Process

Dyeing Process for Single Jersey, 1*1 Rib, PK Fabric

During dyeing the most well-known knit fabric like Single Jersey, 1*1 Rib, PK Fabric the following dyeing process flowchart can be followed. I have tried my best to note here the contemporary dyeing process and chemicals. So that you will be able to easily manage your chemicals and other production related accessories.

>Firstly take the solution’s given below and mixed it-
Ck-1——0.3%
DMB———0.3%
FFC——–1.0%
C——–0.3%
FFC—–0.8%
Soda Ash—–2.0%
>Continue this process at 95˚C for 45 minutes. Liquor Ratio will be 1:12. Machine speed should be fixed with 180 RPM.
CK-1———-0.3%
DMB———–0.5%
C————–0.8%
Hydrogen per Oxide—-3.0%
PH-100—–0.8%
FFC———–0.1%
Caustic——-2.0%
>Again continue this process at 95˚C for 45 minutes. Liquor Ratio will be 1:12. Machine speed should be remained at 180 RPM.
>Use PS-60—–1.0% continue it at 90˚C for 10 minutes.
Croaks-N ——1.0%
Acetic Acid —-1.0%
Continue it at 70˚C for 10 minutes.
44L—1.0% (Single Jersey Fabric)
0.8% (1*1 Rib, PK Fabric)
CK-1 ——–0.1%
Acetic Acid—-0.2%
>This process should be carried out at 58˚C for 40 Minutes.
200B —-1.5%
C———-0.8%
Acetic Acid—-0.1%
>Continue this process for 10 minutes within normal temperature.
Apply Dyes now.
>Salt Dosing
>Soda dosing
>Use acetic acid—1.0%
>PS-60——-1.0% at 80˚C for 10 Minutes
>Fixing —-process continue for 20 minutes
>Apply softener
>Eventually unload the product.
>To dye the Single Jersey (S/J), 1*1 Rib, PK fabric, using above mentioned dyeing procedure will be easier. Hope this flow chart will help you lot.

Process Flow-Chart of Wet Processing Technology | Dyeing Flowchart

 The way a fabric is dyed is called process flowchart of wet processing technology. Actually some of the steps of a dyeing process can be removed or added as per buyer requirement. Suppose your buyer wants the more precised dyed fabric; so in this fact you should mercerize your fabric during the dyeing pre-treatment process.  Basically if the buyer don’t want that so called  particular fabric there is no need to mercerize your fabric.

The dyeing or wet processing flow chart is given below.

Before dyeing a fabric or yarn some pre-treatment and after treatment is needed. A flowchart is drawn here by combining these:

Grey Fabric Inspection

↓

Sewing or Stitching

↓

Singeing

↓

Desizing

↓

Scouring

↓

Bleaching

↓

Mercerizing

↓

Dyeing

↓

Printing

↓

Finishing

↓

Final Inspection

↓

Delivery

This is the most widely used wet processing flow-chart on the contemporary textile industry.  But sometimes on some factories the scouring and bleaching is done simultaneously.

 

Roles of Soap in Textile Pretreatment Process

Soap For Textile Washing:

Soap is a long chain fatty acid, which has detergency power. Soaps are made by boiling natural oils or fatty acid with aquous solution of the hydroxides of potassium or sodium. The formula of the soap is C17H35CooNa
Oils for Soap Manufacturing: Cotton Seed Oil, Tallow, Coconut oil, Olive oil, Soyabean oil, Bone fats, Palm oil.

Properties of soil that used in scouring of textile material:

1. Aquous solution of soap has an alkaline reaction.
2. Effect of no. of carbon atom;
less than 9, no detergent power
within 11 to 17, good detergent
above 17, poor solubility.
3. Reaction with hard water: C17H35CooNa + CaSo4  (C17H35Coo)2Ca + Na2So4. It causes wastage of soap.

Factors Affecting the Choice of Dyeing Methods in Textile

The following is a list of factors which dictate the choice of conditions under which particular blends might best be dyed:

1. Coloristic effect required. Check is it union, serve, tone-in-tone or what-else? Ask your buyers that what he wants from you and dye the fabric or any other textile materials as per buyer requirements.
2. Colorfastness required of the resultant dyeing. It is worth mentioning that – before starting a dying process in textile you must have to ask your buyer that, what type of colorfastness property he/she wants. Use grayscale to measure the colorfastness of the sample that you have dyed and let the buyers informed about it.
3. Suitability of the dyeing for subsequent finishing processes. Finishing is the crucial point to consider. Every dyeing process might have different finishing process. Check what kind of finish you can serve.
4. Compatibility of dyes from different application categories with one another. Blended fiber or Blend textile requires particular and fiber specific dyes to be properly dyed. It is seen that; if you use usual dyestuff to make a blended fiber or blended fabic dyed, then some parts of that fabric has been dyed and some other parts haven’t been dyed.
5. Availability of particular types of batch, semi-continuous and continuous dyeing equipment. If you don’t have the required instruments, materials, dyes and batches; how would you dye? So, check and dye the fabric or fiber if all of the required instruments and materials are available.
6. Cost of the dyes and chemicals involved. It does totally depend on the buyers and on the services you give. If your buyers want a blended dyeing with good color fastness and good conditioned; then you might have to rush to buy good chemical and good dyes. And most importantly; good services mean producing good product by using good materials. So it varies the cost.
7. Economics of the overall process. The last thing one must have to consider; which is Money. How about your budget? How much money do you want to spend to dye these fabrics or fibers?

Some or all of these points should be involved in any decision to proceed with a particular method of dyeing a given blend.

Physico-Chemical Aspects of the Dyeing Process :

 

 

Now here is the physic-chemical of dyeing process number-wise:-

Physico-chemical aspects of Dyeing is a process which shows us how a dye penetrates into the fiber and how many process and time a dye molecules follow to enter completely onto the fiber. Before going to dyeing process we just need to know some basics of Fiber surface on which the dye molecules work.
A textile fiber has three phase; these are- Fiber surface, Diffusion Layer and Electrical Double Layer. Dyes firstly come to in surface then go to diffusion layer; and at the last step it concentrate onto the fiber.
1. Dye In Solution —- Here convective diffusion is happened.
2. Dye In Diffusion Layer —– Here Molecular Diffusion is happened.
3. Dye in the Electrical Double Layer —- Here adsorption is occurred.
4. Dye at the Fiber Surface —-here Dye Diffused into the   Fiber.
5. Dye in the Fiber —– Here fixing is done and dye physically or chemically bound with the fiber polymer. Chemical bond only happens in Reactive Dyeing and on other dyes; the physical bonding is required.