Accelerat ing t he world's research.

Causes and remedies of batch to

batch shade variation in dyeing
textilefloor
MOSTAFIZUR RAHMAN

Related papers Download a PDF Pack of t he best relat ed papers 

Causes and Remedies of Bat ch t o Bat ch Shade Vvariat ion in Dyeing Text ile Floor
K.M. Faridul Hasan

causes-and-remedies-of-bat ch-t o-bat ch-shade-variat ion-in-dyeing-t ext ilefloor-2165-8064-1000264(…

MOSTAFIZUR RAHMAN

Environment al Friendly Dyeing of Silk Fabric wit h Nat ural dye Ext ract ed from Cassia Singueana Plant
Taame Berhanu
 Science Ashaduzzaman et al., J Textile Sci Eng 2016, 6:4
ile &
xt DOI: 10.4172/2165-8064.1000264
urnal of Te

En
gineering
Journal of Textile Science & Engineering
Jo

ISSN: 2165-8064

Research Article
Research Article Open
OpenAccess
Access

Causes and Remedies of Batch to Batch Shade Variation in Dyeing Textile

Floor
Ashaduzzaman1, Hasan KMF2*, Rahman M1, Taher A1, Mia S1 and Xu W1
1
School of Textile Chemistry and Chemical Engineering, Wuhan Textile University, Wuhan, PR China
2
School of Textile Science and Engineering, Wuhan Textile University, Wuhan, PR China

Abstract
Shade variation is a common and big problem for the dyeing industries. Lots of reasons are responsible for
the variation of shade in dyeing textile industries. Batch to Batch shade problem is noticed when the fabric is dyed
in small batch to fulill the whole order quantity. From the thorough investigation it is seen that the most cases, the
shade variation occurs due to lack of the concentration and lack of proper duty by the operator of the concerned
machine. Most of the time, different dyeing faults like shade variations happens due to lacking’s of responsibility
taken by concerned management in the dyeing loor along with some technical issues. Maintenance is also a burning
fact for the shade variation. To keep the machine sound, the maintenance department must be strong enough
and effective. Shade variation is a very unwanted and unexpected thing to a Textile Engineer and also for dyeing
production loor. It is the duty of responsible authority in the dyeing loor to keep the production away from the shade
variation among all the batches of an order along with all the dyeing faults also through performing the duty properly
along with maintaining all the Procedures and parameters smooth in the dyeing loor.

Keywords: Dyeing; Knit fabric; Shade variation; Batch to batch;
Quality; Dyes; Chemicals
Introduction
Dyeing is the prime section of textile where coloration is performed
in the textile substrates. In dyeing lots of problems arise among which
shade variation is most unexpected and important problem. Whenever
a fault like shade variation happens during dyeing, the process has to
be logged behind, thus promoting some loss in productivity [1]. It is
extremely important for the dyeing companies to maintain a higher level
of quality to dyed fabrics for maintaining good relationship with the
buyers and other fellow companies [2]. Batch to Batch running shade in
dyeing carries out a great importance in the textile sector. Textile sector
is a leading ield of socio-economic activity, regarding its technological
state, economical eiciency and social interaction [3]. he faults like
shade variation will make the quality down along with the production
rate and reputation of the organization [4].
Shade is the depth of color or dyes percentage on to the fabric. Shade
is expressed in percentage of dye amount in unit mass of fabric. Shade
matching depends on the accuracy of the man's eye. Shade accuracy
varies to the visual sensation of dyeing master to dyeing master or
person to person [5]. So, experienced dyeing master or expert is needed
for this purpose. Besides the manual shade matching system recently
computer aided data color is also used for the measurement of shades
accurately like as spectrophotometer [6].
Here the color is matched compared with a standard shade which
was approved by the buyer or concerned responsible authority. All the
batch shades are measured against this standard shade in same order
[7]. In dyed fabric shade variation may be found roll to roll, meter
to meter, side to side, selvedge to selvedge, center to side, one end to
another, nozzle to nozzle etc. [8]. Shading or shade variation is thought
as a signiicant and major problem for dyeing industries for why an
order, shipment or production process would be strongly hampered
or cancelled. [9,10]. hough there is a tolerance is given or set but it is
really diicult to maintain the same shade in all the batches but it may be
maintained within the range of 0 to 1 as per CIELAB.
Quality is of prime importance in any aspect of business. And in
dyeing business batch to batch running shade has prime concern as well
as the proper shade of the dyed fabric [11]. As customers are the end
users of inal garments so it is needed to dye and maintain the quality
properly for their ultimate satisfaction.
he inal shade which is achieved ater the coloration process need
to be checked carefully for running shade in diferent stages of dyeing as
well as inishing [12]. his is done to ensure the accurate shade among
all the batches dyed in the same recipe and process. If the deviation is
beyond the tolerance or cross the allowance line then the parameters of
the batch needs to be checked and noted properly for the implementation
in next bathes of the same order and color. he metameric data is also
checked for each and individual colors [13]. Generally the shade is
checked and measured in diferent processing stages like as ater dyeing,
drying ater trial for inishing and even ater inishing.
Experimental Section
Materials
Knit Fabric, Chemicals, dyeing auxiliaries and dyes.
Instruments
Color Matching Cabinet (Model 1: CAC 60, Brand Name: VeriVide,
Origin: UK), DATACOLOR 650 (spectrometer and a photometer),
Dyeing machines (Sclavos, Athena, Fongs, Delminer machine in both
Microiber group and Esquire group of Bangladesh).
Dyeing sample preparation
Ater taking the fabric from knitting department the dyeing
*Corresponding author: Faridul Hasan KM, School of Textile Science and
Engineering, Wuhan Textile University, Wuhan, PR China, Tel: 8613207102972;
E-mail: farid_textile@yahoo.com
Received July 13, 2016; Accepted July 28, 2016; Published August 04, 2016
Citation: Ashaduzzaman, Hasan KMF, Rahman M, Taher A, Mia S, et al. (2016)
Causes and Remedies of Batch to Batch Shade Variation in Dyeing Textile Floor. J
Textile Sci Eng 6: 264. doi: 10.4172/2165-8064.1000264
Copyright: © 2016 Ashaduzzaman, et al. This is an open-access article distributed
under the terms of the Creative Commons Attribution License, which permits
unrestricted use, distribution, and reproduction in any medium, provided the
original author and source are credited.

J Textile Sci Eng

Volume 6 • Issue 4 • 1000264
ISSN: 2165-8064 JTESE, an open access journal
Citation: Ashaduzzaman, Hasan KMF, Rahman M, Taher A, Mia S, et al. (2016) Causes and Remedies of Batch to Batch Shade Variation in Dyeing
Textile Floor. J Textile Sci Eng 6: 264. doi: 10.4172/2165-8064.1000264

Page 2 of 8

section prepares the batch as per order quantity given by the buyer.
hen coloration of the fabric is performed in the designed machine
depending to the shades and fabric.
Acetic Acid is added at 55°C for 5 min
Basic dyeing procedure
here are various dyeing processes available in the industry termed
as isothermal, Migration, Turquoise, Polyester dyeing, Viscose dyeing, PH is Checked (PH=4.8)
white dyeing etc. Dyeing at 60˚C temperature is a common dyeing
process in the textile industry. A basic procedure for isothermal dyeing
process is given here:
Anti pilling
Machine illing with water at normal Temperature
Washing Agent (Flock-BM /SQ-117) is added at 55°C and run for
10 min

Fabric loaded at normal temperature (36-40°C)

PH is Checked (PH=4.8)

Chemicals (Chintex NF-150=Detergent, Jinsoter BSK/

CBF=Anticreasing agent, Ablutex-AP-750 (42% Soln)=Wetting agent,
Reduzin AC-BL-100=Stabilizer) Dozing at 50°C and Run for 4 min Enzyme (Retro cell PLX-TRA) at 55°C runs for 45 min

H2O2 (50% Soln)=Bleaching agent is added at 60°C within 3-4 Drain out
minute

Soda ash + Flock-BM=to reduce the efect of enzyme is added at

80°C and run for 10 min
NaOH=Scouring agent is added for 7 min at 70°C

Aquachron washing is done

Run time 110°C ×20 min.

Acetic Acid is added at 60°C and run for 3-5 min

Cooling at 95-80 °C and then aquachron washing is done

Dyeing (Isothermal)
Water is leveled
Leveling agent (Jinlev-CL/RL) is added at 60°C and run for 10 min

Absorbency test is done. PH is Checked (PH=6-6.5)

Per oxide Killer (Raduzin-THN (50% Soln)) is added at 8°C for 10 Dyes are mixed up for 20 minutes and dosed at 600 with run time
min, for 10 min.

Per oxide is checked (if H2O2=O) Salt is added at 60°C through transfer dosing for 24min and run
for 20 min

Aquachron washing is done at 55°C

Speciic gravity of salt is checked

Water is leveled

J Textile Sci Eng

ISSN: 2165-8064 JTESE, an open access journal Volume 6 • Issue 4 • 1000264
Citation: Ashaduzzaman, Hasan KMF, Rahman M, Taher A, Mia S, et al. (2016) Causes and Remedies of Batch to Batch Shade Variation in Dyeing
Textile Floor. J Textile Sci Eng 6: 264. doi: 10.4172/2165-8064.1000264

Page 3 of 8

Soda is added at 60°C for 24 min and run for 5 min

PH is Checked (PH=10-11.5)
Ater 5 min shade is assessed
Unload
Results and Discussions
he color coordinates of the dyed fabrics (CIE L*, a*, b*) were
determined with Data color SF300 spectrophotometer under illuminant
D65 using the 10° standard observer [14,15]. According to the measured
CIE color coordination, the color diference (E*) was measured as:

If shade is not “OK” then it’s checked again ater every 15 min E*= ( a *) + ( b *) + ( L *)
2 2 2

until matching
Where, L* is the indication of color lightness or darkness, a* is the
red/green and b* is the yellow/blue, h and c (hue and chromaticity)
which are calculated from the relectance data indications of the samples.
If shade is “OK”

Wash is done at 60°C for 25 min

S a m p l e : S ta n d a r d
Acid wash is done at 60°C and run for 6 min for neutralization

PH is checked (acidic condition)

S a m p l e : B a tch 2 5 0 A S a m p l e : B at c h 205
Soaping
Figure 1: Comparison of standard shade with batch for Sample 1 (Navy Marl).
Soaping agent (QSE) is added at 90°C and run for 12 min
Samples DL DC DH Da Db DE Status
Sample 1
0.29 -0.59 0.17 o.20 0.73 0.68 Pass
(Batch250A)
Aquachron washing is done
Sample 2
0.24 -0.51 0.07 0.03 0.59 0.57 pass
(Batch205)
Table 1: Data color report of batches with standard for sample 1 (Navy Marl).

Hot wash at 90°C run for 9 min

Again Aquachron washing is done

Drain out
Sample: Standard

Fixing
Fixing agent (WER) is added for 10 min at 40°C and run for 10
min

Sotening Sample: Batch 54 Sample: Batch 57

Acidic acid +Dosssing Bevsot-CF=Sotener +Jinsoter – Figure 2: Comparison of standard shade with batch for Sample 2 (Grey
Mellange).
WCS=Fixing Agent is added for 10 min at 40°C and run for 20 min

J Textile Sci Eng

ISSN: 2165-8064 JTESE, an open access journal Volume 6 • Issue 4 • 1000264
Citation: Ashaduzzaman, Hasan KMF, Rahman M, Taher A, Mia S, et al. (2016) Causes and Remedies of Batch to Batch Shade Variation in Dyeing
Textile Floor. J Textile Sci Eng 6: 264. doi: 10.4172/2165-8064.1000264

Page 4 of 8

K (1 − R ) 2
=
S 2R
Where K is absorbance coeicient, S is scattering coeicient, and
R is relectance ratio measured at the maximum absorbance using a
relective spectrophotometer. [16,17]. he equations for the calculation of
color diferences arc deined on the basis of theoretical conclusions, experience
and experimental results.
of Batch-54 and Batch-57 are compared with the standard to get the
deviation between the batches. In the light box under the D-65 light,
the samples are compared. Visually it is found that, the batch 54 (1.11)
is a little bit darker than the other Sample of batch 57(0.81). Now,
comparing the visual result with the spectrophotometer data, following
results are obtained. hen according to the Data color report it is seen
that, the color deviation of the batch 54 is 1.11, which is greater than 1
and it is known that if the DE is not less than 1.0, then the DE fails and

DE * = ( DL *)2 + ( Da *)2 + ( Db *)2 

the shade is unacceptable [18]. So this shade is unacceptable according
 
1/2

Samples DL DC DH Da Db DE Status
DE* - total color difference
Sample 1
1.11 0.12 0.03 0.01 -0.09 1.11 Fail
Da* - the diference on the red-green coordinate (Da*=a* sample (Batch 54)
- a* standard) Sample 2
0.81 0.02 0.01 0.02 -0.03 0.71 Fail
(Batch 57)
Da* marks redder, - Da* marks greener.
Table 2: Data color report of batches with standard for sample 2 (Grey Mellange).
Db* - the difference on the blue-yellow coordinate (Db*=b* sample - b*
standard)
+ Db* marks more yellow, - Db* marks bluer;
DL* - the diference in lightness (DL*=L* sample - L* standard)
* DL* marks lighter. - DL* marks darken
Sample: Standard
DC* - the diference in chroma (DC* - C* sample - C* standard)
+ DC* marks more brilliant, - DC* marks more opaque.
DH* - the difference in color hue is calculated by equation:

DH* = ( DE *) − ( DL *) − ( DC*) 
 
2 2 2 1/2

By this formula, the spectrophotometer data can be analyzed and

Sample: Batch 5B Sample: Batch 5C
also can obtain a decision from it.
Figure 3: Comparison of standard shade with batch for Sample 3 (Turquoise).
Diferent sample are taken for this research in the dyeing loor.
hese samples are as follows:
Samples DL DC DH Da Db DE Status
Samples 1 (Navy Marl) Sample 1
-1.69 -0.65 0.17 1.45 0.74 1.82 Failed
(Batch 5B)
Figure 1 represents the Comparison of standard shade with batch Sample 2
for Sample 1. -1.57 -0.06 -0.12 0.50 0.66 1.64 Failed
(Batch 5C)

Data Color Report for sample 1 (Navy Marl): From the samples Table 3: Data color report of batches with standard for sample 3 (Turquoise).
approved by the buyer a sample is considered as a standard and the
other two samples of Batch 250A and Batch 205 is compared with the
standard to get the deviation between the batches. In the light box under
the D-65 light, the samples are compared. It is seen that the standard
Batch is darker than the others, because DL is Positive integer here.
hen as per the Data color report it is also seen that, the color deviation
is 0.68 and 0.57 which are less than 1 and it is also known that if the
DE is less than 1.0, then the DE is passed and the shade is acceptable.
It is seen that the Batch 250A is lighter, less saturated (DL=-0.24) and
more Green in the D65 light. And the Batch 250 is lighter, less saturated Sample: Standard
(DC=-0.59) and more Red in the D65 light (Table 1).
Samples 2 (Grey Mellange)
Figure 2 represents the Comparison of standard shade with batch
for Sample 2 (Grey Mellange).
Data Color Report 2 (Grey Mellange): Table 2 represents the data
color report of batches with standard for sample 2(Grey Mellange).
Sample: Batch 940 Sample: Batch 945
Observation: From the samples a batch is considered as the
standard through approval from the buyer and the other two samples Figure 4: Comparison of standard shade with batch for Sample 4 (Turquoise).

J Textile Sci Eng

ISSN: 2165-8064 JTESE, an open access journal Volume 6 • Issue 4 • 1000264
Citation: Ashaduzzaman, Hasan KMF, Rahman M, Taher A, Mia S, et al. (2016) Causes and Remedies of Batch to Batch Shade Variation in Dyeing
Textile Floor. J Textile Sci Eng 6: 264. doi: 10.4172/2165-8064.1000264

Page 5 of 8

Samples DL DC DH Da Db DE Status 0.65) and more Blue in the D65 light. And the Batch 5C is also darker,
Sample 1 less saturated (DC=-0.45) and more Yellow in the D65 light (Table 3).
-0.55 -0.14 -0.20 -0.15 0.08 0.61 Pass
(Batch 940)
Possible causes behind the failure: Turkish color has a yellowish
Sample 2
-0.52 -0.44 -0.09 -0.26 0.18 0.69 pass efect. When the fabric starts to absorb Turkish color, the shade gets a
(Batch 945)
yellowish tone. he fabric at around 90°C starts to absorb the color. In
Table 4: Data color report of batches with standard for sample 4 (Black).
the batch 5C, the fabric was in the hot temperature (80-90°C) for more
time than the standard one. hat’s why the spectrophotometer is giving
that more yellow tone.
Sample 4 (Black)
Figure 4 Comparison of standard shade with batch for Sample 4
(Turquoise)
Sample: Standard
Data color report 4 (Black): From the samples a batch is considered
as the standard through approval from the buyer and the other two
samples of Batch-940 and Batch-945 is compared with the standard
to get the deviation between the batches. In the light box under the
D-65 light, the samples are compared. Visually it is tough to identify
the variation because it is a dark shade, but using spectrophotometer
makes it easier and perfect. hen according to the Data color report it is
Sample: Batch 168 Sample: Batch 187 seen that, the color deviation of the batch 940 is 0.61, which is less than
Figure 5: Comparison of standard shade with batch for Sample 5 (Red marl). 1 and it is known that if the DE is not less than 1.0, then the DE fails
and the shade is unacceptable. So this shade is acceptable according
Samples DL DC DH Da Db DE Status to the spectrophotometer data. On the other hand the color deviation
Sample 1 of the batch 940 is 0.61. So this shade is acceptable comparing with
-0.14 -0.32 0.13 -0.16 -0.32 0.37 Pass
(Batch 168) the standard. It is also seen that the Batch 940 is darker, less saturated
Sample 2
-0.12 -0.25 0.13 -0.17 -0.22 0.31 Pass
(DC=-0.14) and more Red in the D65 light. And the Batch 945 is darker,
(Batch 187) less saturated (DC=-0.44) and more Green in the D65 light (Table 4).
Table 5: Data color report of batches with standard for sample 5 (Red Marl).
Sample 5 (Red Marl)
to the spectrophotometer data. On the other hand the color deviation Figure 5 Comparison of standard shade with batch for Sample 5
of the batch 57 is 0.71. So this shade is acceptable comparing with the (Red marl).
standard. It is also seen that the Batch 54 is lighter, more saturated
(DC=0.12) and more Red in the D65 light. And the Batch 57 is also From the samples approved by the buyer a sample is considered
lighter, less saturated (DC=-0.09) and more Red in the TL83 light. as a standard and the other two samples of Batch 168 and Batch 187 is
compared with the standard to get the deviation between the batches.
Possible causes behind the failure: he exact tone could not be
found in case of Batch 54 so this batch 54 is needed re dyeing to reach In the light box under the D-65 light, the samples are compared.
the exact shade. Due to the extra dyeing process, the fabric went through It is seen that the Batches are lighter than the others because of DL is
extra stress like washing and heat. Because of that the dye absorbed negative integer here.
by the Batch 54 was more than the other samples. Moreover, the rope
hen according to the Data color report it is also seen that, the color
length of the Batch 54 was lesser among these three batches. hat’s why
deviation is 0.37 and 0.31 which are less than 1 and it is also known
the cycle time of the batch was less and the fabric of this batch absorbed
that if the DE is less than 1.0, then the DE is passed and the shade is
more dyes than the other two batches.
acceptable.
Sample 3(Turquoise)
Data color report 5: Table 5 Data color report of batches with
Figure 3 represents the Comparison of standard shade with batch standard for sample 5 (Red Marl)
for Sample 3
Some considerable factors which efect batch to batch shade
Data Color Report 3(Turquoise): From the samples a batch is variation
considered as the standard through approval from the buyer and the
other two samples of Batch-5B and Batch-5C is compared with the Batch to batch running shade is a general phenomenon noticed
standard to get the deviation between the batches. In the light box almost everywhere in dye houses. here are so many factors that afect
under the D-65 light, the samples are compared. Visually, it is found a particular dyeing operation. By checking this factor eliminates 90 to
that, the batch 5C is a little bit yellowish than the other two shades. 100% of the above problem.
Now, comparing the visual result with the spectrophotometer data, Phase-1: Preparatory stage
following results are found. hen according to the Data color report it
is seen that, the color deviation of the batch 5B is 1.82, which is greater i. Check the quantity of the exactly and carefully for all batches.
than 1 and as the DE value is not less than 1.0, so the DE fails and the Find the exact GSM of the grey fabric and note down on the
shade is unacceptable. On the other hand the color deviation of the assigned Batch card.
batch 5C is 1.64. So this shade is also unacceptable comparing with the ii. Ater Scouring, Bleaching and neutralization and before dying
standard. It is also seen that the Batch 5B is darker, less saturated (DC=- a sample is taken to check the absorbency.

J Textile Sci Eng

ISSN: 2165-8064 JTESE, an open access journal Volume 6 • Issue 4 • 1000264
Citation: Ashaduzzaman, Hasan KMF, Rahman M, Taher A, Mia S, et al. (2016) Causes and Remedies of Batch to Batch Shade Variation in Dyeing
Textile Floor. J Textile Sci Eng 6: 264. doi: 10.4172/2165-8064.1000264
iii. Process loss is noted down on the batch card during scouring
and bleaching stage.
iv. If deviation is there then the following may be the reasons:
a) Material to Liquor Ratio diference during scouring/bleaching.
b) Process timing diference
c) Temperature may be kept high or low.
d) Loses less weight rather than the poor quality short staple
length iber.
e) Alkali and Scouring auxiliaries' concentration or quality may
have changed.
f) Quality of water may be changed.
Dyeing stage
• Check the quality of input fabric and other materials.
• Dyestuf concentration to be checked drum to drum.
• Need to check the quality of sequestering agents.
• Need to check the quality of water hardness and pH.
• Dyes and chemicals should be measure carefully through
checking the brand name and required quantity.
• Making dyestuf solution is extremely important. Dissolving and
iltration of dyestufs should be performed carefully.
• Speciic gravity of salt should be measured carefully..
• Soda ash should be dissolved and iltered properly in case of
critical shades like turquoise, Anthracite etc.
• Allow same parameter for all the batches of a same order.
• Soda dosing or injection should be done carefully..
• Allow running the batch for the same length of time in soda
before raising temperature. If it is 20 minutes. Need to follow
the same procedure for all batches.
• Temperature gradient should be properly maintained.
• Dye bath and ixation PH is very important. So during dye bath
the PH should be kept 6.5 to7.0 and during ixation it should be
more than 10.5 for reactive dyeing.
• Water level in every stage of dyeing should properly be
monitored and maintained.
Causes of batch to batch shade variation in dyeing
Dyeing is one of the sophisticated parts of the textile production.
here are so many reasons behind the batch to batch shade variation.
hey are given below.
Uneven pretreatment (uneven scouring and bleaching): If the
pretreatment of the fabric is not good than the coloration on the fabric
would not also be good. here would be a risk of running shade and
unevenness in the colored fabric.
Improper color dosing: If the color dosing is not proper running
shade and shade variation will happen.
Using dyes of high ixation property: Quality of input chemical
is another factor of shade variation. If concentration of input chemical
is varied from one batch to another then shade variation is occurred.
J Textile Sci Eng
ISSN: 2165-8064 JTESE, an open access journal
Page 6 of 8
he concentration of NaOH is for irst batch is 95% and second bath is
90.5%. As a result the Scouring of irst batch is better than the second
batch. he purity % of salt for irst batch is 93.2% and second bath is
91.8%. As a result the dye bond formation on iber of irst batch is better
than second batch.
Excessive Heat setting: Heat-setting has efect on dye bond
formation on iber. Higher temperatures would assists cotton fabric to
absorb more dyes because of the kinetic energy, So there is scope of
more interaction between the fabric and dye molecules, thus increasing
the chance of a reaction taking place and bond formation.
Lack of control on dyeing m/c: he parts of the dyeing machine
should be checked carefully before going for coloration. he setting of
the diferent machine parameter should be maintained and set carefully.
Rope length and cycle time: Rope length and cycle time is another factor
of batch to batch shade variation. If rope length is same but cycle time is varied
from one batch to another it may cause shade variation. As a result each portion
of the loop will not get same time for exhaustion and ixation of dyestuf. So
the dye penetration percentage would difer from batch to batch. If the
rope length is not same in the entire chamber one sample gets more time to dye
penetration from dye chamber than another sample.
Reel speed: Reel speed depends on the structure of the fabric, such as low
GSM and high GSM of the fabric, total weight of the fabric, diameter of the
fabric etc. Another factor is rope length of the fabric. In this experiment diferent
types of fabrics are used. Due to this variation, one sample gets more time to dye
penetration from dye chamber than another sample.
Running time: During the coloration time every running time of the
processes should be maintained properly to ensure smooth and better quality
oriented colored fabric.
Drum to Drum Variation/ Dyes lot variation: he dye molecules
properties and their characteristics oten may vary drum to drum. hese
properties and characteristics have great inluence on dyeing process.
In production it is observed that the shade variation is occurred due to
drum variation, though all parameters and recipe was same. Sometimes
the laborers/operator's fault or irresponsibility has a great role in case
of shade variation.
PH
• In the beginning of dyeing, the water bath pH should be checked
carefully and kept near about 6.8-7.0. Otherwise premature
hydrolysis of dyestuf will take place and cause (a) uneven
dyeing and (b) lighter shade will be formed.
• If the PH is not properly neutralized during or before soaping
the alkali should stain on fabric and would cause patchy efect.
• If the PH becomes lower during the ixation time dyes will not
properly absorbed onto the fabric so there will be a possibility
of huge dyes wastage and fastness would also be poor.
• Higher dosage of alkali will cause a possibility of hydrolysis of
dyestuf in the solution itself. So the color performance would
be poor.
• Ater the inishing of dyeing, when the alkali still fully remains
on the iber, if the alkali is not neutralized properly with
adequate quantity of acid, it would cause a quality problem onto
the fabric.
• Every dyestuf appears in diferent tone under diferent pH
conditions. Bright Lemon yellow, if allowed dry under alkaline
Volume 6 • Issue 4 • 1000264
Citation: Ashaduzzaman, Hasan KMF, Rahman M, Taher A, Mia S, et al. (2016) Causes and Remedies of Batch to Batch Shade Variation in Dyeing
Textile Floor. J Textile Sci Eng 6: 264. doi: 10.4172/2165-8064.1000264
pH, it will turn to a dull redder yellow and similarly Turquoise
blues and royal blues will appear yellower and duller in alkaline
pH and brighter and redder in acidic pH. So make sure that
the pH is exactly neutral or slightly acidic during inal drying
process.
• he sotening should also be done in acidic PH otherwise the
tone of the shade will be changed.
Soaping: Before adding the soap in to the bath, ill the machine with
adequate volume of water, run blank for 5 minutes, and take out some
water and to check for TDS. he higher residual salt content in the water
would act as exhausting agent for the unixed dyestufs and would not
allow coming out from fabric, during soaping and impairing the quality
of soaping and inally the washing fastness. More over the improperly
removed salt would result in a harsh feel of the inished fabric. Higher
dosages may sometimes cause white patches. In dyeing loor Should
to maintain the timing, temperature, water level and dosing of soap
same for entire soaping processes. Check the Final pH of the fabric; let
it be slightly acidic ranged 6.5 to 7. But in acidic pH condition the fabric
should not be allowed to kept wet for long durations for one day or
two days, because there is a possibility of formation of fungus over the
processed material that not only changes the tone but also impairs the
strength of ibers.
Finishing: Not only the preparation and dyeing operations are
important, inal inishing operation is also very important to avoid the
batch to batch shade variation.
Ater draining dye bath it is needed give some cold wash properly
to remove the extra dyes from fabric surface. hen sotening treatment
is done by using suitable sotener along with maintaining the proper PH.
Cationic ixing operation: Due to the presence of free formaldehyde
in diferent dosages between manufacturers, the inal shade’s tone
changes to bluer or yellower side. Select the best product and adhere to
it. Do not change this product frequently for small cost beneits.
Final cationic sotener treatment: During this phase also there is
every possibility of changes in tone, depth and light fastness of the inal
product. Should to ensure using the best quality oriented product and
maintain the same for all of the production processes.
Drying temperature: During stenter and compacting stage the
fabric should exposed to proper and same temperature for all the
batches to ensure proper shade of the fabric. Over dried fabric and
under dried fabric will show a lot of shade variation.
Poor lab-to-bulk correlation: In theory, a long-term statistical
evaluation of lab-to-bulk correlation should be kept for every machine
in the dye house, as diferent liquor ratios render diferent hydrolisation
efects. Higher liquor ratios cause dye stufs and chemicals to lose their
eiciency, whilst modern machines (such as AIRFLOW) dye cotton
with a dry liquor ratio of only 1:3.75. Unless the lab works with low
liquor ratio beaker dyeing equipment in the irst place, transferring
a lab recipe unaltered to an AIRFLOW machine will result in deeper
shades.
Logistics: here is a growing trend among apparel manufacturers
towards backward integration into dyeing. his relects the widespread
frustration at having to deal with dye quality issues. Proper and adequate
quality of dyes supply must be ensured in dyeing loor. he supply
of all the resources must be smooth in the dyeing loor. Cooperation
and good understanding with all the responsible employees in loor is
necessary for best output and performance.
J Textile Sci Eng
ISSN: 2165-8064 JTESE, an open access journal
Page 7 of 8
Remedies
• Standard dyes and chemicals need to be used.
• Maintain the same liquor ratio in all the batches of same color
in an order.
• Follow the standard pretreatment procedure.
• Maintain the same Reel speed and cycle time.
• Identical dyeing procedure should be followed for the same
depth of the Shade.
• Make sure that the operators add the right bulk chemicals at the
same time and temperature in the process.
• he pH, hardness, SG of salt and sodium carbonate content of
supply water should be checked regularly.
Conclusion
A systematic investigation on batch to Batch shade variation was
performed in the dyeing production units of knit composite industry.
he sequence of the production was observed to monitor and ind out
the root causes of the problem. It is seen that improper follow up of
standard dyeing process is one of the root causes of the batch to batch
shade variation. Various reasons like nozzle to imbalance rope length
of fabric, improper liquor ratio, low quality dyes and chemicals, wrong
procedure of coloration, improper dosing of dyes and chemicals are
responsible for batch to batch shade variation.
Maintenance of the dyeing machine is one of the burning facts
for shade variation. To keep the machine sound, the maintenance
department must be strong enough and efective. Every problem
occurred during dyeing must be solved instantly to resolve the
possibility of excess problem in the dyed fabric. Shade variation is a
very much unexpected faults in a Textile dyeing house. It is the duty of
every responsible person in the dyeing loor to monitor and formulate
the dyeing process properly to keep the production away from the shade
variation among the batches along with all other dyeing faults also.
Acknowledgement
This research is performed at different textile dyeing industries of Bangladesh
named Esquire knit Composite limited, Microiber group, NAZ Bangladesh Limited,
Aswad composite mills limited, Fakhruddin textile mills limited, etc. All of the
authors performed their research in those dyeing factories practically and found
out the effective processes. All of the authors inalized the article under school of
Textile science and Engineering and School of chemistry and chemical engineering
department of Wuhan Textile University.
References
1. Arivithamani N, Mary SA, Kumar MS, Dev VRG (2014) Keratin hydrolysate as
an exhausting agent in textile reactive dyeing process. Clean Technologies and
Environmental Policy 16: 1207-1215.
2. Croft SN, Lewis DM, Orita R, Sugimoto T (1992) Neutral-ixing reactive dyes
for cotton. Part 1-synthesis and application of quaternised S-triazinyl reactive
dyes. Journal of the Society of Dyers and Colourists 108: 195-199.
3. Lewis DM, Vo LTT (2007) Dyeing cotton with reactive dyes under neutral
conditions. Coloration Technology 123: 306-311.
4. Xie K, Hou A (2004) One-bath dyeing of wool/acrylic blends with reactive
cationic dyes based on monofluorotriazine. Coloration technology 120:
307-310.
5. Zhang H, Zhao T (2009) Synthesis and dyeing properties on cotton ibers of a
quaternary ammonium cationic reactive dye. Dyest Color 46: 32-35.
6. Zheng C (2012) Dyeing properties of novel electrolyte-free reactive dyes on
cotton ibre. Coloration Technology 128: 204-207.
Volume 6 • Issue 4 • 1000264
Citation: Ashaduzzaman, Hasan KMF, Rahman M, Taher A, Mia S, et al. (2016) Causes and Remedies of Batch to Batch Shade Variation in Dyeing
Textile Floor. J Textile Sci Eng 6: 264. doi: 10.4172/2165-8064.1000264
7. Broadbent AD (2001) Basic principles of textile coloration. Society of Dyers and
Colorists West Yorkshire, Canada.
8. Trotman ER (1984) Dyeing and chemical technology of textile ibres.
9. Trotman ER (1964) Dyeing and chemical technology of textile ibres.
10. Lallam A, Michalowska J, Schacher L, Viallier P (1997) Diffusion and adsorption
of dye by polyester microibres. Journal of the Society of Dyers and Colourists
113: 107-110.
11. Burkinshaw SM (1995) Chemical Principles of Synthetic Fibre Dyeing. Springer.
12. Jia W (2003) Studies on cationic modiication of cotton fabric and dyeing of it.
Text Aux 20: 26-30.
13. Ristić N, Ristić I (2012) Cationic modification of cotton fabrics and
reactive dyeing characteristics. Journal of Engineered Fibers and
Fabrics 7: 113-121.
Citation: Ashaduzzaman, Hasan KMF, Rahman M, Taher A, Mia S, et al. (2016)
Causes and Remedies of Batch to Batch Shade Variation in Dyeing Textile Floor.
J Textile Sci Eng 6: 264. doi: 10.4172/2165-8064.1000264
J Textile Sci Eng
ISSN: 2165-8064 JTESE, an open access journal
Page 8 of 8
14. McGuire RG (1992) Reporting of objective color measurements. HortScience
27: 1254-1255.
15. Zhang X, Wandell BA (1997) A spatial extension of CIELAB for digital color-
image reproduction. Journal of the Society for Information Display 5: 61-63.
16. Fairchild MD, Berns RS (1993) Image color-appearance speciication through
extension of CIELAB. Color Research and Application 18: 178-190.
17. McLaren K (1976) XIII-The development of the CIE 1976 (L* a* b*) uniform
colour space and colour-difference formula. Journal of the Society of Dyers and
Colourists 92: 338-341.
18. Hill B, Roger T, Vorhagen FW (1997) Comparative analysis of the quantization
of color spaces on the basis of the CIELAB color-difference formula. ACM
Transactions on Graphics (TOG 16: 109-154.
OMICS International: Publication Benefits & Features
Unique features:
• Increased global visibility of articles through worldwide distribution and indexing
• Showcasing recent research output in a timely and updated manner
• Special issues on the current trends of scientiic research
Special features:
• 700+ Open Access Journals
• 50,000+ editorial team
• Rapid review process
• Quality and quick editorial, review and publication processing
• Indexing at major indexing services
• Sharing Option: Social Networking Enabled
• Authors, Reviewers and Editors rewarded with online Scientiic Credits
• Better discount for your subsequent articles
Submit your manuscript at: http://omicsgroup.info/editorialtracking/textile/
Volume 6 • Issue 4 • 1000264