Reactive Dye

Application methods of reactive dye

• Batchwise Exhaust method
• Semi Continuous method (Pad-batch method )
• Continuous method
– Pad-Steam (suitable for heavy woven fabric)
– Pad-dry –thermofixation (Recommended for
turquoise and brilliant green)
– Pad-dry-steam (One bath process)
– Pad-dry-pad-steam (Standard process)
 Exhaust dyeing
## Effect of bleaching agent:
Bleaching agent, even in small
quantities -
Deactivate the dye preventing reaction
with the fiber.
 Primary exhaustion
• Primarily the dye is exhausted at neutral
conditions at the presence of glauber’s salt.

Fig. Dyebath exhaustion as a function of time

 Secondary exhaustion
• Secondary exhaustion takes place
when the alkali is added.
• Dye can migrate during primary
exhaustion but not during secondary.
Here need circulation/stirring to
balance the fixation rate.
Secondary exhaustion

Diagram showing variations in

dye exhaustion (a), reaction with
the fiber (b), temperature (c) and
chemical additions, for dyeing
cotton with a reactive dye of low
substantivity and reactivity.
Batch dyeing/Exhaust dyeing
Knit dyeing machine
Package dyeing/ Yarn dyeing m/c
Cone dyeing/yarn dyeing
 Exhaust dyeing/batch dyeing
• Load the m/c with water & material
• Check pH, peroxide and temp
• Run liquor/fabric for few minutes
• Add pre-dissolved dyes for a specific period
of time (dosing) (eg-10m)
• Run for some time (eg-15m)
• Add a portion of total salt and run (eg. 10min)
 Exhaust dyeing/batch dyeing
• Add the rest of the salt similarly in three
or four steps and run for few
minutes.
• Add Soda for a specific period of
time.(dosing) (eg-10m)
• Check pH
• Not ok? Add more Soda to achieve
desired pH value.
 Exhaust dyeing/batch dyeing
• Raise the temp and run for specific amount of
time (Dyeing)
• Check shade, drop the bath or make adjustment
(addition, run more)
• Cold rinse (one or several times)
• Soaping (@ required time and temp)
• Warm rinsing / hot wash
• Rinsing/ cold wash until clear wash water
• Finishing
 Addition of dyes during dyeing

• Cool the bath first

– Either by dropping ¼ of the bath and
adding cold water, or
– By heat exchanger
• Then add the dyes
• Raise to dyeing temp
• Dye for req. time
 Semi-Continuous method - Pad Batch

• Steps:
1) The fabric is first padded in a padding
mangle with reactive dye in presence of an
alkali.
2) The padded fabric is rolled in a batch and
the batches are wrapped by polyethylene
sheets and stored in wet condition for 1-24
hours at 200-300C in a room.
 Pad Batch
3) During the storage period, the rolls
may be kept slowly rotating to prevent
slippage of the dye liquor.
4) After storing time is finished, fabric
is washed in a rope washing machine
to remove the unfixed dye from fabric
surface.
 Pad Batch
• Dyes, wetting agent, salt and alkali all
together
• Critical to maintain the stability of alkaline
padding liquor.
• Fixation by just storing at room temp for
upto 24hrs
• Low temp– low dye hydrolysis rate.
 Pad Batch
Typical pad-batch dyeing unit
 Continuous dyeing
Typical pad-dry-thermofix process sequence

Typical chemical pad-steam-wash-dry process sequence

 Stripping
Stripping becomes necessary when uneven dyeing occurs. By
stripping azo group (--N=N--) from the dye is removed.
Partial stripping:
Wetting Agent=1 g/l Full stripping:
Sequestering Agent=1g/l Wetting Agent=1 g/l
Glauber salt=10g/l Sequestering Agent=1g/l
Soda ash=5-7 g/l Hydroze=5g/l
Temperature: 70 - 100°C
Caustic soda=5g/l
Time: until desired shade
Temperature:1000C
is obtained.
Time : 60 min
 Hydrolysis of reactive dye
Hydrolysis Reaction of reactive dye with water:

1. Hydrolysis of halogen containing reactive dye,

D-R-Cl + H-OH →D-R-OH + H-Cl

2. Hydrolysis of activated vinyl compound containing dye,

D-F-CH2-CH2-OSO3H + H-OH →D-F- CH2-CH2-OH + H2SO4

 Prevention of Hydrolysis
• As hydrolysis increases with increasing
temperature during dissolving and
application temperature should not be
more than 40°C.
• Dye and alkali solution are prepared
separately and mixed just before using.
• Dye and alkali should not be kept for long
time after mixing.
 Classification of Reactive dyes
• Classification of reactive dyes
based on three important controlling parameters-

• Alkali-Controllable reactive dyes

• Temperature Controllable reactive dyes
• Salt Controllable reactive dyes
 Alkali Controllable
• Have optimal temp of fixation between
40-60c
• Relatively low exhaustion in neutral salt
solution before alkali addition
• Have high reactivity during alkali addition. So,
special care needs to consider for level
dyeing.
• Needs controlled rate of alkali dosing
• DCQ, DCT, DFP and VS reactive system
 Salt Controllable reactive dyes
• Show optimal fixation at temp around
80oc
• Have relatively high exhaustion at neutral
• So, need careful salt addition for level
dyeing
• Portionwise salt addition at control rate is
preferable
• Typically have low-reactivity such as MCT,
MFT.
 Temp-controllable

• Represented only by the Kayacelon React

dyes.
• React with cellulose at temp above boil
• Self-levelling
• Simply control the rate of temp rise.
 Dyeing Faults
• Uneven Dyeing
• Running Shade
• Crease mark
• Dye spot
• Softener Mark
• Soda Mark

• Reason & Remedies

 Advantages
• Full Color Range
• Brilliant, bright colors
• Covalent fixation high Wash Fastness
(WF)
• Varying Reactivities
– Various temperatures including low energy
(cold dyeing)
• Various methods of application
• Inexpensive to apply (but dyes
expensive)
 Disadvantages
• Incomplete fixation (problem with
hydrolysis)
• Need wash-off (for high WF)
• Need high concentrations of salt
– Affect natural balance of watercourses
• High pH
• Some dyes are “AOX” – potentially harmful
to the environment
Thank You!