Innovations in Innovations in Dyeing Dyeing Mr. Thomas Mende IFC International Conference March 2005
Innovations in Innovations in DyeingDyeing
Mr. Thomas Mende
IFC International Conference March 2005
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Dyes
Machinery
Chemicals
Water
Man Power
Energy
Dyeing Components
It has been estimated that in a standard cotton dyeing process
Bleaching, washing and rinsingUSESUSES
* 70% of the total time
* 80% of the water
* 90% of the energy
0
100
200
300
400
500
600
1:15 1:12 1:10 1:8 1:8 1:5
litre
s/kg
Total water per kg of fabric
Process water
Cooling water 30 °C
‘eco master
IImpact of Liquor Ratiompact of Liquor Ratio Cooling and Process WaterCooling and Process Water
Average Steam consumption per kg fabricBased (MCT)Reactive Dyeing
1:15 1:12 1:10 1:8 1:8 1:5
12.08
9.58
7.91
5.96
4.133.30
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00 ‘eco master’
WITH HEATRECOVERY
Impact of Liquor RatioImpact of Liquor Ratio Steam ConsumptionSteam Consumption
5.000 kg day Reactive Dyed Cotton = 1.650.000 kg/year fabricaverage salt used 60 grms/litre
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
SALT
1.980
1.485
990792
495
0
400
800
1.200
1.600
2.000
1:20 1:15 1:10 1:8 1:5
Liquor Ratio
To
nn
es
of
salt
pe
r ye
ar
Impact of Liquor RatioImpact of Liquor Ratio Chemical UsageChemical Usage
1:5 1:6 1:7 1:8 1:9-10 1:10-12 1:14-15
92.5%89.8% 87.0%
70.5%61.0%
53.2%49.0%
0%
20%
40%
60%
80%
100%
120%Reactive Dyeing 80°C
Matching Standard M&S = 0.8
Impact of Liquor RatioImpact of Liquor Ratio Right First TimeRight First Time
New Innovations in dyeing
• new funtions• RINSEtronic
RINSEtronicRINSEtronic
RINSEtronic automatically calculates the correct rinsing producedure to arrive at a bath residual
salt content of less than 1g/lonly necessary to enter the salt concentration & the
dept of shade in the dye program
Result :
• Shorter cycle time
• Lower water consumption
• Reduced effluent
RINSEtronicRINSEtronic
Old system RINSEtronic system
2 to 5% reactive dye stuff
variable
New Innovations in dyeing
• new funtions• RINSEtronic• pH-TRONIC / pH-FiT
pHpH--TRONICTRONICA system for pH controlled dyeing.
The function pH-TRONIC enables pH adjustment following the pH-gradient and at the same time setting the required machine temperature.The control system consists of a pH measuring point and a chemicals dosing unit, which incorporates a dosing valve for linkage to an existing pressure
ring main or alternatively equipped with appropriate dosing pumps.
Result :
• Higher First Time Right rate
• Easy handle of pH
• New / different dye procedure (especially in PA dyeing)
• pH measure and regulating system for pH controlled dyeing
• Stationary or mobile• Re-cooler
pHpH--TRONICTRONIC
pHpH--FiTFiTA system for pH controlled dyeing with a fully automated
cleaning and calibration of the pH-electrodes.The modern pH-FiT Fuzzy-integrated-Technology enables pH adjustment
following the pH-gradient and at the same time setting the required machine temperature.
The control system consists of a pH measuring point and a chemicals dosing unit, which incorporates a dosing valve for linkage to an existing pressure
ring main or alternatively equipped with appropriate dosing pumps.
Result :
• Higher First Time Right rate
• Easy handle of pH
• no operator needed for cleaning and calibration of the probes
• New / different dye procedure (especially in PA dyeing)
• pH measure and regulating system for pH controlled dyeing
• Fully automated calibration of the probes• Stationary or mobile• Re-coolerDeveloped by DyStar, SETEX and Thies
pHpH--FiTFiT
New Innovations in dyeing
• New funtions• RINSEtronic• pH-TRONIC / pH-FiT
• ECD - Electrochemical Dyeing of VAT
Comparison of Dyeing Processes
A) Standard Vat Dyeing Process B) Indirect Electrochemical Dyeing Process
Dyebath
dyedfibre
Dyestuff(oxidised)
Dyestuff(reduced)
e -
Reducingagent
Saltwastewater
Dyebath
Dyestuff(oxidised)
Dyestuff(reduced)
dyedfibre
Cathode
e -
Mediator (red.)
Mediator (ox.)
Fe 2+
Fe 3+
Developed by DyStar (formerly BASF)
Electrochemical Dyeing with Indanthren® DyesDyeing Curve 2 (All-in-Process)
Redox potential[mV]
Temperature[°C]
Cell current[A]
20 °C
-200 mV
60 °C
Time
Dyeing phase IDyestuff reduction
Dyeing phase IILevelling(equilibrium of exhaustion)
Fillingtheapparatus
45 A
9 A
Addition ofdyestuff
Leuco potential of the dyes
-930 mV
-920 mV
Controlrange
Developed by DyStar (formerly BASF)
Electrochemical Dyeing ProcessScheme: Package dyeing range
dye bathregenerated
dyestuff
dyeing rangeelec-trolysiscell
Electric*supply
liquorused
filtration
dyestuff waste
measurement of redox potential
Developed by DyStar (formerly BASF)
Electrochemical Dyeing Process
Consumption of Process Chemicals in an Indanthren® Exhaust Dyeing Process: IN Process, 100 kg CO, LR 10:1
EC-Reduction 0.3 - 4% Dithionite 0.3% Dithionite 2% Dithionite 4%ReductionDepth of shade Conc. Amount Conc. Amount Conc. Amount Conc. Amount
DyeingMediator 13.6 g/l 2 050 g - - - - - -
Dithionite - - 3 g/l 3 000 g 5 g/l 5 000 g 8 g/l 8 000 g
Caustic soda 32 ml 2 100 g 14 ml 6 160 g 19 ml/l 8 360 g 24 ml/l 10 560 g
Reduct. clearingDithionite - - - - 2 g/l 2 000 g 2 g/l 2 000 g
Caustic soda - - - - 2 ml/l 880 g 2 ml/l 880 g
Total amount 4 140 g 9 160 g 16 240 g 21 440 g
Saving 55 % 75 % 80 %
Water in thedyeing process 150 l 1 000 l 2 000 l 2 000 l
Only process chemicals considered;Discharge in the EC technique approx. 15% of the liquor volume.
Savings in Chemicals and Water
Developed by DyStar (formerly BASF)
Electrochemical Dyeing Process
• Product savings
• Less chemicals with special safety requirements
• Maximum process reliability through control of the redox potential
• Existing dyeing machines can be retrofitted
• Unsurpased environmental compatibility
• Reduction of water and waste-water costs through recycling
• Waste-water limits easily achieved
• Better fastness properties
Advantages
Developed by DyStar (formerly BASF)
ecoeco--bloc quattrobloc quattro
New Innovations in dyeing
• New funtions• New dyeing machines
ecoeco--bloc X bloc X „eco bloc quattro“„eco bloc quattro“
Dye up to 4 colours at a time in one machineDye up to 4 colours at a time in one machine
• Kier combinations1 + 1 + 1 + 1 = 4 colours2 + 2 = 2 colours3 + 1 = 2 colours4 = 1 colour
• 4 or 6 packages per kier• „batch reduction“
Total capacity 11 to/batch
New Innovations in dyeing
• New funtions• New dyeing machines
developed by:
&
HTHT--Jigger TiroJigger Tiro
• Woven fabric
• All exhaust dyeing processes
• Fabrics with low length wise stretch
• Very light to very heavy qualities
• Special treatments (open width scouring)
• All substrates
• Crease sensitive fabrics
• Impermeable fabrics
• Varying batch sizes
• Large fabric widths
HTHT--Jigger Tiro (Application range)Jigger Tiro (Application range)
• Fabric tension: 5 to 70 kg/cm²• Speed: 10 to 150 m/min• Fabric width, max. 3800 mm• Roller width, max. 4000 mm• Roller diameter: 270 mm• Roller batch dia.: 1000 or 1230 mm (dependent on the type of m/c)• Fabric height: 365 or 475 mm (dependent on the type of m/c)
HTHT--Jigger Tiro (Technical details)Jigger Tiro (Technical details)
Technical Advantages:• A Fabric Rope Controller automatically calculates the r.p.m. ensuring exact fabric
speed and tension providing excellent dye penetration. Automatic sampling point selection.
• Direct drive of the main rollers by frequency controlled motors with brake current return provide a considerably shorter braking distance compared with hydraulic drives.
HTHT--Jigger Tiro (Technical advantages)Jigger Tiro (Technical advantages)
• Automatic dosing of dyes and auxiliaries depending on the fabric length passing through the bath provides excellent reproducibility.
• High efficiency external pump unit and heat exchanger ensure controlled and even flow throughout the system.
• Constant dyeing conditions in the economical trough for varying batch sizes(55-100% loading capacity; water meter required).
HTHT--Jigger Tiro (Technical advantages)Jigger Tiro (Technical advantages)
• Loading/unloading device for crease-free loading/unloading of the fabric (Option)
HTHT--Jigger Tiro (Further options)Jigger Tiro (Further options)
New Innovations in dyeing
• New funtions• New dyeing machines
ecoMasterecoMaster
• Multi Contact Dyeing
• CCR CCR Combined Cooling and Rising
• 100% Stock tank
• Power drain & fill
• Automatic filter
• Water meter
• Liquor Ratio 1:5
• pH FiT
• Analogue Dosing
• Analogue levels
• Vario chamber
• RINSE RINSE tronic
ecoMasterecoMasterFeaturesFeatures
Multi Contact Dyeing & rinsingusing dual nozzles
Liquor ratio 1:4.5 - 1:5
RINSEtronic –rinsing system reduces process time and water consumption
Winch speed up to 400 m/min
Liquor ratio reduced by new sump and pump configuration
Standard step filter
ecoMasterecoMaster
eco-soft PLUS ecoMaster
Process water (25°C. 60 °C) 46 litres 34.5 litresCooling water 0,00 0,00Effluent 44 litres 32 litresSteam 2.24 kg/kg 1.92 kg/kgElectrical Power 0.1 kW 0.12 kWTime 5.8 hrs 4.83 hrs
New Innovations in dyeing
• New funtions• New dyeing machines
soft TRD DS XLsoft TRD DS XL• Especially suiteable for surface
senstive and light weight fabrics
• Double rope design
• Liquor ratio starts from 1:8
• Fabric speed up to 600 m/min
• Operating temperature up to 140°C
• 1-4 chambers per machine. Option of chamber isolation and coupling of two machines
• Chamber configurations2 x 75 kg = 150 kg/tube2 x 100 kg = 200 kg/tube2 x 125 kg = 250 kg/tube2 x 150 kg = 300 kg/tube
soft TRD DS XLsoft TRD DS XL
• new internal chamber design ⇒ lower liquor ratio
• compact machine design ⇒ minimal floor space requirement
• short fabric circulation and ‚flooded‘ fabric transport ⇒ gentle handle of fabric
New Innovations in dyeing
• New funtions
Developed by:
&
LuftLuft--roto plusroto plus
• New dyeing machines
LuftLuft--roto plusroto plus
A joint development by Thies and DyStar
• Round machine ==> reasonable liquor ratio
• Rotating fabric chamber ==> smooth fabric transport
• Air drive ==> minimised mechanical stress==> improved opening and therefore better folding of
the fabric==> gentle plaiting into the fabric chamber==> flexible application
LuftLuft--roto plusroto plus
A joint development by Thies and DyStar
• 100% Stock tank ==> faster bath changes==> possibility of preparation of the next dye bath==> low set-up times
• CCR Function ==> cooling water used as rinse water ==> very good cleaning effect==> saving of rinse baths
• Rapid drain ==> pump operation during bath change==> time savingLuftLuft--roto plusroto plus
• New dyeing processesprovide access to
• New funtions• New dyeing machines
New Innovations in dyeing
Conventional processConventional process
Te mp.-time -curve
0
10
2030
40
50
6070
80
90
100
110120
130
140
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320
time in min.
Tem
p °C
LR 1:6LR 1:6 LR 1:6
A B C
A x g/l auxiliariesx g/l salt
B x % dyestuff
C x g/l Alkali
Consumption dataConsumption data
Consumption data:Process water: 50 - 60 l/kg Cooling water: 0,0 - 0,5 l/kgSteam: 4,5 - 5,5 kg/kg Electricity: 0,08 - 0,1 kWh/kg
Te mp.-time -curve
0
10
2030
40
50
6070
80
90
100
110120
130
140
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320
time in min.
Tem
p °C
LR 1:6LR 1:6 LR 1:6
A B C
Conventional process
Enhanced dyeing processEnhanced dyeing process
Te mp.-time -curve
0102030405060708090
100110120130140
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210
time in min.
Tem
p °C
LR 1:4,5 LR 1:3,7 LR 1:4,5
A B C
A x g/l auxiliaries
B x % dyestuff1/2 amount of salt
C x g/l Soda1/2 amount of salt
Consumption data:Process water: 28 - 35 l/kg Cooling water:1,4 - 1,8 l/kgSteam: 3,3 - 4,0 kg/kg Electricity: 0,16 - 0,22 kWh/kg
Developed by &
Te mp.-time -curve
0102030405060708090
100110120130140
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210
time in min.
Tem
p °C
LR 1:4,5 LR 1:3,7 LR 1:4,5
A B C
Enhanced dyeing process Consumption dataConsumption data
- 40 % no saving- 30 % no saving
Plant AutomationPlant Automationfor for
Fully or semi automated yarn dye houses Liquid chemical dispensing & supplyDye stuff dispensing and dissolvingBulk powder dispensing & deliveryDye house Management and MonitoringHeat recoveryWater recyling
• Volumetric dosing of Liquid Chemicals
• Modular extension 10, 20 .......
• Low level inlet
• Integrated manual dispensing option
• Low maintenance
Liquid ChemicalsLiquid Chemicals
Liquid ChemicalsLiquid Chemicals
• Option of varying capacities- 20 to 80 products
• Dust Extraction system
• One or more scales
• Automatic product retrieval
• Interface to OrgaTEX
Powder DyesPowder Dyes
CAPACITIES- 100, 200, 300, 600 litres
OPTIONS :- Hot water preparation station- Water blending valve
Powder DyesPowder Dyes
Weighing & Dissolving
Weighing
TIME TEMPERATURE CURVE
0
20
40
60
80
100
120
140
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
Temp °C
Time in minutes
N S
•
737 XL Programmable Micro Processor
Controller
T 737 XLT 737 XL Programable Controller Programable Controller
OrgaTEXOrgaTEX Dye house Dye house -- Central Computer SystemCentral Computer System
Dye house Floor
Fabric / Yarn Store
Dye StoreN St
tt
N St
tt
Plant Main Frame(not part of our supply)
HUB
Dye house Office
ColourMatching
Dye StuffsPowder
Chemicals
Server
T 737
T 737
T 737
T 737
T 737T 737
LiquidChemicals
Agent for Australia
DKSH GroupMelbourne, Australia
Agent for New Zealand
Marinco, Chemcolour
Auckland, New Zealand