DYEING - APETT

Transcription

DYEING - APETT

CHT GROUP
Zona Ind.Maia I,
Sector VII , Rua A
4470 MOREIRA MAI
TEL: 229 478 250
FAX: 229 440 252
E-MAIL: [email protected]
www.cht-group.com
Powerful solutions
to save
water, energy and time...
Susanne Ehret
Pretreatment –
DYEING
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1
Powerful solutions to save
water, energy, and time...

Current cost factors in textile production (using the
example of cotton dyeing)

Possible cost savings for an environmental
sustainability

Chemicals give textiles the colour and performance
that consumers demand

The concerns are:
Optimize resources: water, energy, chemical, time.

On the basis of examples traditional/standard
technology versus best available technology for dyeing
processes is shown
Table of contents
Pretreatment –
DYEING
2
Which current cost factors do we have
in textile finishing ?
Cost factors



Raw material



Textile finishing processing costs
Machine costs
We, as chemical auxiliary supplier,
have no influence on these costs.
Labour costs
Water costs
Energy costs (electricity, gas, oil)
Pretreatment –
DYEING
A positive impact
can be reached.
3
Cost reduction by process optimization

Cost savings
We, as chemical auxiliary supplier, have the following
possibilities to reduce costs:
Product optimization

Production of highly concentrated products which
allows for reduction of
manufacturing, packaging and transportation costs
Process optimization

Pretreatment –
DYEING
Development of new chemicals to optimize process
parameters and reduce the number of treatment baths
- Reduce the water consumption in textile processes
- Reduce energy costs and save time
- Minimize costs.
4
A careful handling of water is more
important than ever before
What is a water footprint ?
• People use lots of water for drinking, cooking and washing,
but even more for producing things such as food, paper,
cotton clothes, etc.
• The water footprint is an indicator of water use that looks
at both direct and indirect water use of a consumer or
producer.
• The virtual water is defined as the volume of water
required to produce a commodity or service.
(Source: World Wide Fund For Nature June 2008)
Our target:
More efficient processing &
Right- first- time dyeing
to save water, time, energy and chemicals
Pretreatment –
DYEING
5
Development trends in cotton dyeing
General
 More efficient dyeing processes,
washing off and aftertreatment
 Cellulosic fibres:
SARABID MIP
COTOBLANC SEL 200
REWIN SRF/SRF-O
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DYEING
6
More efficient dyeing processes:
Multi-functional product for CEL
processes
SARABID MIP
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DYEING
7
Multifunctional product SARABID MIP
"Multum In Parvo"
"FOCUS"
CEL
Much in little !
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DYEING
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Multifunctional dyeing auxiliary
washing
agent/
emulsifyer
enzyme
1
+
2
anticrease
+
3
sequestrant
+
SARABID MIP is an anionic dyeing
auxiliary, a blend of numerous individual
components with parts of very stable
enzymes (pectinase). Due to its versatile
efficiency it can be applied in several
processes.
4
4 individual products are necessary to replace
SARABID MIP
enzyme
washing agent
anticrease
sequestrant
Pretreatment –
DYEING
9
Mode of action of SARABID MIP
SARABID MIP
a product with
washing effect
Rapid - specific - successful.
An environmentally friendly and economic way to
pretreat and dye in one bath with one product.




The product can be used for the cleaning of cellulose
fibres and their blends in one bath.
In the SARABID MIP one-bath procedure,
washing, dyeing and softening of cotton or cotton
blends can be carried out at the same time.
It is not an incompatible partner for the dyes as it is
often the case with nonionic detergents.
It prevents precipitations (particularly in case of
turquoise and blue dye types).
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DYEING
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Process safety and quality of dyeings
with SARABID MIP
Increased
industrial safety
and
reproducibility
Increased industrial safety and reproducibility
 As multifunctional product in the dyeing bath SARABID
MIP enables a higher reproducibility and industrial
safety with all dye classes for cellulose.
 In practice and judged during a longer period there are
less faulty dye lots.
Demands on the fabric quality
 will provide level and clear dyeings thanks to its good
wetting and levelling performance
 gives a soft and pleasant handle to the goods
 Better dimensional stability on piece fabric
 Less hairiness by shorter running times and prevention
of friction
 Fastnesses corresponding to dyes.
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DYEING
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Benefit of SARABID MIP
Benefit









No additional pretreatment, therefore
no additional rinsing and neutralisation before dyeing
No additional heating
No disturbing decomposition products on the fabric, in
the dye bath and in the waste water
Minimum water consumption
Less waste water
Easy and smooth dyeing on medium and dark shades,
high levelness and better reproducibility
Highly efficient on medium – dark shades, therefore
mainly recommended for the discontinuous dyeing of
greige cotton fabrics and their blends
Pretreatment –
DYEING
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SARABID MIP in greige CEL dyeing

A consistent cotton quality is the basis for dyeing greige
cotton with SARABID MIP!
The procedure is not recommended for fabrics:
 Containing elastane
 Polluted with high amounts of oils
 Contaminated with higher amounts of seed husks in
medium shades
 High twisted yarn
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DYEING
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Use of SARABID MIP
Yarn or piece
Special remarks
CEL
Vat or sulphur
Dyes not sensitive to
hardness

Not necessary
-
CEL
Vat or sulphur
Dyes slightly
sensitive to hardness
(especially vat blues)
-
Recommended
Further to the existing
dyeing auxiliaries
-
CEL
Vat or sulphur
High dyestuff amount
& high hardness
level
-
Recommended
dyeing auxiliaries
Demineralisation first
then SARABID MIP
dyeing
-
Recommended
dyeing auxiliaries
-

Not necessary
-
CEL
Reactive or direct
PES/CEL
Disperse/reactive
or disperse/direct
Depending to the
amount of CEL part
SARABID
MIP process
without any
pretreatment
Pretreatment –
DYEING
Pretreat with
SARABID MIP
drop and refill for
dyeing with
SARABID MIP
Further additional
pretreatment
14
Greige dyeing of cellulose fibres
and their blends
Example for
greige dyeing
with vat dyestuffs
SARABID MIP is added to
existing dyeing recipe (3 g/l)
After rewinding for
judgement of levelness
Pretreatment –
DYEING
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Greige dyeing of cellulose fibres
and their blends
Greige CELdyeing –
Dyeing
LR 1:10
0.3 g/l KOLLASOL CDO
3.0 g/l SARABID MIP
2.0 g/l CHT-DISPERGATOR SMS
1.5 g/l MEROPAN DPE
10 min at 40°C
Pigmentation
0.20 % BEZATHREN YELLOW F3GC
0.20 % BEZATHREN BROWN BR
0.24 % BEZATHREN GREY CL
20 min
80°C
Vat
15 ml/ NaOH 50°Bé
2.0 g/l SARABID VAT
8.0 g/l Hydrosulfite
20 min at 80°C
1°C/ min to 50°C
10 min at 50°C
Oxidise
3.0 g/l MEROPAN XRN
1.0 g/l CHT-DISPERGATOR SMS
20 min at 80°C
Rinse
-
Soap
1.5 g/l SARABID MIP, pH 8-9
20 min at 98°C
Rinse
-
10 min at 40°C
yarn recipe
Pretreatment –
DYEING
16
Greige reactive dyeing of cellulose fibres
and their blends
Suitable for
reactive dyed
CEL knitted fabric
with less amounts
of knitting oil
Reactive greige dyeing, knit goods
Customer‘s
standard
Prewashed
Greige dyeing
Prewet
0.5 g/l SARABID MIP
10 min at 50 °C, drop, refill
Customer‘s
standard
Dyeing
Prebleached
2 g/l SARABID MIP in dyeing bath
no separate addition of anticrease and
no sequestering agent needed!
Pretreatment –
DYEING
Greige dyeing
17
Further advantages of SARABID MIP

Fastness
improvement
Rub fastness improvement for vat (and sulphur)
dyeings
dry
wet
Vat dyeing without
SARABID MIP
Vat dyeing with
3 g/l SARABID MIP in the
dyebath and aftersoaping
Pretreatment –
DYEING
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SARABID MIP prevents precipitations
in reactive dyeing bath

Reactive
Conditioner
Without product
reactive blue 71
Additive for all reactive dyeings because
SARABID MIP prevents besides the other benefits also
precipitations with non ionic surfactants in form of residues
of the pretreatment (prebleached for brillant shades),
 A better dye solubility is achieved and thus a
better levelness on the material is obtained.
 We recommend 1-2 g/l to the existing or optimized dyeing
recipe.
SPOTS
Residues of
Non ionic product
will occur
0.1 g/l non ionic
with
without
product
2g/l SARABID MIP
addition of
SARABID
MIP!
Pretreatment –
DYEING
19
Multifunctional dyeing auxiliary
washing
agent/
emulsifyer
enzyme
1
+
2
anticrease
+
3
sequestrant
+
4
4 individual products are necessary to replace
SARABID MIP
...the environmentally friendly and economic way
to dye greige cellulosic articles without any long
enzyme
washing agent
anticrease
sequestrant
pretreatment cyles.
Our SARABID MIP = a benefit for you!
Pretreatment –
DYEING
20
CHT GROUP
More efficient washing off.
New generation of aftersoaping agent
for reactive dyeings and prints.
Susanne Ehret
Pretreatment –
DYEING
21
Demand on end-use of a reactive dyeing

Dyeings with reactive dyes in the exhaust process
guarantee a very high level of shade
reproducibility and produce brilliant, bright shades.

Excellent overall fastness of reactive dyed goods
can only be obtained, if the fabrics are treated
after the dyeing process, especially in case of
medium to dark shades.

A weak point of this process is that during dyeing
about 10 - 30 % of the dyes bond only loosely with
the fibers, or even not at all. If the fabrics are not
washed thoroughly enough, these dyes again
adhere loosely to the fibers.
It results poor colour fastness.
Present situation
Pretreatment –
DYEING
22
Demand on end-use of a reactive dyeing
Present situation
The conventional aftertreatment of reactive dyeings
is done so far by

excellent rinsing
to remove electrolyte, alkali, residual hydrolysed
dyes

soaping
to promote release and outward diffusion of
substantively fixed dye hydrolysates

rinsing
to remove residues of dye hydrolysates to
achieve a good fastness level

Pretreatment –
DYEING
cationic fixation
to obtain the best fastness level
23
Most time and water consuming in textile processing is the rinsing and
soaping after reactive dyeing, especially for dark shades.
Reactive
Dyeing
Rinse 2-3 x
Neutralisation
1–2x
Soaping
Rinse
Removal of
electrolyte
Is there a possibility to minimize water consumption
even in case of deep shades with the same fastness levels
Pretreatment –
DYEING
?
24
Reactive
Dyeing
Neutralisation
pH 7-9
1x
Soaping
New chemistry
of soaping agent
reduces the affinity of the
dyestuff hydrolysate
to the fibre in spite
of salt in the
soaping bath
Pretreatment –
DYEING
Rinse
Water
Energy
Process time
Effluent cost
can be saved
with
COTOBLANC SEL 200
25
Latest generation of soaping agents for
reactive dyeings
Process
optimisation
COTOBLANC SEL 200
Aftersoaping agent with new chemistry
Soaping in presence of ELectrolyte (salt)
Pretreatment –
DYEING
26
COTOBLANC SEL 200

Compound of sequestering agents and polymers with
affinity for the dyestuff

For aftersoaping reactive dyeings and reactive prints in
neutral to slightly alkaline medium


Concentrated, surfactant-free, non foaming
Product features
Conventional soaping
COTOBLANC SEL 200
Reduces the number of necessary rinsing and soaping
steps;
COTOBLANC SEL 200 soaping can be carried out
directly after neutralising, additional rinsing is not
necessary,
because SEL 200 is effective in liquors containing salt
Pretreatment –
DYEING
27
Excellent soaping properties in the
presence of electrolyte
Test method:
Dyeing: padding with 1 g/l BEZAKTIV RED HE-3B, dye hydrolyzate,
liquor pick-up 80%, dry
Soaping: pH 8.0, 5°dH, 5 g/l NaCl, LR 1 : 20,
15 min at 98 °C, rinse cold
Aftersoaping effect with 5 °dH and 5 g/l NaCl
without
standard
COTOBLANC
initial material
auxiliary
soaping agent
SEL 200
2 g/l
1 g/l
Pretreatment –
DYEING
28
Standard soaping process versus
COTOBLANC SEL 200
110
100
90
80
temperature [°C]
Standard process
Dyeing with
2 % BEZAKTIV
RED S-3B 150
+
2 % BEZAKTIV
YELLOW S-3R 150
Dyeing
70
60
50
40
30
Fix &
Soften
20
10
Neutralisation
0
Total time 320 min
0
50
100
150
200
250
300
350
time [min]
110
100
COTOBLANC SEL
process
80
temperature [°C]
Total time 270 min
90
70
Dyeing
60
50
40
30
pH 7.5-8.0
Fix & Soften
20
10
Neutralisation
0
Pretreatment –
DYEING
0
50
100
150
200
250
300
350
time [min]
29
Soaping off - dark red dyed fabric- on MCS®
jet
Bulk trial
Material
Dyeing
100 % Cotton
Liquor ratio 1 : 12
2.9 % BEZAKTIV RED HE-7B / 1.2 % B. BLUE HE-RM 133
Standard procedure
1 soaping bath
less
(together 3 baths)
Time reduction
> 50 min
Time
Water
(including heating,
cooling, drain, fill)
(including liquor
retention)
95 min
10,0 l/kg
3 min
3,0 l/kg
12 min
10,0 l/kg
12 min
10,0 l/kg
5 Soaping
36 min
10,0 l/kg
6 Soaping
36 min
10,0 l/kg
7 Overflow rinse
8 Rinse 70 °C
3 min
3,0 l/kg
12 min
10,0 l/kg
209 min
66 l/kg
1
2
3
4
Dyeing
Overflow rinse
Rinse 70 °C
Neutralisation
CHT-Trial
Time
Water
(including heating, (including liquor
cooling, drain, fill)
retention)
Dyeing
Overflow rinse
Neutralisation
95 min
10,0 l/kg
3 min
3,0 l/kg
36 min
10,0 l/kg
12 min
10,0 l/kg
12 min
10,0 l/kg
Soaping
Pretreatment –
DYEING
Rinse 70 °C
Rinse 50 °C
158 min 43 l/kg
Time saving
Bath saving
Water saving
24 %
30 %
35 %
30
Benefits of COTOBLANC SEL 200
Product benefits









Reduced process time
Less water and waste water
Reduced energy costs
Higher productivity
Applicable on all reactive anchor dyestuffs
No foam behaviour
Excellent efficiency in presence of salt and
hardness
No redeposition provided that the bath-pH is
slightly alkaline
Suitable on all machinery equipment
COTOBLANC SEL 200
makes a reactive dyeing faster and more profitable!
Pretreatment –
DYEING
31
CHT GROUP
More efficient aftertreatment
for reactive and direct dyeings with
reduced process time and cost
REWIN SRF and SRF-O
Susanne Ehret
Pretreatment –
DYEING
32
Benefit of REWIN SRF and SRF-O
REWIN SRF and SRF-O are both
one-bath fixing agent and softener.
Created was one product out of two with an excellent
performance.


REWIN SRF:
cationic fixative + hydrophobic softener
REWIN SRF-O: cationic fixative + hydrophilic softener
Pretreatment –
DYEING
33
Benefit of REWIN SRF/SRF-O
REWIN SRF/SRF-O
Cationic fixing agent
and softener
One- shot product !
REWIN SRF & SRF-O combine in a unique way the
effects of a formaldehyde-free aftertreatment with a
soft handle.
The process time and cost in exhaust method is
reduced at the same time.
Water fastness DIN EN ISO 105-E04
CO
WO
Without fixative
3,0 % REWIN SRF
Pretreatment –
DYEING
34
Powerful solutions to save
water, energy, and time...
Powerful
solutions with
CHT
... can be achieved on
cellulosic fibres with
SARABID MIP
COTOBLANC SEL 200
REWIN SRF/SRF-O
Thanks for your attention!
Pretreatment –
DYEING
35

DYEING - APETT

Transcription

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