
2% 7%
(%)
without auxiliary 67,22 70,88 pick up

(%)
COLORCONTIN
68,93 71,44
VGP

OVER-DRIED FABRIC
sample Over-dried Over-dried /
re-conditioned
residual moisture 2% 7%
Smallest pick up,

Without auxiliary darkest shade
67,22 70,88
Surface dyeing
109 100 (ring dyeing)
Highest pick up
COLORCONTIN VGP Levells out most differences in fabric
68,33 70,44
No ring dyeing 99 100
Color strength
(%)

DIFFERENT WETTABILITY
Pretreatment: 1 2 3 4
FELOSAN FOX ml/l 6.0 6.0 6.0 4.0
CONTAVAN ICE ml/l 4.0 4.0 4.0 -
BEISOL SED ml/l - - - 1.0
BEIXON Q ml/l - - - 3.0
Caustic soda 50 % ml/l 35.0 80.0 100.0 -
H2O2 50 % ml/l 45.0 45.0 45.0 -
Pick up 70 – 100 %
Cold pad bleach
Rinse 3x hot, 3x cold
neutralize
FELOSAN FOX ml/l - - - 5.0 Dyeing: A B C
CONTAVAN ICE ml/l - - - 4.0
sample 1-4 1-4 1-4
Caustic soda 50 % ml/l - - - 20.0
H2O2 50 % ml/l - - - 35.0 BEZAKTIV Blue V-RN spec g/l 50.0 50.0 50.0
70 – 100
Pick up - - - COLORCONTIN VGP g/l - 4.0 -
%
Steaming - - - 20 min Competitors product g/l - - 4,0
3x hot, Sodium silicate g/l 50.0 50.0 50.0
Rinse - - -
3x cold
- - - neutralize Caustic soda 38 °Bé g/l 30.0 30.0 30.0
Pretreatment 1 2 3 4
whiteness degree 72 75 75 87
residual size TEGEWA 2 5 6 6
TEGEWA drop test >300 s 210 s 4-5 s <1 s

DIFFERENT WETTABILITY
sample 1 2 3 4
-drop test- >300 s 210 s 4-5 s <1 s
Without auxiliary 98,15 96,94 105,56 104,18
COLORCONTIN
103,57 111,82 110,57 117,39
VGP
Competitors pick up (%)

100,83 103,19 108,23 117,15
product

TRIAL ON REDUCING TAILING / LISTING – DIFFERENT HYDROPHILITY
sample 1 2 3 4
Drop test >300 s 210 s 4-5 s <1 s
Without auxiliary 98,15 96,94 105,56 103,57
COLORCONTIN VGP 103,57 111,82 109,57 117,39
Competitors product 99,83 103,19 108,23 117,35

TRIAL ON REDUCING TAILING / LISTING – DIFFERENT HYDROPHILITY
sample 1 2 3 4
TRIAL ON REDUCING TAILING / LISTING
Drop test >300 s 210 s 4-5 s <1 s
Color strength
(%)
100
98,15 122,56
96,94 135,73
105,56 138,16
103,57
Without auxiliary
COLORCONTIN VGP 100

103,57 111,80
111,82 115,30
109,57 119,67
117,39
Competitors product 100

99,83 114,11
103,19 128,77
108,23 127,69
117,35

WETTING TEST
2 g/l
Time (seconds)
COLORCONTIN VGP 6
Primasol NF 15
COLORCONTIN SAN 32
Sera Wet C-AS 44
Albaflow PAD 65
in sec.
10 g/l BEZAKTIV Blue V-RN spec. 50 ml/l sodium silicate 38°Bé

2 g/l auxiliary 20 ml/l NaOH 38°Bé

Excellent wetting performances
Reduces tailing, listing effect based on material differences caused by

temperature/moisture and wettability
COLORCONTIN VGP
COLORCONTIN • Phosphoric acid ester, anionic,
VGP 2g/l
• Easily to be washed out
• Good deaerating effect, foam-inhibiting
• Silicone free

OTHER AUXILIARIES IN CPB
Deaerating agent
KOLLASOL CDS
• Very good deaerating effect
• Permanent stable in highly alkali and acid medium, compatible with dyestuffs
• Strong and long lasting anti-foam properties, excellent in combination with COLORCONTIN VGP
• Additional wetting effect
• Hydrophilic, easily to be washed out
• 0,1 – 0,3 g/l

OTHER AUXILIARIES IN CPB
Dispersing agent
SARABID LDR
• Increase of the dyestuff solubility, excellent dispersing effect
• Good sequestering properties of hardness
• Masking non ionic detergents
• Prevents precipitations with cotton accompanies
• Reduces dyeing differences caused by material / yarn differences
• „Must“ in greige dyeing / dyeing with poor pretreatment

Customer is facing
problems in streakiness
SARABID LDR
Production trial CPB in Brasil,
March 2018
dense CO weave shirting quality

• Desized
• Continuous bleaching Referring customer clear
• Mercerisation, washing off improvement concerning
streakiness and surface levelness
• CPB dyeing
with additionally
with 60 g/l silicate / 9 g/l NaOH
5 g/l SARABID LDR
• soaping / drying CIE Colour
Colour strength
difference
[%]
[ DE ]
Standard CPB recipe Standard Standard
without SARABID LDR [ 100 % ] [ 100 % ]
Trial: CPB recipe with
98 0.28
5 g/l SARABID LDR
ALKALINE SYSTEM
Sodium silicate / caustic soda traditional • Standard,20-30°C, reduced silicate
Sodium silicate / caustic soda - tropical method • 25-35°C –high amount of silicate
Sodium carbonate/ caustic soda version • 20-25°C, silicate free
18 Markus Boehme. TS dyeing aux.

SYSTEMS OF ALKALINE Sodium Sodium
carbonate/ silicate /
caustic caustic
soda soda –
tropical
method
immediatly
after 1hr
1 2
stability Fixing time after 3hr
(hr)
Reactive yellow g/l 15,3 15,3 low 8
Reactive red g/l 3,4 3,4 high 12
Reactive navy g/l 11,5 11,5 medium 12
19 Markus Boehme. TS dyeing aux.

GENERAL PROBLEMS WITH LIQUID SODIUM SILICATE
• Hardness and heavy metall ions reduce water solubility of silicates, crystallisation starts uncontrolled
Hardness can also be carried in process by cotton (400-700 mg/kg Ca2+, 300-500mg Mg2+)

SODIUM SILICATE - TO PREVENT DEPOSITS
Sodium silicate / caustic soda

traditional
+ HEPTOL SF4
Sodium silicate / caustic soda -
tropical method Sequesting agent
Sodium carbonate/ caustic soda − high capacity of binding hardness
version
− no de-metallisation effect to dyestuff
Si – CONTROL KKV / • 1:1 Replacement of sodium silicate

caustic soda with same amount, no sediments

SI-CONTROL KKV VS. SODIUM SILICATE
• CPB liquor with 200 ppm Calcium
• Test on filter paper after dwelling 5min. , showing Ca-Silicate
Si – CONTROL KKV 100g/l /

Sodium silicate 100 g/l /
caustic soda 20 g/l
caustic soda 20 g/l
DEPOSITS
100 g/l Sodium silicate

100 g/l Si – CONTROL KKV 100 g/l Sodium silicate
20 g/l caustic soda
20 g/l caustic soda 20 g/l caustic soda
2 g/l HEPTOL SF4
Procedure:
• The padding liquors (dye and alkaline) were

prepared with water 10°dH
• air-dry 10 days
• rinsed with warm water (photo )
SILICIUM CONTENT ON FABRIC
RFD cotton fabric

• Padding with alkaline, 20g/l NaOH
100 g/l sodium silicate
• Dwelling time: 12h
• Rinsing
20 g/l NaOH
2 x rinsing 5min 50°C pH7,
100 g/l Si-CONTROL KKV
1x rinsing 5min 50°C pH5
20g/l NaOH
100 g/l sodium silicate
2 g/l HEPTOL SF4
20g/l NaOH
(reference)

SILICIUM CONTENT ON FABRIC measured by AAS (atomic aborption spectroscopy)
remaining silicium content after rinsing

(in mg Si/kg fabric)
525
500
400
300
200
80
100 50
20
20g/l NaOH 20 g/l NaOH 20g/l NaOH 20g/l NaOH

100 g/l Si-CONTROL KKV 100 g/l sodium silicate 100 g/l sodium silicate
2 g/l HEPTOL SF4

ALKALINE-SYSTEMS
Dosing of a separate sequesting agent to your HEPTOL SF4

sodium silicate CPB process.
The required quantity depends on
- Concentration of sodium silicate
- Concentration of Ca, Mg, heavy metals
- Temperature and pH-value
Advantage: Flexible dosing of sequestering agent
Usage of a modified sodium silicate with anti-scalant

as alternative to your standard sodium silicate, 1:1 replacement
Si-CONTROL KKV
Advantage: Easy replacement of standard sodium silicate

WASHING AFTER CPB DYEING
How does COTOBLANC SEL work?
SEPARATION OF
COMPLEX PREVENTION OF
DYE
FORMATION RE-ADSORPTION
HYDROLYSATE
(dyestuff hydrolysate (even in presence of
(independent of + COTOBLANC SEL) electrolyte)
temperature)
27
COTOBLANC SEL
• At 80° - 98°C the hydrolysate elimination is the most effective

• Efficiency is independent from
- salt content, electrolyte
• Soluble and strong dye complex, works from pH 6 – 10
• Neutralisation at the end
• Lighter - medium shades 0.5 g/l – 1.0 g/l COTOBLANC SEL
Dark shades 1.0 g/l – 4.0 g/l COTOBLANC SEL
• In case of hardness plus HEPTOL SF4

COTOBLANC SEL AFTER CPB

COTOBLANC SEL
• Hydrolysed dye is kept in liquor

• No backstaining of hydrolysed dye
• Reduced water amounts of appr. 10-15 l/kg
• Excellent fastness

REVOFIX WET – for improving the wet rubbing fastness
REVOFIX WET forms a film For all of the important dye

around the fibre preventing thus classes
the abrasion of fibre/dye
CEL (reactive, sulphur, vat,
pigment, direct)
On various fibre types (including

PES)
No impact on the other fastnesses

and on the hydrophilicity
Low impact on shade and handle
Improves the wet rubbing fastness

by up to 2 grades
Meets demands of Oekotex,

ZDHC MRSL, GOTS
bluesign® approved
REVOFIX WET PRODUCTION TRIAL AFTER CPB
100% CO Pique´, 260 g/m2
Febuary 2018, Germany
Standard procedure customer Production trial at customer
• Cont. bleaching • Cont. bleaching
• CPB dyeing • CPB dyeing
• Cont. washing • Cont. washing
• Drying stenter • Wet/wet application REVOFIX WET
• Easy care finish • Easy care finish
− Residual moisture after cont. washing: 85%

− Pick up REVOFIX WET 98%
− REVOFIX WET 240 g/l, PADICOLL DYE 2 g/l
3% REVOFIX WET on fabric

REVOFIX WET - PRODUCTION TRIAL
100% CO Pique´, 260 g/m2
Fastness to
rubbing
Dry Wet Dry Wet
After CPB dyeing /

4-5 2
washing
3% REVOFIX WET 4-5 4
3% REVOFIX WET plus

easy care finish 4-5 3

REVOFIX WET PRODUCTION TRIAL 100% CO Pique´, 260 g/m2

Thank you for your attention
REVOFIX WET - PRODUCTION TRIAL
Performance: production trial successful as per customer

Handle / shade good
Test polo shirt are made for long term testing abrasive wear

CHT SWITZERLAND –Technical Conference Dyestuffs
COLD PAD BATCH
24-25. April 2018
CPB Dyeing Centre

Machinery requirements and options
J. Ströhle /CTO
Introduction
CPB_2018 /J. Ströhle/ 13.04.18 2

160 Years Textile Experience
BENNINGER produces dyeing padders since more than 90 years
Benninger AG is
founded in Uzwil,
Switzerland
1859 1914 1925 1930– 1975 1971– 1975 1975 -1991 2001 2007 2015
Dyeing first BENNINGER Peter BENNINGER Acquisition of Acquisition Launch of

Jigger BENNINGER 4 Walzen FIBE Foulard CK Padder Kleinewefers Küsters new Küsters
2 roller Padder (Bicoflex Dyeing Dyepad
padder) 333.xx
CPB_2018 /J. Ströhle/ 13.04.18 3

COW: The ecological sound textile finishing processes
Benninger KÜSTERS Dyepad

Benninger Trikoflex Washing Range
Carbon
Water Energy footprint Costs Quality
CPB dyeing vs. jet dyeing of knitwear - 75% - 77% - 78% - 32% +
Jet
100% salt free dyeing- Liquor ration < 1:1

CPB_2018 /J. Ströhle/ 13.04.18 4
COW: Savings per day for a knitwear D & F factory
(capacity of 30 tons per day; continuous versus discontinuous)
Saving 1800 m3 Saving 170t Steam/day Saving 12 to Salt/day

Water/day 75 ton/d CO2
Equal to Equal to emission of Equal to daily salt

1 olympic size 9’000 mid size cars for intake of 1.5 million
swimming pool one day people
50 x 20x 1.8 m
CPB_2018 /J. Ströhle/ 13.04.18 5

CPB dyeing
40 years innovation in motion
CPB dyeing CPB dyeing

1975 2015
CPB_2018 /J. Ströhle/ 13.04.18 6

KÜSTERS DYEPAD Datasheet Küsters Dyepad –CPB Station
Passport Speed (mech.) 6- 60 m/min
Working width 1600- 3600 (5400) mm
Pick up 45 – 120 %
Installed power 20 kW
Space L= 6 m , W = 6.7 m
Control system/ • Siemens S7 PLC
drive • Frequency controlled drive
• Colored Touchscreen HMI
Speciality/Options • 2 original Küsters S-rolls
• Nip & Troughdyeing
• Automatic cleaning
• 4:1 Dosing or Single
component dosing
(CONTIDOS)
• Automatic cooling
• Tensionless winding
• Suitable for Cold Bleach
thanks to specialrubber
CPB_2018 /J. Ströhle/ 13.04.18 7

CPB Station
Cooling increases the reproducibility
Dissolving Dyestuff tank Alkaline tanks 1. Entrance with fabric
tank
centralizing and uncurling
10 2. Cooling drum
1000l 1000l
1000l 300l 300l
200l
3. Dyeing Trough
4. Nip Dyeing mode with
Dyestuff 8 Alkaline solution
solution 5. S-rolls adjustable nip pressures
9 left/centre/right
6. Transfer rollers
2 7. Contact winding with
6 moveable platform or
7
1
4 central winder for woven
8. Ratio dosing with closed loop
control
3 5 9. Dyestuff inline cooling
10. Dyeing kitchen
CPB_2018 /J. Ströhle/ 13.04.18 8

Type of Squeezing mangles
No dyeing w/o Left/Center/ Right pressure adjustment !
Type Flexi- Dyeing Market-

bility share
Fix „Bombage“
0%
Central supported 2%
roller (Pigment)
Air cushions
5%
S-roller
> 90%
CPB_2018 /J. Ströhle/ 13.04.18 9

Type of Troughs
Type Liquor content Market Market-
WW 1800 mm share share
Woven Knit
Trough with
underliquor Squeezer 22 l 80% 0%
Trough with displacer

18 l 20% 0%
Trough with displacer

for Knit 29 l 0% 95 %
Nip Dyeing
3.8 l 5% 100%
CPB_2018 /J. Ströhle/ 13.04.18 10

Comparison trough dyeing vs. Nip dyeing
Trough dyeing Nip dyeing
Liquor content 10 l/m Working width 1.8 l/m Working width
Speed 60 m/min 40 m/min

Process CPB Dyeing (Reactive) CPB Dyeing (Reactive)
and CPB Bleaching
Min/max lot length 1000- ….. m 30 – …….m

Fabric tension low Very low
Danger of tailing in some cases possible No tailing
Applications - Woven fabrics - Knitwear

- Cold Bleach or fabric - short lots
with very bad hydrophility
- sometimes Rayon/Viscose
Handling Easy Very easy, very good visibility
CPB_2018 /J. Ströhle/ 13.04.18 11

Squeezing Roller
CPB_2018 /J. Ströhle/ 13.04.18 12

KÜSTERS DYEPAD – Swimming roller
Extended correction potential
CPB_2018 /J. Ströhle/ 13.04.18 13

KÜSTERS DYEPAD
Extended correction potential
Linear Nip Center pressure Side pressure

25/25/25 N/mm 20/30/20 N/mm 30/20/30 N/mm
CPB_2018 /J. Ströhle/ 13.04.18 14

BICOFLEX ®
Roller design
5 air cushiones flexible sleeve

air
supply
needle bearings
CPB_2018 /J. Ströhle/ 13.04.18 15

BICOFLEX ® - Aircushion roller
Flexibility
0 40 N/mm 0 -130 40 N/mm -130 90 90

10 N/mm
10 bar 10 bar
3 bar 3 bar 1.4 bar

6,05 bar 6 bar 10 bar 10 bar
Linear Nip Center pressure Side pressure
CPB_2018 /J. Ströhle/ 13.04.18 16

Screenshoots
CPB_2018 /J. Ströhle/ 13.04.18 17

HMI with touchscreen
All drive related function on one screen
30 m/min
Active speed
Safety switches
active
Login Manager
Fabric weight
Default
values
Maintenance
Trend curves Incident recorder
manager
CPB_2018 /J. Ströhle/ 13.04.18 18

All dyeing function on 1 screen
Inline dyestuff
Trough cooling
cooling
30 m/min
27 °C 29 °C 282 mm
Trough level
Filling
4:1 Dosing
Automatic
cleaning
2m
Tailing Control
196 ml/l 460 l/h

Pressure
adjustment
575 l/h L/C/R
68%
10 N/mm 20 N/mm 10 N/mm
Recipe
Management
Draining
CPB_2018 /J. Ströhle/ 13.04.18 19

Troubleshooting
CPB_2018 /J. Ströhle/ 13.04.18 20

Troubleshooting (I)
Uneven fabric tension leads into shade variation
Article: SJ CV/PUE 96/4% Article: SJ CV/LI 70/30% Padder: Mathis Lab pad with nip dyeing
Weight: 200g/m2 Weight: 190 g/m2 Recipe: 35 g/l Remazolblack B
30 g/l Soda ash
6 ml/l NaOH 50%
Tensionless
Tensionless
Tension 15 N/m Tension 15 N/m

dL= -1.04 (darker) dL= 0.53 (ligther)
dE= 2.11 dE= 2.25
Tension 30 N/m
dL= -1.46 (darker) Tension 30 N/m
dE= 3.12 dL= 0.53 (lighter)
dE= 2.25
CPB_2018 /J. Ströhle/ 13.04.18 21

Troubleshooting (II)
Squeezing line with talcum powder checked? Weekly!!
recommended
Procedure:
1. Close squeezer at desired pressure,
2. Run the squeezer for 25 min in order to heat up theoil
3. Distribute talcum powder onto the rollers (Caution for fingersetc.),
4. Stop machine
5. Remove the excess talcum (compress air pistol)
6. Open Squeezer,
7. Measure line in mm (1 digit accuracy)
Only the dynamic talcum powder method gives reliable results !!
CPB_2018 /J. Ströhle/ 13.04.18 22

Troubleshooting (III)
Tailing because of different fabric moisture begin to end
1.00 ADD ON development during dyeing 120

0.90
Fabric 100
0.80 Liquor
Fabric surface temp.
surface temp. consumption 55°C
0.70
Opening dosing valve
32°C Increases 80
Add on in %
constantly by
0.60 approx 6 – 8 %
0.50 60
0.40
40
0.30
0.20
Linear (Alkali) Linear (Farbe) 20
0.10
0.00 0
0
45
90
135
180
225
270
315
360
405
450
495
540
585
630
675
720
765
810
855
900
945
990
1035
1080
1125
1170
Sec.
Conclusion:
• variation of fabric temperature and residual moisture has an influence onLiquor
consumption (add on).
• End is overdryed (=> end is darker than begin)
• Example: begin 8 % +58% dyeliquor = 66% , end 0 %. + 66 % dyeliquor = 66%)
CPB_2018 /J. Ströhle/ 13.04.18 23
Troubleshooting (IV)
Without cooling the oil the temperature of roller surface increases undesired !!
45 °C
35 °C
w/o cooling
with cooling
25 °C
0 10 min 20 min 30 min
CPB_2018 /J. Ströhle/ 13.04.18 24

IMAGES
CPB_2018 /J. Ströhle/ 13.04.18 25

Benninger KÜSTERS DYEPAD
Knitwear gently dyed
CPB_2018 /J. Ströhle/ 13.04.18 26

CPB dyeing stations
Woven fabric
CPB_2018 /J. Ströhle/ 13.04.18 27

Different Winding
Woven Knitwear
CPB_2018 /J. Ströhle/ 13.04.18 28

Bleaching and Dyeing on same machine
CPB_2018 /J. Ströhle/ 13.04.18 29

THANK YOU
COW processing saves resources

Left/Center/Right pressure adjustment for dyeing padders are a must
Controlled temperature increases the reproducibility
Küsters Dyepad Copies do not have the save performance than the ORIGINAL
24-25. April 2018
Dosing for CPB Dyeing

J. Ströhle /CTO
CPB Station
Dissolving Dyestuff tank Alkaline tanks 1. Entrance with fabric

tank
centralizing and uncurling
10 2. Cooling drum
1000l 1000l
1000l 300l 300l
200l
3. Dyeing Trough
4. Nip Dyeing mode with
Dyestuff 8 Alkaline solution
solution 5. S-rolls adjustable nip pressures
9 left/centre/right
6. Transfer rollers
2 7. Contact winding with
6 moveable platform or
7
1
4 central winder for woven
8. Ratio dosing with closed loop
control
3 5 9. Dyestuff inline cooling
10. Dyeing kitchen
Dosing_2018 /J.Ströhle/ 13.04.18 2

Types of dosing unit
Type Accu- Flexibility Costs Market-

racy share
4:1 with dosing
pump
50%
4:1 dosing with

closed loop 30%
control
Single chemical
dosing
20%

4:1 dosing units
SERA Dosing pump with open loop Contidos SF 1 with closed loop control
Hose pipe to
padder Feeding to
padder
Alkaline pump Flowmeter
Alkaline pump
Frequency
controlled motor
Storage tank Max. flow valve

16/4 l
Dyestuff pump
Dyestuff pump

CONTIDOS SF1 (4:1) - One screen – all information
Inline-cooling
dyestuff
Dyestuff
Filling
Alkaline
Actual
flowrates
Draining

Contidos
Single chemical dosing
Dissolving
tank
Dyestuff tanks
Chemicals Küsters Dyepad

Contidos
Single chemical dosing
Static mixer
Flowmeter
Chemical pumps
Storage tanks min.

1000 mm elevated

CONTIDOS SF4 - One screen – all information
4 chemicals
Rinsing, cleaning
Target values
(recipe)

4:1 dosing vs. single Chemical dosing
Schematic description of dosing concepts
4:1 Dosing Single chemical dosing

Dyestuff Alkaline Dyestuff
WettingA. (Silicate) WettingA.
SiO2 NaOH
50 ml
20 ml
800 ml 200 ml 930 ml
1000 ml 1000 ml
to the to the
padder padder

THANK YOU
Majority of customers use 4:1 dosing pumps

Inline dyestuff cooling is most efficient and reliable way to control temperature
Correct mechanic and hydro- dynamical installation at site is important
Dosing_2018 /J.Ströhle/ 13.04.18

1
4:1 Dosing pump with INLINE cooling
Bypass Cold bleach
hose tube max 3 m
hose tube max 3 m
hose tube
hose tube
Cold Bleach
Dyestuff
Alkaline
11
4:1 dosing
Calculation of recipe (I)
Article: 100 % CO
Weight: 220 g/m2 Running meter
1 0.352 g/rm
Width: 160 cm Quantity
Lot length: 5000m
2 1’760 kg Theoretical liquor
3 consumption
Pick up: 65 %
1’144 Liter
4 Required Total Volume
Theoretical liquor consumption 1’144 Liter

Kanalmenge 40 Liter
Initial trough filling+ piping 30 Liter
Spare (approx 3%) 30 Liter
Total liquor demand 1’244 Liter
Practical liquor volume 1‘250 Liter

4:1 dosing
Calculation of recipe (II)
1 Total Liquor Volume: 1250 l
Dyestuff (4) 80% = 1000 l 4

:
Alkaline (1 ) 20%= 250l 1
Total 1250 l
2 Dyestuff recipe (Example) 3 Alkaline recipe (Example)
8 g/l yellow x 1250 l = 10.0 kg

50 ml/l Sod. silicate 38°Bé x 1250 l = 62.5 l
4 g/l red x 1250 l = 5.0 kg
20 ml/l NaOH 38°Bé x 1250l = 25 l
2 g/l blue x 1250 l = 2.5 kg
2 g/l Wetting A x. 1250 l = 2.5 kg
1000 l 250 l
1250 l

Contidos – Single chemical dosing
Article: 100 % CO
Weight: 220 g/m2 Running meter
1 0.352 g/rm
Width: 160 cm Quantity
Lot length: 5000m
2 1’760 kg Theoretical liquor
3 consumption
Pick up: 65 %
1’144 Liter
4 Required Total Volume
Theoretical liquor consumption 1’144 Liter

+ Drain 40 Liter
+ Initial trough filling+ piping 30 Liter
+ Spare (approx 3%) 30 Liter
= Total liquor demand 1’244 Liter
- 50 ml/l Sodium silicate - 62.2 Liter
- 20 ml/l NaOH 38 °Be‘ -24.9 Liter
= Total dyestuff volume 1’157 Liter
= Practical dyestuff volume (Stocktank) 1’150 Liter
Contidos –single chemical dosing
Fabric data Calculation of dyeing liquor
Article name/number Fabric consumption [L] 272
Volume pipes [L] 10
Weight [g/m2] 160 Volume drain [L] 20
Width [cm] 170 Volume trough/nip [L] 50
Batch length [m] 1000 Total needed dyeing liquor [L] 352
Batch weight (calclulated) [kg] 272.0
Batch weight [kg] 272.0 Scaling dyestuff tank [L] 50
Recommended amount
[L] 350
Pick up [%] 100 of dyestuff-solution
Dyeing recipe
Dyestuff Amount of Needed amount Calculated amount
(and chemicals to be put into the dyestuff-tank) dyestuff-solution of dyestuff of dyestuff
(dyestuff tank) in dyestuff-tank
[L] [g] [g/l] Conc of dyestuff
1 Leatfor Brill Yellow 4GL g/l 24.1000 9'218.6 26.34 in the 350 L
2 Fonazol Turgoloo G X133% g/l 27.0000 10'327.9 29.51
3 Novacron Blue EC-R g/l 1.6500 631.1 1.80
4 Urea g/l 30.0000 11'475.4 32.79
5 g/l 350
6 g/l
7 g/l
8 g/l
9 g/l
Chemicals Amount of direct
dosing per batch
[L]
1 NaOH 50% ml/l 17.00 6.5
2 Silicate / HW-386 Fixation alkal ml/l 68.00 26.0
3 ml/l
4 ml/l
5 ml/l
6 ml/l
7 ml/l
8 ml/l 350l /0.085
Factor 0.085
Total volume dyeing liquor [L] 383

Calculation of recipe (II)- Chemicals are part in 1000
1 1150 Liter Dyestuff volume = 1236 Liter
Total Liquor Volume= (1 l/l - 0.05 l/l Silicate – 0.02 l/l NaOH)
8 g/l yellow x 1236 l = 9.88 kg

4 g/l red x 1236 l = 4.94 kg
2 g/l blue x 1236 l = 2.47 kg
2 g/l Wetting A x. 1236 l = 2.47 kg 50 ml/l Sod. silicate 38°Bé
20 ml/l NaOH 38°Bé
50 ml
20 ml
1150 l
930 ml
1000 ml to padder
Calculation of recipe (II)- Chemicals are additional to 1000
1 Total Liquor Volume= 1150 Liter dyestuff volume + 1150 x(0.05 Silicate + 0.02 NaOH) = 1230 Liter
8 g/l yellow x 1230 l = 9.84 kg

4 g/l red x 1230 l = 4.92 kg
2 g/l blue x 1230 l = 2.46 kg
2 g/l Wetting A x. 1230 l = 2.46 kg 50 ml/l Sod. silicate 38°Bé
20 ml/l NaOH 38°Bé
50 ml
20 ml
1150 l
1000 ml
1070 ml to padder
Dyestuff cooling

4:1 with dosing pump with inline cooling

DYESTUFF SELECTION
AND ALKALINE SYSTEMS
OVERVIEW
• Fibre affinity
• Pad liquor stability
• Fixing speed / Fixing time
• Padding / Dwelling temperature
• Alkaline systems
• CPB calculator
• Dyestuff selection
2 01.05.2018 Ralf Krämer-Technical Service Dyestuffs

FIBRE AFFINITY
Batch sample beginning Batch sample end

FIBRE AFFINITY
Batch sample beginning Batch sample end

PAD LIQUOR STABILITY
Dyestuff comparison in combination with BEZAKTIV Turquoise V-G conc.
Recipe 1 Recipe 2

PAD LIQUOR STABILITY

FIXING SPEED / MINIMUM FIXING TIME
Influence of the fixing time to the dye yield
8h 16 h 24 h
DE 2.4 DE 1.4
Padding temperature 25°C

PADDING / DWELLING TEMPERATUR

PADDING / DWELLING TEMPERATUR
Influence of the temperature to the dyeing yield
0°C
BEZAKTIV Yellow V-2R 150
BEZAKTIV Red V-RB 133
BEZAKTIV Blue V-RN spec.
30°C

ALKALINE SYSTEMS
Reduced silicate method
Most used method
Amount of sodium silicate: 50 ml/l
Caustic Sodium
soda silicate
Tropical method
Recommended when padding temperature
is higher as 30°C
1
Amount of sodium silicate: 70-100 ml/l :
As an alternative to sodium silicate 4
an use of Si-CONTROL KKV is possible!
Sodium carbonate method

Sodium silicate free method
Longer dwell time needed
Shorter washing and soaping process

ALKALINE SYSTEMS
EGASOL
SF
EGASOL SF method
Sodium silicate free method
Alkali compound 1
An using of caustic soda is not necessary
:
4
The fixing time is extended by 1.5 times
compared to the sodium silicate methods
The dyes BEZAKTIV Blue V-RN spec.,
BEZAKTIV Blue V-R and
BEZAKTIV Royal S-B are not suitable!

CPB CALCULATOR
How to calculate a padding recipe?

DYESTUFF SELECTION
Generally each dyestuffs, appart from BEZAKTIV HE dyes, are suitable for CPB process!
Standard selection with a good combinability
BEZAKTIV S-MATRIX 150 BEZAKTIV COSMOS S-C

BEZAKTIV Yellow S-MATRIX 150 For dark shades
BEZAKTIV Red S-MATRIX 150
BEZAKTIV Blue S-MATRIX 150

DYESTUFF SELECTION
Selection for dyeing emerized fabric
BEZAKTIV S-MATRIX 150 BEZAKTIV HP

BEZAKTIV Yellow S-MATRIX 150 BEZAKTIV Yellow HP-C
BEZAKTIV Red S-MATRIX 150 BEZAKTIV Red HP-3B
BEZAKTIV Blue S-MATRIX 150 BEZAKTIV Blue HP-R
Without special fastness requirements When high fastnesses are required
! The dyeing result is depending on the fabric and degree of emerize !

DYESTUFF SELECTION
Selection for ecological dyeing
BEZAKTIV GO BEZAKTIV GO
BEZAKTIV Golden Yellow GO BEZAKTIV Golden Yellow GO
BEZAKTIV Orange GO BEZAKTIV Scarlet GO
BEZAKTIV Red GO BEZAKTIV Blue GO
BEZAKTIV Blue GO BEZAKTIV Dark Blue GO
BEZAKTIV Dark Blue GO When high light fastness is required
BEZAKTIV Navy GO
BEZAKTIV Velvet Black GO
BEZAKTIV Black GO
Without special fastness requirements
DYESTUFF SELECTION
Selection for discharge printing
BEZAKTIV V
Preliminary tests recommended

THANK YOU FOR YOUR ATTENTION
Be coloured!

WASH OFF PROCESS
PARAMETERS
- Dye group system

- Fixation degree of the dyes
- Kind of Fabric
- Wash off behaviour of the hydrolysate
- Number of wash compartments
- Hardness and pH of process water
- Water supply
- Auxiliaries
IMPORTANT FACTORS FOR REACTIVE WASHING OFF
- At least 7 wash compartments

- 5 – 15 l/kg fresh water supply depending on colour depths
- quick removal of the hydrolized dyestuff
- Optimal temperature control
- soft water required
- Reduction of alkaline concentration
- pH value of 8.0 – 9.0 for soaping process
Giuseppe Melis, Technical Service Dystuffs

WASHING OFF OF REACTIVE DYESTUFFS
Unfixed Dye, hydrolysed Dye
Fixed Dye
C Chemicals, Auxiliaries
C C
C C
C C
C C
4 01.05.2018 Giuseppe Melis, Technical Service Dystuffs

PHASE 1
- Remove unfixed, hydrolysed dyestuff, alkali and auxiliaries from the surface of the fiber
- Ideal conditions
- High fresh water supply
- Mechanical effect
Phase 1
C C
C C
C C
C C

PHASE 2
- High bath temperatures

- Diffusion of hydrolyzed dyestuff to the surface
- Keep dyestuff concentration difference between liquor and fibre (equilibrium effect)
Phase 1 Phase 2
C C
C C C C
C C C C
C C
6 01.05.2018 Giuseppe Melis, Technical Service Dystuffs.

PHASE 3
- Thoroughly rinse out the remaining residuals

- The final process is neutralisation so that the product ideally reaches a pH of 7
Phase 1 Phase 2 Phase 3

C C
C C C C
C C C C
C C
7 01.05.2018 Giuseppe Melis, Technical Service Dystuffs.

FOR RECEIVING AN EXCELLENT WASH OFF RESULT, THE FOLLOWING
SHOULD BE NOTED
- The wash off process can be optimised by adjusting the various auxiliaries
- Sufficient water supply to the washing compartments
- Use counterflow principle to avoid high hydrolysate concentrations
- Make sure that the rinsing and soap baths are renewed continuously
- In case of silicate-containing alkali, neutralize in the last rinsing bath

DIFFERENTIATE SILICATE AND SILICATE FREE ALKALINE SYSTEM
2 ml/kg COTOBLANC SEL Neutralization

silicate containing dyeing systems 2-5 lt/kg 1-2 lt/kg 1-2 lt/kg 2 lt/kg 1-2lt/kg 1-2 lt/kg
50°C 70°C 80°C 95°C 95°C 95°C 70°C 40°C
for silicate free dyeing systems Neutralization 2 ml/kg Cotoblanc SEL
2-5 lt/kg 1-2 lt/kg 1-2 lt/kg 2 lt/kg 2-4 lt/kg 1-2 lt/kg
40°C 50°C 70°C 95°C 95°C 95°C 70°C 40°C

TO ACHIEVE AN OPTIMAL WASH-OFF PROCESS WE RECOMMEND
THESE PRODUCTS
COTOBLANC SEL
Concentrated, surfactant-free special product for soaping reactive dyeing
- Efficiency is independent from electrolyte content
- is well stable to alkalis and hardenss in the
usual industrial concentrations.
HEPTOL SF4
Universally applicable sequestering and complexing agent
- high capacity of binding hardness
- no de-metallisation effect to dyestuff

COLD PAD BATCH
24-25. April 2018
Washing
J. Ströhle /CTO
Costs Drivers Textile Finishing
Water = Energy => Costs
Maintenance
3% Chemicals &
Capex dyes
12% 41%
Labour
13%
Electricity
5%
Water
7%
Energy/Steam
19%
Trouser GAP (Reactive. 3.5%)
100% CO, 16 x 12 OE/108x 56 L1/1, 288 g/m2
Process: Bleach-Merc-CPB-Finishing/ Energy
carrier:Coal
Cuntry: India
Wash_2018 / J.Ströhle/ 13.04.18 2

4 factors influencing the washing process
Mechanics Temperature
Water Time
Wash_2018 / J.Ströhle/ 13.04.18 3

Facts on textile finishing
Huge potential by substituting obsolete equipment
Continuous - Benninger Discontinuous – Jet/Jigger
Desizing EUROPE ∅ 60 l/kg

ASIA ∅ 160 l/kg
Sourcing
Bleaching
Mercerizing
Dyeing
Printing
Finishing
0 50 100 150
Liters/kg
WATER SAVING = ENERGY SAVING

Source: Mark Messura Cotton Inc.
Benninger market survey 2009
Wash_2018 / J.Ströhle/ 13.04.18 4

Reasons of high utility consumption
Obsolete washing equipment
Mechanics Temperature Mechanics Temperature

Water Time Water Time
Wash_2018 / J.Ströhle/ 13.04.18 5

Reasons of high utility consumption
Wrong washing equipment
Water Time
Wash_2018 / J.Ströhle/ 13.04.18 6

Counterflow principle: EXTRACTA washing machine
Most common washing machine for woven fabrics
Direction of fabric run
Water/ Time
Liquor guidance
Wash_2018 / J.Ströhle/ 13.04.18 7

TRIKOFLEX high performance washing for Elastic’s
Fabric run
Water Time
■ Patented TRIKOFLEX Drum

■ 40% higher washing efficiency thanks to front and back
washing and counterflow guiding
Wash_2018 / J.Ströhle/ 13.04.18 8
TEMPACTA
High performance for Soaping and reaction processes
Water Time
Counterflow and multiple chamber
Wash_2018 / J.Ströhle/ 13.04.18 9

TEMPACTA
High performance for Soaping and reaction processes
Wash_2018 / J.Ströhle/ 13.04.18 10

The ideal machine for soaping reactive dyed fabrics (I)
Better fastnesses, less utility consumption, less costs
Section 1 Section 2 Section 3 Section 4 Section 5
Surface wash Dilution wash Fastness Wash Surface wash Neutralisation
Removing surface Removing Hot boiling Removing pH 5- 5.5

contaminations alkaline, pH 8 -9 1-15 min hydrolysate
Wash_2018 / J.Ströhle/ 13.04.18 11

The ideal machine for soaping reactive dyed fabrics (II)
Wishful thinking – only for bedsheets our ideal soaper can be configured
Drumwasher Up/down Dwelling Criteria
washer compartment
Popline Laymarks, creases
Bottom weight Laymarks

Bottom weight with Fabric tension &
Lycra Laymarks
Bedsheets
Terry Towel Distortion of pile
Knitwear Fabric tension
Wash_2018 / J.Ströhle/ 13.04.18 12

TRIKOFLEX WASHING RANGE – CPB Soaping
Low tension washer for Knitwear (CO and CV)
40°C 60°C 95°C 95°C 95°C 70°C 60°C
Wash_2018 / J.Ströhle/ 13.04.18 13

THANK YOU
Water saving = Energy Saving = Cost Saving

4 Factors are influencing the washing efficiency
Ideal are combinations of different type of washing aggregates
Ideal type of washing machine does not always fit to the fabric processed
Wash_2018 / J.Ströhle/ 13.04.18

1
COLD PAD BATCH DYEING
Dye padder in cold pad batch dyeing
1 25.04.2018 Ludger Wilbers, Technical Service Dyestuffs

COLD PAD BATCH DYEING / DYE PADDER
25.04.2018 Ludger Wilbers, Technical Service Dyestuffs 2

DYE PADDER IN COLD PAD BATCH DYEING
The dye padder is the important part for continuous / semi-continuous dyeing
Based on the construction defines the immersion time
Bath exchange rate
Defines the liquor on the fabric (pick up)
Has to ensure a regular pick up over the width of the fabric
Has to level out differences of the fabric coming out of the weaving, pretreatment or predrying

INFLUENCE OF DIFFERENT PICK UP
High pick up
Humidity of ready for dyeing fabric

left center right
11% 9% 11%
Real humidity after padding
70% 70% 70%
Real pick up
59% 61% 59%
Difference edge / center
2% -- 2%
Absolut colour difference seen (edge / center)
aprox. 3.3% -- aprox. 3.3%

High pick up Low pick up
Humidity of ready for dyeing fabric Humidity of ready for dyeing fabric
left center right left center right
11% 9% 11% 11% 9% 11%
Real humidity after padding Real humidity after padding
70% 70% 70% 50% 50% 50%
Real pick up Real pick up
59% 61% 59% 39% 41% 39%
Difference edge / center Difference edge / center
2% -- 2% 2% -- 2%
Absolut colour difference seen (edge / center) Absolut colour difference seen (edge / center)
aprox. 3.3% -- aprox. 3.3% aprox. 5% -- aprox. 5%

High pick up Low pick up

Influence of trough volume, speed on immersion time
Machine speed between 40 m/min and 60 m/min
Fabric content in the trough (immersion length): 1.2 to 1.5 m
40 m/min 1.8 -2.3 s
60 m/min 1.2 – 1.5 s

Influence of trough volume, speed on immersion time
Fabric content in the trough: 0.8 to 1.2 m
40 m/min 1.2 -1.8 s
60 m/min 0.8 – 1.2 s

Influence of nip volume, speed on immersion
Fabric content in the trough: 0.1 m
40 m/min 0.15 s
60 m/min 0.1 s

Relation of trough volume, speed on liquor exchange
Volume: 45 l
Pick up: 65%
Fabric weight: 250 g/rm
Liquor exchange: 6.9 min at 40 m/min

4.6 min at 60 m/min

Influence of trough volume, speed on liquor exchange
Volume: 25 l
Pick up: 65%

2.6 min at 60 m/min

Influence of trough volume, speed on liquor exchange
Fabric content in the trough: 0.1 m
Volume: 10 l
Pick up: 65%

1.0 min at 60 m/min

Summary of trough / nip volume, liquor exchange and immersion time
Liquor content: 45 l 25 l 8-10 l

Liquor exchange: 6.9 -4.6 min 3.8 – 2.6 min 1.5 – 1.0 min
Immersion time: 1.2 s – 2.3 s 0.8 s – 1.8 s 0.15 s – 0.1 s

LIQUOR EXCHANGE

Exchange in [ ]=
% [ ]
Out of this formula you see that:
With smaller trough volume you reach faster the point of equilibrium
By higher pick up, the liquor exchange increases
By increasing the speed you reach faster the point of equilibrium,

but the amount of fabric passing the dye padder is the same
With light weight fabric the curve is less steep, that’s telling that you need
more meters to reach the point of equilibrium

LIQUOR EXCHANGE
Y = Liquor exchange [L], less volumen and higher pick up result in smaller “y “
Y
105
100
relative colour strength [%]
95
90
85
80
75
70 ∞
Equilibrium in the trough Colour strength practical experience
65
(two times exchange) Comercialy aceptable
60
0 200 400 600 800 1000 1200
Yardage [m]
LIQUOR EXCHANGE Berechnung des Flottenumsatzes Calculation of liquor exchange
Chassisinhalt 45 l trough volume

Warengewicht 250 g/lfm // g/rm fabric weight
Flottenaufnahme 65 % pick up
Geschwindigkeit 60 m/min speed
Flottenumsatz in Minuten 4.6 min.
Ware pro Liter Flotte 6.15 m fabric per liter liquor
Meter Ware bis 2x Chassisaustausch 553.85 m meters of fabric until 2x trough volume
Berechnung des Flottenumsatzes Calculation of liquor exchange
Chassisinhalt 25 l trough volume

Warengewicht 250 g/lfm // g/rm fabric weight
Flottenaufnahme 65 % pick up
Geschwindigkeit 60 m/min speed
Flottenumsatz in Minuten 2.6 min.
Ware pro Liter Flotte 6.15 m fabric per liter liquor
Meter Ware bis 2x Chassisaustausch 307.69 m meters of fabric until 2x trough volume

THE PICK UP
Depends on:
Shore hardness of the rollers

Pressure adjustments
Speed
Thickness of the fabric
Kind of weaving and fibre
Ply twist
Pretreatment
Swelling of the cellulosic fibre

THE PICK UP
Where you get the higher pick up?
Where you get the better penetration?
Higher pick up
Better penetration

SOME THOUGHTS ABOUT VISCOSE DYEING IN CPB
Trough dyeing?
Nip dyeing?
Immersion time

Summary of trough / nip volumen, liquor exchange and immersion time

Liquor exchange: 6.9 -4.6 min 3.8 – 2.6 min 1.5 – 1.0 min

Swelling behaviour of cellulosic fibres
destilled water 20 g/l Sodium carbonate
Values recorded by Lenzing fibres

Swelling behaviour of cellulosic fibres
CV fibre before the contact with water / pad liquor
CV-fibre after the contact with water / pad liquor

Winding up CV-fabric to avoid Moiré
Ø ≤ 30 cm not suitable Ø ≥ 30cm most suitable

CPB TAILING / LISTING
Technical meeting 04/2018
CHT Switzerland
Tailing - Listing ?
Meaning of
Testing method
Difference between CO an CV
Padding parameters
Precaution and improvement
2 Klaus-Dieter Maurer - Technical Service Dyestuffs

Tailing - Listing ? What’s the difference ?
Tailing and Listing

Dyeing problems, which can appear in all continuous processes !
Tailing
Tailing effects are mentioned, if variations in shade or depth, occur over the
entire length of a production batch !
Listing
Listing effects are mentioned, if variations in shade or depth, occur over the
entire width of a production batch !

Tailing ? What does it mean ?
Tailing can be understood as a continuous decrease in depth, with or
without colour change, from the beginning of padding to the end.
Tailing without shade change Tailing with shade change
Start padding Start padding
End of padding End of padding

Tailing ? Influencing factors !
kind of fabric (CO mercerized or non mercerized, CV or others)
fabric construction (woven, knitted, emerised, weigth in g/rm.)
used dyestuff group and alkali system

(consideration of substantivity, reactivity, fixing time)
padding temperature
(optimum between 20-25°C)
padding speed
(depending on fabric construction and g/rm up to 60 m/min)
electrolyte
dwelling temperature
(consideration of seasonal conditions , < 20°C dwelling temperature extends fixing time)
5 Maurer Klaus-Dieter -Technical Service Dyestuffs

Tailing ? Influencing factors !

Exchange in [ ]=
% [ ]
Optimal exchange rate: 24 ltr x 100.000

= 2 min
300 g/rm x 80% x 50 m/min
Critical exchange rate: 40 ltr x 100.000

= 5 min
200 g/rm x 80% x 50 m/min
The above shown calculation provides a guideline, to decide, if the padding liquor exchange rate
is sufficient, or if the padding conditions are critical. It is of course a theorectical calculation, since
the padding liquor is never completely exchanged. Depending on the fabric width, the exchange
rate from side to side can differ!
But if 2 min exchange rate is considered, highest safety is given from that point!

Listing ? What does it mean ?
Listing can be understood as a shade variation over the entire fabric width.
Listing effect is mainly visible as darker or lighter effect.
Side Middle Side

Listing ? Influencing factors !
chemical pretreatment (for e.g. bleaching, mercerizing)
mechanical pretreatment (for e.g. emerising, brushing)
difference in fabric density (g/m2)
padding pressure over the entire width
padding nip (adjustment depending on woven or knitted fabric)
drying and storage conditions (before padding), conditioning
dwelling conditions (temperature variation inside-outside)
tension difference (especially knitware)
winding tension after padding

Tailing Test methods !
1. Method procedure
This method is the main test method used at CHT Switzerland, because of easy handling and
good visibility of the tailing effect!
Procedure:
a.) prepare 3 samples with a size of approximately 15 x 20 cm
b.) prepare dyestuff and alkali solution separate as per recipe with a ratio of 4:1 (200 ml)
c.) pad first sample with 100 ml according to standard padding settings ( 3 m/min and 2 bar, 2xpadding)
drain that liquor !
d.) immerse second sample for 30 sec in the remaining 100 ml fresh padding liquor
e.) squeeze the second sample only 1x with 3 m/min and 2 bar on the padder
f.) use residual and sqeezed liquor again and pad third sample as first sample (c.)
g.) fixation, washing off and soaping as for normale reactive dyeing
h.) measure difference in depth and shade (mainly visuell is enough)

Tailing Test methods ! Typical tailing on cotton
1. Method example for CO
Prepare dye liquor and pad immediately 2 times

with 3 m/min and 2 bar
1. Sample
Drain padding liquor
standard
Immerse second sample for 30 sec in fresh liquor

2. Sample
and squeeze 1x with 3 m/min and 2 bar
darker
Do not drain nip and refill with residual liquor !
3. Sample Take third sample and pad again

lighter 2 times with 3 m/min and 2 bar

Tailing Test methods ! Reverse tailing on viscose
1. Method example for CV
Prepare dye liquor and pad immediately 2 times

with 3 m/min and 2 bar
1. Sample
Drain padding liquor
standard
Immerse second sample for 30 sec in fresh liquor

2. Sample
and squeeze 1x with 3 m/min and 2 bar
lighter
Do not drain nip and refill with residual liquor !
3. Sample Take third sample and pad again

darker 2 times with 3 m/min and 2 bar

2. Method procedure
This secondary method can also be applied for testing issues, but out of experience
handling as well as result evaluation are more difficult !
Procedure:
Step 1 Step 2 Step 3
Prepare 100 ml padding Take fabric 15x20cm and

liquor as usual! pad appr. 15 cm. Stop
padder for 20 sec and hold
end!

2. Method procedure

3. Method procedure
This method can also be used and is easy in the handling:

- preparation of 6 samples RFD fabric, with a size of 15x20cm each.
- prepare 200 ml of padding liquor as usual
- pad samples one by one, according to standard lab padder settings ( 3 m/min / 2bar)
- dwelling for 20 h, then washing and soaping
- measure shade difference between samples 1-6 (evaluation from samples, 1, 3, 6)
- result indicates the dyestuff combinability and fibre affinity
example:

Tailing Test methods - Summary
- the demonstrated test methods can only give an idea about the used dyestuff
combination
- test methods, which require 5 mtr or even 20 mtr test fabric are not considered,
because of capability for usual laboratory equipment
- fabric variation because of pretreatment, can not be detected
- test methods can not exclude additional negative machine parameters as for e.g.,
padding temperature, trough volume, padding speed
Main test method:
As there are several test methods possible to evaluate tailing effects, we decided
to consider the method 1 as main test method for internal analysis!
Additionally other methods can be also used, considering local production parameters !

Cotton and viscose !
Dyeing recipes and procedures are basically the same, but where are differences ?
Cotton: Viscose:
- residual humidity 6-8% - residual humidity 9 - 14 %
- generally prebleached - strong swelling behaviour
(appr. 10 sec for maximum swelling effect)
- often mercerized (listing ?)
- tendency to Moiré effect
- higher tensile strength in wet conditions
- lower tensile strength in wet conditions
- typical tailing in trough dyeing
(padding start darker, getting lighter) - reverse tailing effect in trough dyeing
(padding start lighter, getting darker)
- absorbency very important (pretreatment)
- particular liquor uptake due to capillary
effect (water is absorbed faster)

Padding parameters
Machine parameters with direct influence on tailing and listing effect:
- trough or nip dyeing have main impact on tailing issues. “The faster
the liquor exchange rate, the lower the tailing problem!”
- higher fabric weight in g/rm is advantageous in trough dyeing,
whereas light weight fabric is better in nip dyeing (depends also on
construction and fabric width!)
- padding nip has direct influence on listing effect
- for woven fabrics mainly linear pressure in nip is usual
- for knit fabrics often pressure adjustment from side - middle - side
required (in most cases middle pressure is slightly higher)!
- dosing systems close to the padder
- dosing pipes as short as possible

Padding parameters
Padding rollers
- rubber hardness usually 65 - 70° Shore

- clean and smooth surface (no coating effect because of residual silicate)
- regular check of the nip consistancy (blue paper or talkum powder)
blue paper
talc powder
65-70° shore

Padding parameters Padding nip
Typical nip pictures for woven and knit fabrics:
- padding nip adjustment depends on fabric, but also on pretreatment!

(setting to be adjusted, if one or two S-rollers are controlled)
- padding nip has no influence on tailing
nip picture under pressure
linear pressure
for woven fabric
reduced side pressure

for knit fabric

Padding parameters Padding nip
Particular nip pictures for woven and knit fabrics:
- particular nip settings can be required, depending on fabric construction,

or variation after pretreatment (especially mercerization!)
- higher pressure on the selfedges can be required, if variation in g/m2 is high
- lower pressure only one side, indicates more any faulty situation
nip picture under pressure
lower pressure
on one side
higher pressure
on both sides

Padding parameters Padding trough
Trough design considers the application field:
- bigger trough size with higher volume for heavy fabric or pretreatment
- bigger trough size with installed underliquor squeezing rollers for woven high
density fabrics
- small trough size for lighter weight fabric to ensure sufficient liquor exchange
rate
- for knit fabrics and lighter weight woven fabrics, usually only small trough with
single deflecting roller

Padding parameters Padding trough
Characteristic padding trough designs:
Small trough with Bigger trough with Bigger trough with

displacer (appr. 15-20 ltr) displacer (appr. 25-40 ltr) underliquor sqeezer (appr. 25-40 ltr)
depending on width depending on width depending on width
Light to medium weight fabrics Heavy weight fabric High dense heavy weight fabric
appr. 150-300 g/rm > 300 g/rm > 300 g/rm
All above shown trough’s are only basic examples and construction, as well as design can vary from machine supplier and customer!

Precaution and improvement…
…to reduce tailing!
- fast liquor exchange rate in the trough < 2 min

- change to nip dyeing if equipment is available
- use sufficient leading cloth before padding the original fabric and ensure fast
speed acceleration to padding speed
- padding speed as high as possible, depending on fabric 40-60 m/min
- clean pumps and pipes properly before starting with the original pad liquor
- considering the “reverse tailing” effect on viscose, higher concentration of
dyestuff solution in the first trough filling, can reduce the “reverse tailing”
(applicable, but absolute exact and reproducible handling necessary!)
- for viscose, use A-frames with bigger diameter (40 cm or more) ! Additionally A-
frame can be covered with some foam fabric! (swelling problem of CV)
- ensure correct dwelling conditions (temperature, packing)

Precaution and improvement…
…to reduce listing!
- correct pressure set up L-M-R in the padder considering the fabric

- ensure correct conditioning of the RFD before dyeing
- homogeneous pretreatment (pH, absorbency)
- adjust drying width, depending on width after padding (heavy shrinkage during
padding)
- do not store RFD fabric (rolled or plaited) in humid conditions
- avoid overdrying (for viscose even more critical)
- when dyeing knits, avoid curling selfedges before immersion
- bounded fabric transport after sqeezing, before winding knit fabric
- pack dyed fabric properly and ensure homogeneous dwelling temperature

Are you now RFD ??

CPB DYEING
Parameters for Viscose
VISCOSE AND TENCEL IS GROWING BECAUSE OF FOODPRINT
2 01.05.2018 SpK Technical Service Dyestuffs

PROPERTIES OF CELLULOSIC FIBER
M odal
Cotton Lyocell Polynosics HWM Viscose Cupro
Fiber code CO CLY CM D CM D CV CUP
Degree of fibrillation 2 4-6 3 1 1 2-3
(0= min, 6= max)
Tenacity [cN/ tex]
Dry 22 42 38 35 22 20
Wet 28 36 30 20 12 10
Water retention [% ] 42 - 53 60 - 70 55 - 70 65 - 90 90 - 120 80 - 90
Average degree of 1600 - 2000 600 500 400 300 500
polymerisation [DP] (bleached)

TECHNICAL DIFFERENCES COMPARING TO COTTON
Viscose Cotton
− - only pre-wash process necessary

− - intensive pre-treatment steps
necessary, bleaching process
− - cooled fabric, − - cooled fabric,

moisture of app. 8 – 10 % moisture of app. 4 – 5 %
− - fabric looses strength in wet − - approximately +25% stronger in wet

conditions ( app -50 % ) conditions
− - light fastness up to 1 note higher

− - limited light fastness without selected
reactive dyes
− - swelling behaviour very critical in yarn

− - less sensitivity to swelling parameters
dyeing and CPB process

VISCOSE PROPERTIES

SUMMARY OF TROUGH / NIP VOLUMEN, LIQUOR EXCHANGE AND IMMERSION TIME

Liqour exchange: 6.9 -4.6 min 3.8 – 2.6 min 1.5 – 1.0 min

6
SWELLING BEHAVIOR OF VISCOSE

SWELLING OF VISCOSE
30 % swelling leads to an icrease in area of 70 % !!!
with water
capillary effect
with padding solution

CAPPILARY EFFECT
Padding Liquor: 100 ml

Pic up: 96 %
Speed: 5 m/min
Pressure: 2 bar
Padding Liquor: 200 ml

25 % lighter
Pic up: 96 %
Speed: 1 m/min
Pressure: 2 bar

TAILING: REVERSE TAILING
• Diffusion of water is faster, than dyestuff solution

• use of pre-run-fabric is neccessary, to have the right run speed
• chassis liquor amount as low as possible
• Nip dyeing is possible also
• the final equilibrium is after 2-3 liquor exchanges in chassis
• speed as high as possible

TAILING BEHAVIOR COTTON VERSUS VISCOSE

WINDING UP CV-FABRIC TO AVOID MOIRÉ
Air passage 1,5 seconds
Constant speed
Low and constant tension
Adjustable direct drive
Ø ≤ 40 cm not suitable Ø ≥ 40cm most suitable

PADDING PARAMETERS FOR VISCOSE
• time between first contact with pad liquor and winding should be 1,5 to 2,0 seconds
• alkaline scoured CV fabric show better and consistent swelling properties
• take care for good overlock seam
• optimal pick up between 80 and 120 % depending to the fabric
• Urea can improve dyestuff diffusion
• optimal speed is between 30 and 60 m/min, constant speed !!!
• air passage bevor winding is of advantageous for equal swelling and to prevent moire effect
• absolut constant tension is necessary for good reproducibility
• bigger diameter for A-frame ( 40 cm and more )

RECOMMENDATIONS FOR
CPB IN LABORATORY
Foulard types
vertical horizontal
2 01.05.2018 Marcel Krassnig, Technical Service Dyestuffs

VERTICAL FOULARD TYPE
Advantage
• Better penetration, because of dwelling between
trough and nip
Disadvantage
• Guide fabric necessary
• Normally 2 persons necessary
• Difficult handling
• Clean working hardly possible
• Bigger amount of padding liquor necessary

HORIZONTAL FOULARD TYPE
Advantage
• Easy handling
• Much cleaner working as with a vertical foulard
• 100-200 ml padding liquor is enough
• No guide fabric necessary
Disadvantage
• Two times padding necessary

Preparation
Fabric should be:
- same fabric like in the production
- pretreated from the production, in best case from the middle of production batch
- dry
- cool

Procedure
- Prepare material
- Weight up dyestuff
- dissolve dyestuff with hot water (max.50% of total amount)
- Cool down dyestuff solution
- Add auxiliaries
- Fill up to 80% volume
- Add alkaline (20% volume)
- Padding immediately 2 times to imitate production conditions
- Storage / dwelling (in laboratory minimum 16 h)
- Rinsing
- soaping

Calculation
Recipe:
5.0 g/l BEZAKTIV Yellow S-MATRIX 150
7.0 g/l BEZAKTIV Red S-MATRIX 150
10.0 g/l BEZAKTIV Blue S-MATRIX 150
50.0 ml/l Silicate 38°Bé
20.0 ml/l caustic soda 38°Bé

CALCULATION
Recipe: Total amount for padding liquor = 100 ml

5.0 g/l BEZAKTIV Yellow S-MATRIX 150 0.5 g BEZAKTIV Yellow S-MATRIX 150
7.0 g/l BEZAKTIV Red S-MATRIX 150 0.7 g BEZAKTIV Red S-MATRIX 150
10.0 g/l BEZAKTIV Blue S-MATRIX 150 1.0 g BEZAKTIV Blue S-MATRIX 150
Dissolve dyestuffs with hot soft water

Not more than 50 ml
Add into the cooled liquor COLORCONTIN VGP
Fill up with cold soft water to 80 ml

CALCULATION
Alkali recipe: Total amount for padding liquor = 100 ml

50.0 ml/l silicate 38°Bé 5 ml Silicate
20.0 ml/l caustic soda 38°Bé 2 ml caustic soda 38°Bé
Add alkaline to the dyestuff solution

Fill up to total volume
Padding immediately at room temperature

CALCULATION
Alkali recipe: Total amount for padding liquor = 100 ml

50.0 ml/l silicate 38°Bé 20 ml alkaline stock solution
20.0 ml/l caustic soda 38°Bé
Method at Bezema Colour Solutions
Add alkaline to the dyestuff solution

Padding immediately at room temperature

PREPARATION OF ALKALINE STOCK SOLUTION
We use in our lab stock solutions for alkaline, from each stock solution we use 20 ml
for padding (for 100 ml total padding liquor)
Example:
50 ml/l sodium silicate 38°Bé / 20 ml/l caustic soda 38°Bé required
Take 250 ml sodium silicate 38°Bé + 100 ml caustic soda 38°Bé and fill with water to
1000 ml. Fill this stock solution in a bottle and keep closed.
You can use this stock solution for 6-7 weeks!
This calculation can be used for all alkaline solutions when 20 ml from this solution
will be taken for a total 100 ml padding liquor! If the total padding liquor is 200 ml,
then you have to use the double amount of stock solution

Storage condition
- Constant temperature
- Optimal room temperature 20°C – 25°C
- Sample should be airtight packed ( to avoid influence of carbon dioxide)
- Glass or foil should be dry (avoid water spots on material)

MISTAKES AT STORAGE
Same recipe, same material
Storage in foil: Storage without foil:

MISTAKES AT STORAGE
Same recipe, same material
Storage in foil: Storage without foil at

the edges:
Carbon dioxide neutralise alkaline at the edges and result is insufficient fixing of dyestuff

STORAGE IN OUR LABORATORY
Using of glass tube is:

• Ecologic
• Re-usable
• Save
• Clean
• Easy in handling

Wash procedure
- Rinse intensive with cold soft water

- Rinse with warm soft water (~40°C)
- Soaping with 1.0 g/l COTOBLANC SEL for 10 minutes at 95°C
- Rinse with warm soft water (~40°C)
- Rinse with cold soft water
- Neutralise

Rapid fixation
Microwave Dry cabinet
method method

MICROWAVE METHOD
Required for this method is a commercially available microwave oven with the possibility to control the
heating power continuously on a wide range. The power of the microwave oven should be controlled in
a way, that 1 l water in a plastic beaker or beaker glass has reached the mentioned temperatures after
the following times:
Start temperature: 25 °C
After 5 min.: 31 – 32 °C
After 10 min: 41 – 42 °C
After 20 min: 58 – 59 °C
After 30 min: 72 °C
Furthermore, you need a plastic beaker with a lid clip, suitable for the use in microwave ovens. At the
superior part of the plastic beaker, you have to cut two notches for the insertion of the glass bar. The
subsequent fixation conditions evaluated with a 1.4 l beaker.

MICROWAVE METHOD
Fill 50 ml of cold water into the plastic beaker

For good repeatability, we recommended to use always the same dimension of the sample. Best is
to use a 9 x 15 cm pattern.
Put the padded fabric with the narrow side over the thin glass tab and fix it with another thin glass
tab. The lower edge of the fabric is not touching the surface of the water in the beaker. With the lid
clip the dyeing is locked up between the two glass tabs.
Put the closed plastic beaker in the middle of the microwave oven and then fix the dyeing for 6
minutes. Dyes with lower reactivity (e.g. BEZAKTIV Turquoise V-G, BEZAKTIV Turquoise S-BF 150,
BEZAKTIV Green V-6B 175) are fixed for 8 Minutes.
The after treatment of the dyeing is as usual:
Rinse cold and warm
Soaping 10 Minutes at 95°C
Rinse warm and cold
Neutralise

DRY CABINET METHOD
Required for this method is:
Foulard
Dry cabinet
sealable foil bag

DRY CABINET METHOD
For good repeatability, we recommend to use always the same dimension of the sample. Best is to
use a 9 x 15 cm pattern.
Heat up drying cabinet to 60°C
Put the padded fabric into a sealable foil bag
Squeeze out the air and lock the foil bag
Dwell for 15 minutes at room temperature
Put the foil bag to the drying cabinet
Fixing time is 45 minutes at 60°C
The after treatment of the dyeing is as usual:
Rinse cold and warm
Soaping 10 Minutes at 95°C
Rinse warm and cold
Neutralise

CONCLUSION OF RAPID METHODS
Microwave Dry cabinet

special equipment microwave + plastic beaker sealable foil bag
handling moderate easy
reproducibility moderate good
spots risky seldom
time 6 minutes 60 minutes
Our recommendation: Dry cabinet method

THANKS FOR YOUR ATTENTION

HANDBOOK FOR COLD PAD
BATCH PROCESS
Cemal ARIK, Özgür OK CHT Turkey

Why did we prepare this presentation?
2 Cemal ARIK, Özgür OK CHT Turkey

1-) Fabric moisture
2-) The mixture of dyestuff solution
3-) The colour control of dyestuff solution
4-) Cleaning system
5-) Colour kitchen / dyestuff tanks
6-) Cooling system (fabric, trough...etc.)
6a- Cooling the fabric
6b- Cooling the dyestuff solution
6c- Cooling the tanks
6d- Cooling the trough
7a+b-Winding capacity
7a- Entrance tension
7b- Exit tension
8-) Pressure contol

1. Pre-treatment 13. Foulard volume
2. Mercerization 14. Foulard temperature
3. pH 15. Diving time
4. Pick-up % 16. Dwelling time
5. Liqour exchange time 17. Dwelling temperature
6. Fabric moisture 18. Alkaline selection
7. Fabric temperature 19. Wetting agent and urea
8. Fabric tension 20. Washing cycle
9. Fabric speed 21. Sprinkle pressure
10. Dyestuff selection 22. Winding tension
11. Dissolving dyestuff 23. “Y” pipe distance
12. Squeezing rollers

Alkaline table (ml/l)
Reduced silicate process
Temperature 20-30° C
Dyestuff g/l ≤ 20 20 30 40 50 60 70 >70 - 100
Sodium silicate (38° Bé) ml/l 50 50 50 50 50 50 50 50
NaOH (38°Bé) ml/l 20 20 23 26 29 32 35 35
NaOH (48°Bé) ml/l 13 13 15 16 18 20 22 22
Tropical process
Temperature >30° C
Dyestuff g/l ≤ 20 20 30 40 50 60 70 >70 - 100
Sodyum silicate (38° Bé) ml/l 100 100 100 100 100 100 100 100
NaOH (38°Bé) ml/l 10 12,5 15 17,5 20 22,5 25 25
NaOH (48°Bé) ml/l 6 8 9,5 11 12,5 14 16 16
Soda ash/caustic soda process

Dyestuff g/l ≤ 20 20 30 40 50 60 70 >70 - 100
Soda ml/l 20 20 20 20 20 20 20 20
NaOH (38°Bé) ml/l 7,5 7,5 10 13 16 19 22 27
NaOH (48°Bé) ml/l 5 5 6,5 8 10 12 14 17

Alkaline table (g/l)
Reduced silicate process
Dyestuff g/l ≤ 20 20 30 40 50 60 70 >70 - 100
Sodium silicate (38° Bé) g/l 67,5 67,5 67,5 67,5 67,5 67,5 67,5 67,5
NaOH (38°Bé) g/l 27 27 31 35 39 43 47 47
NaOH (48°Bé) g/l 19 19 22 24 27 30 33 33
Tropical process
Temperature >30° C
Dyestuff g/l ≤ 20 20 30 40 50 60 70 >70 - 100
Sodium silicate (38° Bé) g/l 135 135 135 135 135 135 135 135
NaOH (38°Bé) g/l 14 17 20 24 27 31 34 34
NaOH (48°Bé) g/l 9 12 14 16 19 21 24 24
Soda ash/caustic soda process

Dyestuff g/l ≤ 20 20 30 40 50 60 70 >70 - 100
Soda g/l 20 20 20 20 20 20 20 20
NaOH (38°Bé) g/l 10 10 14 18 22 26 30 37
NaOH (48°Bé) g/l 7 7 10 12 15 18 21 25

The most important factors are;
Pre-treatment Contact time

Pick up % Alkaline (g/l or ml/l) ?
Foulard temperature Auxiliaries
Fabric speed Tension
Squeezing pressure Dwelling condition
Diving distance and time Washing cycle

1. Same fabric should be used.
2. Dyestuff solutions should be renewed frequently and should be covered.
3. Alkaline/sodium silicate solutions should be renewed frequently and should
be covered.
4. Adding the same auxiliaries both in lab and production.
5. Water quality (pH, hardness, sodium bicarbonate content)
6. Lab and production should have the same batch number of dyestuff? If not
checking the consistency of the dyestuff samples. (Lot control)

7. Dyeing from the same pre-treated fabric both in lab and also in the
production.
8. Contact time adjustment: Dipping two times in lab can be closer result to
bulk.
9. Pick up %
10. Temperature (impregration, dwelling, process)
11. Same washing cycles and effects
12. The principle of drying machines should be same. (ex: natural gas,
electricity...etc)

I. Pre-treatment
II. Tailing
III. Opposite tailing - Viscose
IV. Middle/edge differences
V. Shade fluctuations on fabric (lighter and darker)
VI. Moire problem

Cemal ARIK, Özgür OK CHT Turkey
CASE 1
Customer : MENDERES TEKSTIL, Denizli, Türkiye
Subject : Reproducibility problem in CPB dyeing
Date : 15.01.2018
Fabric : 100 % CO Woven
Colour : Grey
Width : 280 cm
Grammage : 120 g/m2
Company Recipe
4,97 g/l BEZAKTIV Yellow HP-NP

6,70 g/l Drimaren Red HF 6BL
7,10 g/l BEZAKTIV Blue S-RN
130,0 g/l Sodium silicate (380Be)
21,0 g/l Caustic soda (48 0Be)
Method : Tropical
Dwelling time : 16 hours
Washing : 8 chambers washing cycle
CASE 1
Company Recipe CHT Recommendation
4,97 g/l BEZAKTIV Yellow HP-NP 4,97 g/l BEZAKTIV Yellow HP-NP
6,70 g/l Drimaren Red HF 6BL 6,70 g/l Drimaren Red HF 6BL
7,10 g/l BEZAKTIV Blue S-RN 7,10 g/l BEZAKTIV Blue S-RN
130,00 g/l Sodium silicate (380Be) 130,00 g/l Sodium silicate (380Be)
21,00 g/l Caustic soda (48 0Be) 9,00 g/l Caustic soda (480Be)
Method : Tropical Method : Tropical

Dwelling time : 16 hours Dwelling time : 16 hours
Washing : 8 chambers washing cycle Washing : 8 chambers washing cycle

CASE 1

CASE 1
RECOMMENDATIONS
1) Liquor exchange time
•The average grammage of fabric is 120 g/m2 . That is why the liquor exchange
time is too long.
•We strongly recommend max. 2 min for liquor exchange time.
– speed up from 55 m/min to 60 m/min.
– decrease the foulard volume from 55 lt to 35 lt.
– pick up is suitable : 85%.

CASE 1
2) Caustic soda amount:
•Too much alkaline amount in the foulard solution.

• CHT recommendation (21 g/l 9 g/l)
3) Conditioning (Dwelling area):
•Average temperature
Winter season : 5 0C
Summer season : 35 0C
•Conditioning system in dwelling area (to prevent colour change between the
seasons.)

CASE 2
Customer : BEZ TEKSTIL, Denizli, Türkiye
Subject : Edge-middle-edge difference and reproducibility problem
Date : 20.12.2017
Fabric : 100 % CO Woven
Colour : Green
Width : 150 cm
Grammage : 120 g/m2
Recipe
5,94 g/l BEZAKTIV Yellow S-W

2,00 g/l BEZAKTIV Red HP-BL
1,00 g/l wetting agent
50,00 ml/l Sodium silicate (380Be)
13,00 ml/l Caustic soda (48 0Be)

CASE 2
Pre-treatment control
Mercerised Fabrics The degree of mercerization
MIDDLE OF FABRIC (EDGE 1) 106
MIDDLE OF FABRIC (MIDDLE) 95
MIDDLE OF FABRIC (EDGE 2) 112
Middle – edge pick up% test
Step 1:
1 sample from right edge.
1 sample from middle.
1 sample from left edge.
Step 2:
Sew them endwise pass through the same foulard solution.
Step 3:
Dwelling + washing + drying at the same conditions.
Result:
Edges are darker, the middle part is lighter which signs us that there is a
mercerization difference between middle to edges.

CASE 2
Pick up % adjustment (Lab to bulk)
13th trial has been changed as

Production pick up : 62 %
standard in lab.

CASE 2
Liquor exchange time calculation

CASE 3
Customer : BEZ TEKSTIL, Denizli, Türkiye
Subject : Longitudinal lighter part 25 cm far away from the edge
Date : 27.03.2017
Fabric : 100 % 40/1 CO Woven
Colour : Beige
Fabric length : 200 m
Width : 156 cm
Grammage : 165 g/m2
Recipe
0,770 g/l BEZAKTIV Yellow S-W
0,265 g/l BEZAKTIV Scarlet GO
1,000 g/l wetting agent
50,000 ml/l Sodium silicate (380Be)
8,600 ml/l Caustic soda (48 0Be)

CASE 3
Everything seemed normal at the start ???
Parameters
Speed : 50 m/min
Foulard volume : 20 lt
Foulard temperature : 24 0C
Liquor exchange time : 2,2 min
Dwelling time : 12 hours
Pressure : Right: 2,7 bar Middle: 2,5 bar Left: 2,7 bar
Pick up (100%) : Right: 67 Middle: 70 Left: 67

CASE 3
Control points
1) checking pre-treatment (hydrophility – capilarity)
more than enough !!!
2) adjusting squeezing cyclinder pressure
the problem was still same !!!
3) changing the direction of fabric.
4) adjusting the same pick up %.
What was the reason???

End of the story...
However the main problem was sooo simple...
We opened the sprinkle system and we noticed that

there was a plastic glove inside which plugged the
pipes !!!

25
26

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CPB DYEING

Padding with dye Batching and storring Washing off

2 01.05.2018 Kurt Speckle, Technical Service Dyestuffs

• cold dye fixation – energy savings

3 01.05.2018 Kurt Speckle, Technical Service Dyestuffs

• reliability of production process

4 01.05.2018 Kurt Speckle, Technical Service Dyestuffs

5 01.05.2018 Kurt Speckle, Technical Service Dyestuffs

• Neutral pH (pH values should be checked using a pH meter)

• Low conductivity (no electrolyte)

• No copper, manganese, iron, nitrate etc.

• No solid substances in the water

3 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

4 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

It’s important to have uniformity from batch to batch.

Requirements for a uniform dyeing is a uniform pretreatment.

Well pretreated is half dyed!

5 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

6 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

TEGEWA violet scale PVA

iodine solution at a concentration Polyacrylate

7 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

8 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

9 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

10 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

Morapex Merck pH-Indicator pH scale

equal pH over the entire width and length

11 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

12 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

13 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

14 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

+ 0,1 g/l non-ionic surfactant

+ 0.1 g/l non ionic surfactant

15 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

16 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

100 g/l NaOH 100 %

Well mercerized yarns:

200 g/l NaOH 100 %

17 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

18 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

20 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

Free of dust / powder

21 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

22 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

23 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

In generally the goods should be stored:

• Without big temperature fluctuations

• No expose to the direct sunlight

• Protect the fabric against impurity and damage

25 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

27 01.05.2018 Michael Zschemisch, Technical Service Dyestuffs

2 01.05.2018 Markus Boehme. TS dyeing aux.

3 01.05.2018 Markus Boehme. TS dyeing aux.

4 01.05.2018 Markus Boehme. TS dyeing aux.

Sinking test Sinking

KOLLASOL CDS 2g/l < 3sec

competitors product 2g/l 3-5 sec

COLORCONTIN VGP 2g/l < 3sec

5 01.05.2018 Markus Boehme. TS dyeing aux.

Shade differences (tailing, LCR) within batch

• Fabric not cooled:

6 01.05.2018 Markus Boehme. TS dyeing aux.

without auxiliary 67,22 70,88 pick up