Yaa Dyeing Cotton Wool Knit Goods Without Bleaching (Part-2)

Scope of Dyeing Cotton Knit Goods without Bleaching Operation for Energy Saving together with Cost Reduction (Part-2)

Md. Palash Hossain
Department of Textile Engineering
Dhaka University of Engineering & Technology (DUET)
Email: palashsakal@yahoo.com

Previous Part


2.2 Methods:
Method followed: Exhaust Method

2.2.1 PROCESSES FOLLOWED IN LABORATORY TRIAL:

A. Pretreatment:

Table 6: Recipe for pretreatment

With Bleaching			Without Bleaching
Name of chemicals	Quantity (g/l)		Name of chemicals	Quantity (g/l)
Wetting agent	1.5		Wetting agent	1.5
Sequestering agent	1.5		Sequestering agent	1.5
Caustic soda                                (NaOH)	5		Caustic  soda                               (NaOH)	5
Hydrogen peroxide(H2O2)	5		-	-
Stabilizer	1.5		-	-
Peroxide killer	0.05		-	-
M:L	1:10		M:L	1:10
Temperature	100oc		Temperature	100oc

Sequence followed inwards scouring & bleaching:

Figure-1: Scouring together with bleaching physical care for system inwards IR lab dyeing machine

Sequence followed inwards scouring without bleaching:

Figure-2: Scouring without bleaching physical care for system inwards IR lab dyeing machine

Working procedure:
All the chemicals were taken according to recipe. 10% stock solution of caustic soda was prepared. Then the samples were given inwards scouring bath. The plan was laid for xl min at 1050c. After unloading of the samples normal launder were done for v minutes. Then peroxide killer was used inwards conventional means for removing H2O2 from the stuff at 800c for 15-20 min. After that acid launder was done for the both samples for 10 min. Then hot launder was performed alongside detergent for 10 min at 800c. Finally mutual frigidness launder was done.

Figure-3: Infra Red lab dyeing machine

A. Dyeing:
Table 7: Recipe for lab dyeing (0.5% shade)

With peroxide treated fabric			Without peroxide treated fabric
Name of chemicals	Amount(g/l)		Name of chemicals	Amount(g/l)
Leveling agent	1.5		Leveling agent	1.5
Wetting agent	1.5		Wetting agent	1.5
G. Salt	25		G. Salt	25
Soda ash	8		Soda ash	8
Detergent	1		Detergent	1

Working procedure:

Stock solution preparation: During the lab dip, fiddling sum of dyes together with other chemicals were required. 1 gm of dye has been taken inwards 100 ml of warm H2O together with was made every bit 1% stock solution of dye. Similarly 20% of Na2CO3 (Sodium carbonate) together with 20% of Gluber common salt solution get got been prepared. The formulae below was exercised to larn the accurate sum of dyes together with chemicals

Sample preparation: The pretreated stuff had been cutting together with made sample of v gm yesteryear electronic balance. The sample size was required every bit rectangular to assess rubbing fastness test. Then all the samples ware soaked inwards distilled H2O for few minutes together with squeezed good which together with thence got ready for dyeing. 

Dyeing : All the auxiliaries, common salt together with dyes were placed inwards dye lavatory from stock solution together with H2O was taken to keep 1:10 liquor ratio. Then stuff was added inwards dye lavatory at room temperature together with run for v minute. Temperature was gradually increased (2o/min) upward to 60oC. At this temperature the organisation was run for xv min together with soda dosing was performed for 45 min. After Completing dyeing the dye liquor was drained out. 

After treatment: Normal launder was done. Then hot launder was performed at 80oC alongside detergent for 10 min. Finally mutual frigidness launder has been done for v min followed yesteryear drying at 100oc for twenty min.


Sequence followed inwards laboratory dyeing:

Figure- 4: Dyeing physical care for system inwards IR lab dyeing machine

2.2.2 PROCESS FOLLOWED IN BULK TRIAL:

Specification of used machineries:

• Machine name-MCS
• Origin-Italy
• Machine capacity-1500 kg
• Maximum capacity for unmarried jersey-1000 kg
• Maximum Temperature 13000c
• Maximum H2O capacity-11200 liter
• No. of nozzle-06

A. Pretreatment:
Recipe for K kg knitted (S/J) Fabric:
Table 8: Recipe of pretreatment physical care for for mass production
 
Working procedure:

Conventional process				Proposed process
Steps	Tem	Time		Steps	Tem	Time
Fabric loading		20 min		Fabric loading		20 min
Addition(detergent + seq. agent + anti creasing + stabilizer)	500c	5min		Add (detergent + seq. agent )	500c	3 min
Caustic dosing	500c	5 min		Caustic dosing	500c	5 min
Rising temperature together with improver H2O2	700c	10 min		Rising temperature	800c	15 min
Rising temperature	980c	15 min		Run time		30 min
Run time		60 min		Drain out + fill		5 min
Cooling	800c	10 min		Hot wash	800c	10 min
Drain out + fill		5min		Drain out + fill		5 min
Hot wash	800c	10 min		Neutralization	600c	15 min
Drain out + fill		5 min		Enzymes wash	550c	60 min
Peroxide killer	900c	10 min		Drain out + fill		5 min
Drain out + fill		5 min		Washing		10 min
Neutralization	600c	15 min		Drain out + fill		5 min
Enzymes wash	550c	60 min
Drain out + fill		5 min
Washing		10 min
Drain out + fill		5 min
Total time	255 min			Total time	188 min

 

 

A.Dyeing:
Recipe:
Table 9: Recipe for dyeing together with afterward treatment

Conventional process				Proposed process
Name of dyes & chemicals	Brand name	g/l		Name of dyes & chemicals	Brand name	g/l
Leveling agent	Dekoven-LVR	1		Leveling agent	Dekoven-LVR	0.5
Anticr . agent	Rucolin-JES	1		Anticr . agent	Rucolin-JES	2
A.acid	Ruco Acid	1		A.acid	Ruco Acid	1
G.salt		30		A.acid	Ruco Acid	0.75
Yellow	Polafix Yellow 3RS	1.0%		Yellow	Polafix Yellow 3RS	1.0%
Red	Polafix Red 3BS	0.3%		Red	Polafix Red 3BS	0.3%
Black	Polafix Black B	0.7%		Black	Polafix Black B	0.72%
Soda		12		Soda		12
Soaping  agent	Albatex-AD	0.5		Soaping  agent	Albatex-AD	0.5
Fixing agent	Neofix-R250	0.5		Fixing agent	Neofix-R250	0.5
Softener	Sapamine-CWS	1		Softener	Sapamine-CWS	1

Working procedure:
Sequence followed inwards dying:

Conventional Process				Proposed process
Steps	Tem	Time (min)		Steps	Tem	Time            (min)
Add leveling	500c			Add leveling	500c
Salt dosing	500c	10		Salt dosing	500c	10
Color dosing	500c	15		Color dosing	500c	15
Run time		10		Run time		10
Soda ash dosing	500c	20		Soda ash dosing	500c	20
Fixation	600c	60		Fixation	600c	60
Drain out + fill		5		Drain out + fill		5
Total time	120 min			Total time	120 min

Sequence followed inwards afterward treatment:

Conventional process				Proposed process
Steps	Tem	Time		Steps	Tem	Time
Normal wash		10		Normal wash		10
Drain out + fill		5		Drain out + fill		5
Hot wash(soaping)	800c	10		Hot wash(soaping)	800c	10
Drain out + fill		5		Drain out + fill		5
Normal wash		10		Normal wash		10
Drain out + fill		5		Drain out + fill		5
Neutralization		10		Neutralization		10
Drain out + fill		5		Drain out + fill		5
Fixing		10		Fixing		10
Drain out + fill		5		Drain out + fill		5
Softening		10		Softening		10
Drain out + fill		5		Drain out + fill		5
Unload		20		Unload		20
Total time	110			Total time	110

2.2.3 PROCESS FOLLOWED IN TESTING

A. Color fastness to launder
Method followed: ISO 105 C03

B. Color fastness to rubbing /crocking
Method followed: EN ISO 105×12

C. Color fastness to perspiration:
Method followed : ISO105E02 

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