4/20/2012

Pad Dyeing with Reactive Dyes

Dr. Tanveer Hussain

Dean Faculty of Engineering & Technology
National Textile University Faisalabad.
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Pad dyeing methods with reactive dyes

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Reactive dye requirements for pad dyeing

• Powder and liquid dyes

• Excellent solubility
• Excellent bath stability
• Low-to-medium substantivity, good compatibility
• Good diffusion and levelling properties
• Similar reactivity and rapid fixation
• Unaffected by fixation time variations
• High degree of fixation
• Excellent washing-off properties
• Good fastness level

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CIBACRON C Dyes

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Dye solubility in the presence of alkali

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Dye solubility in the presence of alkali

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Degree of fixation

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Degree of fixation of CIBACRON C

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Bath stability in pad-batch

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Stability vs. bath pH

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Dye affinity & pad dyeing

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Pad batch process

• Padding
– X g/l dyes
– 1 g/l wetting agent
– 2 g/l sequestring agent

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Kuesters Contidos System

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Batching

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Changing pH during batching

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Merits & demerits of pad batch method

Merits Demerits
• Modest investment layout • Batch process
• Suitable for small and fairly large
batches • Higher dye consumption
• Very simple working conditions than pad-dry-pad-steam
• Limited manpower required • Moderate coverage of dead
• Low energy consumption and immature cotton
• Lower water consumption than
exhaust dyeing
• Good penetration and level
dyeing
• Good reproducibility
• Suitable for dyeing knitgoods

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Pad-dry-pad-steam process
• Dye Pad
– X g/l dye
– 1 g/l wetting agent
– 2 g/l sequestering agent
– 5-10 g/l migration inhibitor
• IR pre-drying
– To residual 30-35% moisture content
• Drying
– 120◦C
• Chemical Pad
– 250 g/l salt
– 15 ml/l Caustic Soda (36◦Be)
• Steaming
– 60 seconds with saturated steam
• Washing-off

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Pad-dry-pad-steam process

Merits Demerits
• Economical process for large • Shade changes are time
production runs consuming
• Still economical for fairly
small runs (>5000m) on • Less suitable for dyeing
modern equipment fabrics prone to migration
• High colour yield problems or difficult to dry
• Very good appearance of the (pile fabrics)
dyed fabric
• Good reproducibility
• No detrimental influence on
light and/or chlorine fastness

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Pad thermo-fix process

• Dye Pad
– X g/l dye
– 1 g/l wetting agent
– 2 g/l sequestering agent
– 5-10 g/l migration inhibitor
– 20-100 g/l urea
– 10 g/l soda ash
• IR pre-drying
– To 30-35% residual moisture content
• Drying
– 120◦C
• Thermo-fixation
– 60 seconds as 160◦C
• Washing-off

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Pad thermo-fix process

Merits Demerits
• Good colour yield on cotton • Not recommended for dyeing
and coverage of dead cotton regenerated cellulose
• Very good lab to bulk • Possible specky appearance
reproducibility of the dyed fabric
• A negative influence on the
• Good batch to batch fabric handle is possible
reproducibility
• Danger of yellowing of the
• Moderate soiling of substrate
machinery • Lower light / chlorine fastness
• No need for a chemical pad level
liquor • The process requires urea

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Pad-steam process

• Dye Pad
– X g/l dye
– 1 g/l wetting agent
– 2 g/l sequestering agent
– 3 g/l thickener/migration inhibitor
– 60-90 g/l salt
– 10-30 g/l soda ash
• Steaming
– 60-90 seconds in saturated steam
• Washing-off

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Pad-steam process

Merits
• Continuous method mainly
used for dyeing fabrics with
high liquor retention, such as
terry fabrics and corduroy,
because no intermediate
drying is required
• No migration problems
• Reduced energy costs
• Good appearance of the dyed
fabrics
• No detrimental influence on
fastness
Demerits
• Higher amounts of dye are
required to produce deep
shades compared to the
pad-batch or pad-dry-pad-
steam processes
• Worthwhile for dyeing
deep shades when the
higher dye costs are at least
balanced by savings in
energy and gains in
productivity

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Pad humidity-fix process - Econtrol

• Dye Pad
– X g/l dye
– 1 g/l wetting agent
– 2 g/l sequestering agent
– 5-10 g/l migration inhibitor
– 20 g/l soda ash
– Y ml/l caustic soda (36◦Be)
• Drying/fixation
– 2-3 minutes at 120-130◦C, 25% RH (depending on
fabric weight)
• Washing-off

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Pad humidity-fix process - Econtrol

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Pad humidity-fix process - Econtrol

Merits
• Low chemical and auxiliary
requirements
• Suitable for dyeing viscose and
cellulosic blends
• Good colour yield
• Good appearance of the dyed
fabric
• No need for a chemical pad
liquor or steamer
• No detrimental influence on
fastness (light or chlorine)
Demerits
• Lower fixation level when
compared to pad-batch or pad-
dry-pad-steam
• For heavy weight fabrics IR pre-
drying is necessary to control
migration and prevent surface
dyeing
• Controlling the chamber climate
can be problematic, especially
when processing a mixture of
different fabric qualities
• Lab shade matching requires
specialist equipment (e.g.
universal steamer, type DH/DHe
from Mathis AG)

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Continuous washing-off reactive dyes

• Best washing conditions:

– When substantivity of the dye is as low as possible
– When diffusion rate as high as possible
• Phase 1: Dilution or exchange
– Removal of unfixed dye, alkali, auxiliaries & alkali
residues from the fabric surface.
– Influenced by:
• The number of bath changes.
• The amount of water.
• Turbulence, running speed and bath circulation.

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Continuous washing-off reactive dyes

• Phase 2: Diffusion and desorption

– Removal of unfixed dye, chemicals and alkali
residues from inside the fibre.
– Influenced by:
• Amount of unfixed dye and electrolyte content
• Substantivity and diffusion rate of the unfixed dye
• Time & Temperature
• Liquor ratio (number of wash baths, turbulence)
• Phase 3: Dilution & removal of diffused out dye

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Effect of washing temperature

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Effect of washing time

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Washing-off profile

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Washing-off profile

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Setting-up washing-off conditions

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