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Contents
Introduction 5
The basic principle of the Econtrol process 6
Dyes, auxiliaries and alkali systems for Econtrol and Econtrol knit 7
® ®
Guide process recommendations for Levafix and Remazol 8
Econtrol laboratory dyeing process 9
®
Controlled Coloration with Levafix dyes 10
Triangle Levafix Amber CA / FastRed CA / Olive CA 100 11
Triangle Levafix Yellow CA / FastRed CA / Blue CA 12
Triangle Remazol UltraYellow RGB / UltraRed RGB / Navy RGB 13
Build up Remazol RGB 14
Trichromat recommendations 15
Pale shades with good light fastness 15
Medium to dark shades 15
Brilliant orange, scarlet and bright pink shades 15
Brilliant blue, green and turquoise shades 15
Recommended dyes for Econtrol 16
Dyeing of PES/CO blends 18
Page 3
Page 4
Introduction
With the tendency to shorter lot sizes per shade in continuous dyeing and the requirement for
simple processes, the Econtrol process for reactive dyes was developed in the mid nineties. It has
now been established with DyStar technology worldwide.
The Econtrol process is a simple, rapid and an economical one pass, pad - dry - wash-off continuous
dyeing process with drying in a hotflue at 120 - 130 °C and controlled humidity
(25 - 30% volume) to obtain fixation in 2 - 3 minutes.
Using a Monforts Thermex® machine it is possible to dye stretch fabrics and also knit goods.
Econtrol® is a registered trademark of DyStar.
Benefits
• Ideal option for short or long lot dyeing
• Full shade range
• Excellent reproducibility of shade
• No yellowing due to low temperatures – bright shades possible
• No machine contamination caused by urea fumes due to mild Econtrol conditions
• No salt (easy wash-off of unfixed dye)
• Instant shade viewing
• Accurate, easy and rapid laboratory check method
• No unproductive batching sequences, no moiré effects
• Migration minimised by rapid fixation and humidity control
• No crushing of pile fabrics (e. g. corduroy)
• Improved penetration of difficult fabrics due to presence of humidity at high cloth
temperature
• Energy efficient by optimum humidity control
• Ideal process for rapid change technology
• Suitable for knitwear and highly elastic fabric
Page 5
The basic principle of the Econtrol process
The Econtrol process comprises just three steps:
Application of the dye → drying →washing-off
Monforts Thermex® Hotflue
drying washing
padding
steam injection
steam injection
In normal drying processes the temperature on the goods can drop to 50 - 55 °C.
The exact temperature depends on the humidity of the air and the surrounding temperature used to
dry the goods. This effect is called "wet bulb temperature".
In Econtrol steam is injected into the air flow. The humidity rises up to 25 - 30%. The resulting
temperature on the surface of the goods is 68 - 71 °C.
The Econtrol process uses this physical fact to fix the reactive dye during drying. Three key variables
- time, temperature and humidity - are used to ensure accurate control of the dyeing process in the
Thermex hotflue. The graphic below shows a typical drying curve and the resultant temperature of
the goods throughout the Econtrol dyeing process.
The goods should spend about 2 - 3 minutes in the hotflue. However, it should be noted that these
are average values: the actual drying time depends principally on the material to be dried.
Page 6
Dyes, auxiliaries and alkali systems for Econtrol and Econtrol knit
Recommended dyes
Evidently, the dyes used in the Econtrol process have to be suitable for the process conditions. Since
dyeing is completed in approx. 2 - 3 min, reactive dyes with high to medium reactivity are
particularly suitable. All Levafix® and most Remazol® dyes can be used.
In practice, Levafix dyes are used for pale to medium shades, while Remazol dyes are used for
medium to very deep shades.
Dyes with MCT anchors such as Procion® H-EXL and Procion PX are not recommended for the
Econtrol process.
Alkali and auxiliaries
Soda ash or soda ash/NaOH is normally used as the alkali system. To ensure optimum reliability, it
is essential to dose the alkali and dye solutions separately.
The following auxiliaries are recommended for continuous dyeing processes:
Sera™ Wet C-AS
Low foaming rapid wetting and deaerating agent
Sera Sperse C-SN
Efficient complexing agent and protective colloid for dyeing cotton and blends
Sera Quest C-PX
Removal of hardness formers in dyebaths for dyeing cellulosic and synthetic fibres
Sera Con M-LU
Mild oxidizing agent for dyeing with reactive and vat dyes
Sera Gal M-IP
Reduces dye migration in the pad dyeing of cellulosic fibres and their blends
Sera Gal C-PS
Antifrosting agent for Econtrol dyeing of Tencel, Viscose and raised Cotton
In Econtrol usually a wetting agent Sera Wet C-AS and a migration inhibitor Sera Gal M-IP is
recommended to use. A sequestering agent Sera Quest C-PX is helpful in case of water hardness. A
mild oxidant Sera Con M-LU can be added to prevent reduction of the reactive dyes.
Urea is not essential for the Econtrol process but up to 50 g/l may be advantageous in some
circumstances.
Guide recipe
Levafix or Remazol dye x g/l
Sera Wet C-AS 2-4 g/l (wetting agent)
Sera Gal M-IP 5-10 g/l (antimigrant)
Sera Com M-LU 0-5 g/l (mild oxidant)
Soda ash 20 g/l
Caustic soda see tables on page 8
Page 7
® ®
Guide process recommendations for Levafix and Remazol
The optimal choice of dyes, auxiliaries and alkali
1. Levafix dyes:
Levafix dye x g/l
Sera Wet C-AS 2-4 g/l (wetting agent)
Sera Gal M-IP 5-10 g/l (antimigrant)
Sera Com M-LU 0-5 g/l (mild oxidant)
Urea 0-50 g/l
Soda ash 20 g/l
Caustic soda see tables below
Amount of dye Up to 10 g/l >10-30 g/l > 30 g/l
Soda ash 20 g/l 20 g/l 20 g/l
NaOH 50% - 2 ml/l 4 ml/l
Econtrol settings:
Temperature: 110 - 130 °C
Humidity: 25-30% (vol)
Time: 2-3 minutes
2. Remazol dyes:
Remazol dye x g/l
Sera Wet C-AS 2-4 g/l (wetting agent)
Sera Gal M-IP 5-10 g/l (antimigrant)
Sera Com M-LU 0-5 g/l (mild oxidant)
Urea 0-50 g/l
Soda ash 20 g/l
Caustic soda see tables below
Amount of dye Up to 20 g/l > 20-40 g/l > 40-60 g/l > 60-80 g/l > 80-100 g/l > 100 g/l
Soda ash 20 g/l 20 g/l 20 g/l 20 g/l 20 g/l 20 g/l
NaOH 50% 3,5 ml/l 6 ml/l 8 ml/l 10 ml/l 12 ml/l 14 ml/l
Econtrol settings:
Temperature: 110-130 °C
Humidity: 30% (vol)
Time: 2-4 minutes
Important: The Material should come out of the machine completely dryed.
Page 8
Econtrol laboratory dyeing process
As with all dyeing processes a good laboratory dyeing method is essential for shade matching and
bulk checking of pad liquors.
In collaboration with Mathis, DyStar has therefore developed a method that allows accurate
reproduction of the Econtrol dyeing conditions in the lab. This comprises a Type DH lab steamer
especially adapted for the Econtrol process. This allows regulation of all process parameters that
influence the drying and dyeing results on the Monforts Thermex Hotflue
Î Temperature
Î Steam content Air Temp.:
Î Air flow
Î Time
121 °C
120 °C
Abs. Steam:
Econtrol® 27 %
25 %
Fan Speed:
802rpm
800rpm
DwellTime:
2:30
2min 30sec
As an alternative to this laboratory steamer, all lab processes commonly used for cold pad-batch
process can be used. However, the performance is in no way comparable and these processes greatly
increase the overall time required for the process.
Page 9
®
Controlled Coloration with Levafix dyes
Levafix dyes are particularly suitable for the Econtrol process. This dye range provides:
• High fixation
• Excellent robustness to dyeing variables
• Non phototropic recipes
• Color Confidence® due to premium fastness properties excepted by all major retailers
Controlled Coloration with Levafix CA
Safe production and reproducible results is the effect of Controlled Coloration with Levafix CA
dyes even under varying production conditions.
The example below shows the excellent behaviour of a Levafix CA combination under different
temperature and alkali conditions.
Standard: 120 °C, 25% humidity, 20 g/l soda ash, 2 ml/l NaOH 50%
1,5
110 °C 130 °C
1,0
z outside tolerance limits
greener
z critical
0,5 z excellent reproducibility
delta H
0,0
-1,5 -1,0 -0,5 0,0 0,5 1,0 1,5
redder
-0,5
-1,0
The Levafix alkali recommendation ensures full fixation and excellent stability. The graph below
displays the stability of a khaki shade over 4 h at 25 °C.
Pad liquor stability with soda ash / NaOH
% yield
Levafix Yellow CA / FastRed CA / Blue CA
120
100
80
60
40
20
0
5 min 10 min 15 min 20 min 30 min 1 h 2 h 4 h
Page 10
Triangle Levafix Amber CA / FastRed CA / Olive CA 100
This combination shows an excellent behaviour e. g. in terms of tailing even on very critical material
like corduroy and emerized material.
Recommended particularly for very critical beige and olive shades.
Superb fastness properties and safety in production concerning reproducibility and tailing
behaviour.
• No photochromism
• Superior reproducibility
• Low tailing tendency
• Excellent fastness properties
Levafix Amber CA
6.0 g/l
4.8 g/l 1.2 g/l 4.8 g/l 1.2 g/l
3.6 g/l 2.4 g/l 3.6 g/l 1.2 g/l 1.2 g/l 3.6 g/l 2.4 g/l
2.4 g/l 3.6 g/l 2.4 g/l 2.4 g/l 1.2 g/l 2.4 g/l 1.2 g/l 2.4 g/l 2.4 g/l 3.6 g/l
1.2 g/l 4.8 g/l 1.2 g/l 3.6 g/l 1.2 g/l 1.2 g/l 2.4 g/l 2.4 g/l 1.2 g/l 1.2 g/l 3.6 g/l 1.2 g/l 4.8 g/l
6.0 g/l 4.8 g/l 1.2 g/l 3.6 g/l 2.4 g/l 2.4 g/l 3.6 g/l 1.2 g/l 4.8 g/l 6.0 g/l
Levafix FastRed CA Levafix Olive CA 100
Page 11
Triangle Levafix Yellow CA / FastRed CA / Blue CA
Standard trichromat
Excellent fastness properties including light fastness, very good dyeing properties with unbeatable
stability against production variables.
• Excellent reproducibility
• Premium fastness properties
• Stable to dyeing variables
Levafix Yellow CA
10 g/l
8 g/l 2 g/l 8 g/l 2 g/l
6 g/l 4 g/l 6 g/l 2 g/l 2 g/l 6 g/l 4 g/l
4 g/l 6 g/l 4 g/l 4 g/l 2 g/l 4 g/l 2 g/l 4 g/l 4 g/l 6 g/l
2 g/l 8 g/l 2 g/l 6 g/l 2 g/l 2 g/l 4 g/l 4 g/l 2 g/l 2 g/l 6 g/l 2 g/l 8 g/l
10 g/l 8 g/l 2 g/l 6 g/l 4 g/l 4 g/l 6 g/l 2 g/l 8 g/l 10 g/l
Levafix FastRed CA Levafix Blue CA
Page 12
Triangle Remazol UltraYellow RGB / UltraRed RGB / Navy RGB
Remazol RGB dyes are particularly suitable in Econtrol for economic medium and heavy shades
• Excellent build up
• No photochromism
• Good fastness properties
• Unbeatable price / performance relationship
Remazol UltraYellow RGB
30 g/l
24 g/l 6 g/l 24 g/l 6 g/l
18 g/l 12 g/l 18 g/l 6 g/l 6 g/l 18 g/l 12 g/l
12 g/l 18 g/l 12 g/l 12 g/l 6 g/l 12 g/l 6 g/l 12 g/l 12 g/l 18 g/l
6 g/l 24 g/l 6 g/l 18 g/l 6 g/l 6 g/l 12 g/l 12 g/l 6 g/l 6 g/l 18 g/l 6 g/l 24 g/l
30 g/l 24 g/l 6 g/l 18 g/l 12 g/l 12 g/l 18 g/l 6 g/l 24 g/l 30 g/l
Page 13
Build up Remazol RGB
Remazol RGB dyes build up to extreme deep shades. High degrees of fixation ensure good wash off
and sufficient fastness properties.
Remazol
UltraYellow RGB
5 g/l 10 g/l 20 g/l 40 g/l 60 g/l 80 g/l
Remazol
UltraRed RGB
5 g/l 10 g/l 20 g/l 40 g/l 60 g/l 80 g/l
Remazol
Navy RGB
5 g/l 10 g/l 20 g/l 40 g/l 60 g/l 80 g/l
Page 14
Trichromat recommendations
Pale shades with good light fastness
Levafix Amber CA* Levafix Amber CA* Levafix Yellow E-3RL*
Levafix FastRed CA or Levafix FastRed CA or Levafix Brown E-2R
Levafix Rubine CA Levafix Scarlet CA* Levafix Brilliant Blue E-B
Levafix Blue CA Levafix Olive CA 100
• No photochromism • Recommended particularly for very • The classical pale shade trichromat
• Superior reproducibility
critical beige and olive shades
• No photochromism
• Low tailing tendency
• Superb fastness properties and safety
• Low Tailing
in production concerning
• Excellent fastness properties reproducibility and tailing behaviour • Very good fastness properties incl.
even on critical material chlorine fastness
Medium to dark shades
Levafix Yellow CA or Levafix Yellow CA or Remazol UltraYellow RGB*
Levafix Amber CA* Levafix Amber CA* Remazol Orange RGB
Levafix Red CA or Levafix Red CA Remazol UltraRed RGB
Levafix Rubine CA Levafix Navy CA Remazol Blue RGB
Levafix Blue CA Remazol Navy RGB
• Standard trichromat • Recommended trichromat, if • Economically very attractive dyes
• Excellent fastness properties and
lightfastness is not an issue
• Good dyeing behaviour and fastness
appropriate light fastness by using Red • Levafix Navy CA is a real CA-Navy, properties
CA, very good dyeing properties with
unbeatable stability against
not a Black 5 based dye, therefore it fits
perfectly in the Levafix CA range
• Remazol RGB dyes incl. Navy RGB
will pass the most fastness
production variables
• It shows the same excellent robustness requirements.
• Levafix Rubine CA provides excellent to dyeing variables
light fastness and very good build up
properties
Brilliant orange, scarlet and bright pink shades
Levafix Yellow CA Remazol Yellow GR* Levafix Brilliant Red E-6BA
Levafix Orange CA* Remazol UltraYellow RGB* Levafix Brilliant Blue E-FFN 150%
Levafix Scarlet CA* Remazol Orange RGB Levafix Royal Blue E-FR
Levafix Red CA Remazol Red RGB
• Very brilliant scarlet, orange and red • Economical alternative trichromat for • This combination is suitable to dye
shades can be achieved brilliant scarlet and orange shades with extreme bright pink shades, which
• Fastness properties and dyeing
"fit for purpose" properties cannot be achieved with any other
reactive dyes
behaviour are on "CA-level"
Brilliant blue, green and turquoise shades
Levafix Brilliant Yellow CA* Levafix Brilliant Red E-6BA Remazol Brilliant Blue RN
Remazol Luminous Yellow FL** Levafix Brilliant Blue E-FFN 150%
Remazol Turquoise Blue G 133% Levafix Royal Blue E-FR
Remazol Brilliant Green 6B 175%
Remazol Brilliant Blue BB 133%
• The ideal combination of dyes for • Levafix Brilliant Blue E-FFN 150% is • Very economical bright blue
brilliant green and turquoise shades:
- high light fastness
the most brilliant reactive blue
available. Particularly suitable for pale
• Superior behaviour in padding
processes compared to other
- no catalytic effects to medium shades
"Blue 19" – type dyes
- less dichroism in green shades
by using Remazol Brilliant
• Levafix Royal Blue E-FR with Levafix
• No precipitations in
Brilliant Red E-6BA as shading
Green 6B 175% padding processes
component are recommended also for
medium and deep bright blue shades
* Non phototropic
** Remazol Luminous Yellow FL is the only available reactive dye with luminous properties that
allow to produce workwear according to EN 471.
Page 15
Recommended dyes for Econtrol
Levafix CA dyes Granulate Powder
Levafix Brilliant Yellow CA x
Levafix Yellow CA x
Levafix Amber CA x
Levafix Orange CA x
Levafix Scarlet CA x
Levafix Red CA x
Levafix FastRed CA x
Levafix Rubine CA x
Levafix Olive CA 100 x
Levafix Blue CA x
Levafix Navy CA x
Levafix dyes Granulate Powder
Levafix Golden Yellow E-G 150%
Levafix Yellow E-3RL x
Levafix Orange E-3GA x
Levafix Scarlet E-2GA x
Levafix Brilliant Red E-BA x
Levafix Brilliant Red E-4BA x
Levafix Brilliant Red E-6BA x
Levafix Brilliant Red E-RN x
Levafix Brown E-RN x
Levafix Brown E-2R x
Levafix Brilliant Blue E-FFN 150%
Levafix Brilliant Blue E-BRA x
Levafix Brilliant Blue E-B x
Levafix Royal Blue E-FR x
Levafix Blue E-GRN x
Levafix Navy Blue E-BNA x
Page 16
Recommended Dyes for Econtrol
Remazol RGB dyes Granulate Powder
Remazol Golden Yellow RGB x
Remazol UltraYellow RGB x
Remazol Orange RGB x
Remazol Red RGB x
Remazol UltraRed RGB x
Remazol Blue RGB x
Remazol Navy RGB 150%
Remazol dyes Granulate Powder
Remazol Luminuous Yellow FL x
Remazol Yellow GR** 133%
Remazol Yellow 3RS 133%
Remazol Yellow RR x
Remazol Golden Yellow RGB** x
Remazol Golden Yellow RNL** 150%
Remazol Brilliant Orange 3R special** x
Remazol Orange BN** x
Remazol Brilliant Red BB** 150%
Remazol Brilliant Red 3 BS x
Remazol Red RGB x
Remazol Red RR x
Remazol Red RB 133%
Remazol Brilliant Blue BB** 133%
Remazol Brilliant Blue RN x
Remazol Blue RR** x
Remazol Blue RGB** x
Remazol Dark Blue SLT x
Remazol Navy RGB** 150%
Remazol Turquoise G 133%
Remazol Brilliant Green 6B 175%
Remazol Black B** 133%
Remazol Black GS-A** x
Remazol Black NF** x
Remazol Deep Black N 150** x
** Dischargeable Remazol dyes
Page 17
Dyeing of PES/CO blends
For dyeing PES/CO blends a two-stage-process is required. In any case a thermosol step has to take
place to fix the Dianix dyes on PES.
The following methods are suitable to dye PES/CO blends using the Econtrol equipment:
1. The TTN Econtrol process (1 bath - 2 step)
Shade area Process
Recommended for pale to medium shades Dye application - Econtrol drying - Thermosol
step at 210 °C - wash off
Recipe
Dianix dye x g/l
Levafix dye y g/l
Alkali and fixation assistant
Sera Gal M-IP 10-20 g/l Levafix dye < 5 g/l 5-20 g/l > 20 g/l
Sera Wet C-AS 2-4 g/l
Dicyaniamide 15 g/l dicyandiamide 15 g/l 15 g/l 15 g/l
sodium bicarbonate 2-10 g/l
Borax 10 g/l sodium bicarbonate 2 g/l 2-5 g/l 10 g/l
Recommended Dyes:
All Dianix dyes, which are recommended for thermosol, and all Levafix dyes are suitable for the
TTN-Econtrol process. When using the following Levafix dyes, it is not necessary to add sodium
bicarbonate when dyeing pale to medium shades.
Levafix Orange E-3GA Levafix Brilliant Red E- 6BA
Levafix Scarlet E-2GA Levafix Brilliant Blue E-BRA
Levafix Brilliant Red E-BA Levafix Brown E-RN
Levafix Brilliant Red E-4BA Levafix Navy E-BNA
This is an advantage because sodium bicarbonate causes slight yellowing of cellulosic fibres at high
fixation temperatures. An additional advantage is increased reproducibility because of the low pH
value even with those Dianix dyes, which are sensitive to high pH.
Page 18
2. Thermosol/Econtrol (2-bath-2-step) without intermediate reduction clearing
Shade area Process
Recommended for pale to heavy shades, Dianix dye pad - Thermosol step at
Dianix XF/SF dyes are particularly suitable 210 °C - 220 °C - Reactive dye pad -
for this process. Dianix XF/SF dyes can be Econtrol drying - wash off
cleared within the Econtrol process step.
Recommended dyes:
All Dianix dyes, which are recommended for thermosol, and all Levafix and Remazol dyes
recommended for Econtrol can be used.
Dianix XF/SF dyes are particularly suitable because these dyes do not need to be reductive cleared.
Alkaline clearing during the Econtrol step provides highest fastness performance.
Dianix dye selection:
Page 19
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