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1. 2. 3. 4. 5. 6. 7. 8 8. 9. General overview DyStar Product Offer Dyeing machinery and principle Pretreatment Dyeing Metering system Guideline recipes Aft t Aftertreatment t t Conversion factors for caustic soda
Page 2 June 2003
Slasher dyeing: The ends (approx. 4000) from several section-warp beams are assembled to form a warp warp, which is dyed in the open-width open width form, form sized and then wound onto beams for the loom.
Disadvantages z Possibility P ibilit of f side-to-center id t t shade h d variations in the finished fabric z Yarn wastage g from lot changes g z Short immersion times and/or a small number of dips which are particularly likely with older dyeing ranges result in a lower standard of fastness with dark shades z Relatively long stoppages during lot changes
Page 7 June 2003
The dyebath can consist of one box only or be made up of several boxes.
Squeezing 70 80% liquor pick-up contributes to rapid oxidation improves the fastness
Rinse cold
2 - 4 g/L complexing agent e.g. Trilon TA (BASF) Temperature: room temperature Immersion time: 10 15 s Replenishment: by level control
To maintain a NaOH concentration of 20 B in the causticizing box, the liquor must be replenished with NaOH of 22 B.
Regional Business Development Denim
Page 14 June 2003
g with subsequent neutralization Causticizing Causticize 1 2 x rinse hot ( (approx. pp 60 C) ) Neutralize/acidify 1 2 x rinse cold
Page 15 June 2003
5. Dyeing 5 ye g
Irregular dyeing results particularly variations within dyeing lots are a problem in denim production. As a rule, the finished denim material is classed into groups according to the dyeing results and the appearance after washdown. Maintaining the dyebath parameters constant reduces the number of these groups and also the proportion of off shades.
Lowering
pH 13.2
pH 11.5
pH 13.2
pH 11.5
6.1 Stoc 6 Stock vat at without t out c chemical e ca replenishing ep e s g add additions to s
DyStar Indigo Granules NaOH Hydrosulfite Auxilliaries
Little flexibility when there is a change in the style to be dyed Little flexibility when it is necessary to change the processing parameters instable because of d decomposition iti of f hydrosulfite h d lfit not recommended
6.2 Stoc 6 Stock vat at with t sepa separate ate c chemical e ca replenishing ep e s g add additions to s
DyStar Indigo Granules NaOH Hydrosulfite Auxilliaries NaOH Hd Hydrosulfite lfit
Most frequently used method More flexible than the stock vat method without chemical replenishments Does not allow automatic pH control limited stability of dissolved h d hydrosulfite lfit
6.3 6 3 Stoc Stock vat at with t sepa separate ate c chemical e ca add additions to sa and d metering ete g of the caustic soda
DyStar Indigo Granules NaOH Hydrosulfite Auxilliaries NaOH Hd Hydrosulfite lfit
NaOH
Particularly flexible Processing parameters can be readily changed by altering the setting of the metering pumps Allows automatic pH control Allows several dyeing ranges to be supplied from one mixing station t ti The recipes for the stock vat and chemical replenishment need not be changed limited stability of dissolved hydrosulfite
6.4 DyStar 6 ySta Indigo d go Vat at 40% 0% So Solution ut o with t separate sepa ate c chemical e ca replenishment additions
DyStar Indigo Vat 40 % Solution Storage tank NaOH Hydrosulfite
No stock vat preparation Dye metered direct from the storage tank Particularly flexible Allows automatic pH control
6.5 6 5 DyStar ySta Indigo d go Vat at 40% 0% So Solution ut o with t separate sepa ate c chemical e ca additions and metering of the caustic soda
DyStar Indigo Vat 40 % Solution Storage tank NaOH Hydrosulfite
No stock vat preparation Dye metered direct from the storage tank Does not allows automatic pH control
NaOH
4 8 g/L 1 70 65 g/L
Chemical liquors should be stored under cool conditions and protected from exposure to t air. i The Th amounts t prepared d should h ld be b such h that th t they th are consumed within 60 90 min .
The dyebath is set cold with salt, caustic soda and hydrosulfite, followed by addition of the stock vat. 12.5 mL/L of the stock vats described in 7.1 corresponds to 1 g/L DyStar Indigo Granules.
Page 31 June 2003
Stock vat at : 1 1.6 6 L/min replenishment 80 65 70 g/L Dystar Indigo Granule g/L hydrosulfite mL/L NaOH 50%
Chemical liquor : 0.7 L/min replenishment 135 g/L hydrosulfite 70 mL/L NaOH 50%
8. Aftertreatment 8 te t eat e t
2 3 x rinse hot (up to 50 C) The dyed warp yarns are rinsed at least twice with cold or, better, warm water of up p to 50 C to wash out any y unfixed dye y and chemicals. With rope-dyeing ranges, a softener should be used. The last rinsing bath to facilitate rebeaming rebeaming. Warp yarns dyed on slasher machines are given an intermediate drying to a residual moisture content of approx. 30% and are then sized.