Innovations in Dyeing

IFC International Conference March 2005

Mr. Thomas Mende

We are your experienced partner!

Dyes

Man Power

Chemicals

Energy Water

Machinery

Dyeing Components

It has been estimated that in a standard cotton dyeing process Bleaching, washing and rinsing
USES

* 70% of the total time * 80% of the water * 90% of the energy

Total water per kg of fabric

600 500 litres/kg 400 300 200 100 0 1:15 1:12 1:10 1:8 1:8 1:5
Process water Cooling water 30 C

eco master

Impact of Liquor Ratio

Cooling and Process Water

Average Steam consumption per kg fabric

Based (MCT)Reactive Dyeing
WITH HEAT RECOVERY

14.00 12.00 10.00 8.00 6.00 4.00 2.00 0.00 1:15

12.08 9.58 7.91 5.96 4.13

eco master

3.30

1:12

1:10

1:8

1:8

1:5

Impact of Liquor Ratio

Steam Consumption

5.000 kg day Reactive Dyed Cotton = 1.650.000 kg/year fabric

average salt used 60 grms/litre
1.980

Tonnes of salt per year

2.000 1.600 1.200 800 400 0

SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT

1.485
SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT

990 792 495

SALT SALT SALT

1:20

1:15

1:10

1:8

1:5

Liquor Ratio

Impact of Liquor Ratio

Chemical Usage

Reactive Dyeing 80C

120% 92.5% 100% 80% 60% 40% 20% 0% 1:5 1:6 1:7 1:8 1:9-10 1:10-12 1:14-15 89.8% 87.0% 70.5% 61.0% 53.2% 49.0%

Matching Standard M&S = 0.8

Impact of Liquor Ratio

Right First Time

New Innovations in dyeing

new funtions RINSEtronic

RINSEtronic
RINSEtronic automatically calculates the correct rinsing producedure to arrive at a bath residual salt content of less than 1g/l only necessary to enter the salt concentration & the dept of shade in the dye program Result : Shorter cycle time Lower water consumption Reduced effluent

RINSEtronic
2 to 5% reactive dye stuff

variable

Old system

RINSEtronic system

New Innovations in dyeing

new funtions RINSEtronic pH-TRONIC / pH-FiT

pH-TRONIC
A system for pH controlled dyeing. The function pH-TRONIC enables pH adjustment following the pH-gradient and at the same time setting the required machine temperature. The control system consists of a pH measuring point and a chemicals dosing unit, which incorporates a dosing valve for linkage to an existing pressure ring main or alternatively equipped with appropriate dosing pumps.

Result : Higher First Time Right rate Easy handle of pH New / different dye procedure (especially in PA dyeing)

pH-TRONIC
pH measure and regulating system for pH controlled dyeing Stationary or mobile Re-cooler

pH-FiT
A system for pH controlled dyeing with a fully automated cleaning and calibration of the pH-electrodes. The modern pH-FiT Fuzzy-integrated-Technology enables pH adjustment following the pH-gradient and at the same time setting the required machine temperature. The control system consists of a pH measuring point and a chemicals dosing unit, which incorporates a dosing valve for linkage to an existing pressure ring main or alternatively equipped with appropriate dosing pumps.

Result : Higher First Time Right rate Easy handle of pH no operator needed for cleaning and calibration of the probes New / different dye procedure (especially in PA dyeing)

pH-FiT

pH measure and regulating system for pH controlled dyeing Fully automated calibration of the probes Stationary or mobile Re-cooler Developed by DyStar, SETEX and Thies

New Innovations in dyeing

New funtions RINSEtronic pH-TRONIC / pH-FiT ECD - Electrochemical Dyeing of VAT

Comparison of Dyeing Processes

A) Standard Vat Dyeing Process

Reduc ing agent

B) Indirect Electrochemical Dyeing Process

Dyestu f f (ox ised) id

Media r ( . to red )
Fe
2+

Dyestu f f (ox ised) id

e
waste water

e
Dyestu f f ( reduced)

Sal t

dyed f re ib

Fe

3+

Media r ( . to ox ) Cathode

Dyestu f f ( reduced)

dyed f re ib

Dyebath

Dyebath

Developed by DyStar (formerly BASF)

Electrochemical Dyeing with Indanthren Dyes

Dyeing Curve 2 (All-in-Process)
Addiion of t dyestu f f
Fli il ng the appara tus Contro l range - 930 mV - 920 mV Leuco po tent l o the dyes ia f 60 C 45 A Dyeing phase I Dyestu freduct f ion Dye ing phase I I Leve l ling (equ l r iib ium o exhaus i f ton)

- 200 mV 9A 20 C

Time Redox pot ia ent l [mV] Cel cur l rent [A ] Te mpera ure t [ C]

Developed by DyStar (formerly BASF)

Electrochemical Dyeing Process

Scheme: Package dyeing range

dyestu f f Elec r c ti * supp ly

measurement o redox po t a f ten i l dye ing range

e lect lys ro is ce l l

dye bath regenera ed t

flra ion it t dyes f waste tu f

lquor i used

Developed by DyStar (formerly BASF)

Electrochemical Dyeing Process

Savings in Chemicals and Water
Consumption of Process Chemicals in an Indanthren Exhaust Dyeing Process: IN Process, 100 kg CO, LR 10:1 Reduction Depth of shade Dyeing
Mediator Dithionite Caustic soda 32 13.6 ml g/l 2 050 g 2 100 g 3 g/l 14 ml 3 000 g 6 160 g 5 g/l 19 ml/ l 2 g/l 2 ml/ l 5 000 g 8 360 g 2 000 g 880 g 8 g/l 24 ml/ l 2 g/l 2 ml/ l 8 000 g 10 560 g 2 000 g 880 g

EC-Reduction 0.3 - 4% Conc. Amount

Dithionite 0.3% Conc. Amount

Dithionite 2% Conc. Amount

Dithionite 4% Conc. Amount

Reduct. clearing
Dithionite Caustic soda

Total amount Saving

W ater in the dyeing process

4 140 g
150 l

9 160 g 55 %
1 000 l

16 240 g 75 %
2 000 l

21 440 g 80 %
2 000 l

Only process chemicals considered; Discharge in the EC technique approx. 15% of the liquor volume.

Developed by DyStar (formerly BASF)

Electrochemical Dyeing Process

Advantages Product savings Less chemicals with special safety requirements Maximum process reliability through control of the redox potential Existing dyeing machines can be retrofitted Unsurpased environmental compatibility Reduction of water and waste-water costs through recycling Waste-water limits easily achieved Better fastness properties

Developed by DyStar (formerly BASF)

New Innovations in dyeing

New funtions New dyeing machines

eco-bloc quattro

Dye up to 4 colours at a time in one machine Kier combinations 1 + 1 + 1 + 1 = 4 colours 2 + 2 = 2 colours 3 + 1 = 2 colours 4 = 1 colour 4 or 6 packages per kier batch reduction

eco-bloc X

eco bloc quattro

Total capacity 11 to/batch

New Innovations in dyeing

New funtions New dyeing machines

HT-Jigger Tiro
developed by: &

 Woven fabric All exhaust dyeing processes Fabrics with low length wise stretch Very light to very heavy qualities Special treatments (open width scouring)

All substrates Crease sensitive fabrics Impermeable fabrics Varying batch sizes Large fabric widths

HT-Jigger Tiro (Application range)

 Fabric tension: Speed: Fabric width, max. Roller width, max. Roller diameter: Roller batch dia.: Fabric height:

5 to 70 kg/cm 10 to 150 m/min 3800 mm 4000 mm 270 mm 1000 or 1230 mm (dependent on the type of m/c) 365 or 475 mm (dependent on the type of m/c)

HT-Jigger Tiro (Technical details)

Technical Advantages: A Fabric Rope Controller automatically calculates the r.p.m. ensuring exact fabric speed and tension providing excellent dye penetration. Automatic sampling point selection. Direct drive of the main rollers by frequency controlled motors with brake current return provide a considerably shorter braking distance compared with hydraulic drives.

HT-Jigger Tiro (Technical advantages)

 Automatic dosing of dyes and auxiliaries depending on the fabric length passing through the bath provides excellent reproducibility. High efficiency external pump unit and heat exchanger ensure controlled and even flow throughout the system. Constant dyeing conditions in the economical trough for varying batch sizes (55-100% loading capacity; water meter required).

HT-Jigger Tiro (Technical advantages)

 Loading/unloading device for crease-free loading/unloading of the fabric (Option)

HT-Jigger Tiro (Further options)

New Innovations in dyeing

New funtions New dyeing machines

ecoMaster
Multi Contact Dyeing
CCR Combined Cooling and Rising 100% Stock tank Power drain & fill Automatic filter Water meter Liquor Ratio 1:5 pH FiT Analogue Dosing Analogue levels Vario chamber RINSE tronic

ecoMaster
Features
Multi Contact Dyeing & rinsing using dual nozzles Liquor ratio 1:4.5 - 1:5 RINSEtronic rinsing system reduces process time and water consumption Winch speed up to 400 m/min Liquor ratio reduced by new sump and pump configuration Standard step filter

ecoMaster

eco-soft PLUS Process water (25C. 60 C) Cooling water Effluent Steam Electrical Power Time 46 litres 0,00 44 litres 2.24 kg/kg 0.1 kW 5.8 hrs

ecoMaster 34.5 litres 0,00 32 litres 1.92 kg/kg 0.12 kW 4.83 hrs

New Innovations in dyeing

New funtions New dyeing machines

soft TRD DS XL
Especially suiteable for surface senstive and light weight fabrics Double rope design Liquor ratio starts from 1:8 Fabric speed up to 600 m/min Operating temperature up to 140C 1-4 chambers per machine. Option of chamber isolation and coupling of two machines Chamber configurations 2 x 75 kg = 150 kg/tube 2 x 100 kg = 200 kg/tube 2 x 125 kg = 250 kg/tube 2 x 150 kg = 300 kg/tube

soft TRD DS XL

new internal chamber design compact machine design short fabric circulation and flooded fabric transport

lower liquor ratio minimal floor space requirement gentle handle of fabric

New Innovations in dyeing

New funtions New dyeing machines

Luft-roto plus
Developed by: &

Luft-roto plus

A joint development by Thies and DyStar

Round machine Rotating fabric chamber Air drive

==> reasonable liquor ratio ==> smooth fabric transport ==> minimised mechanical stress ==> improved opening and therefore better folding of the fabric ==> gentle plaiting into the fabric chamber ==> flexible application

Luft-roto plus

A joint development by Thies and DyStar

100% Stock tank

==> faster bath changes ==> possibility of preparation of the next dye bath ==> low set-up times ==> cooling water used as rinse water ==> very good cleaning effect ==> saving of rinse baths ==> pump operation during bath change ==> time saving

CCR Function

Rapid drain

Luft-roto plus

New Innovations in dyeing

New funtions New dyeing machines

provide access to

New dyeing processes

Temp C

Te mp.-time -c urve

140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30

LR 1:6

LR 1:6

LR 1:6

40

50

60

70

80

90

100

110

120

130 140

150

160

170

180 190

200

210

220

230

240 250

260

270

280

290 300

310

320

time in min.

A x g/l auxiliaries x g/l salt B x % dyestuff C x g/l Alkali

Conventional process

Temp C

Te mp.-time -c urve

140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30

LR 1:6

LR 1:6

LR 1:6

40

50

60

70

80

90

100

110

120

130 140

150

160

170

180 190

200

210

220

230

240 250

260

270

280

290 300

310

320

time in min.

Consumption data: Process water: 50 - 60 l/kg Steam: 4,5 - 5,5 kg/kg

Cooling water: 0,0 - 0,5 l/kg Electricity: 0,08 - 0,1 kWh/kg

Conventional process

Consumption data

Temp C

Te mp.-time -c urve

140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 0 10 20

LR 1:4,5

LR 1:3,7

LR 1:4,5

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

time in min.

A x g/l auxiliaries B x % dyestuff 1/2 amount of salt C x g/l Soda 1/2 amount of salt

Enhanced dyeing process

Temp C

Te mp.-time -c urve

140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 0 10 20

LR 1:4,5

LR 1:3,7

LR 1:4,5

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

time in min.

Developed by

&

Consumption data: Process water: 28 - 35 l/kg - 40 % Cooling water:1,4 - 1,8 l/kg Steam: 3,3 - 4,0 kg/kg - 30 % Electricity: 0,16 - 0,22 kWh/kg Enhanced dyeing process

no saving no saving

Consumption data

Plant Automation for

Fully or semi automated yarn dye houses Liquid chemical dispensing & supply Dye stuff dispensing and dissolving Bulk powder dispensing & delivery Dye house Management and Monitoring Heat recovery Water recyling

 Volumetric dosing of Liquid Chemicals Modular extension 10, 20 ....... Low level inlet Integrated manual dispensing option Low maintenance

Liquid Chemicals

Liquid Chemicals

 Option of varying capacities - 20 to 80 products Dust Extraction system One or more scales Automatic product retrieval Interface to OrgaTEX

Powder Dyes

CAPACITIES - 100, 200, 300, 600 litres OPTIONS : - Hot water preparation station - Water blending valve

Powder Dyes

Weighing & Dissolving

Weighing

Temp C
140 120 100 80 60 40 20 0 0 20 40 60 80

TIME TEMPERATURE CURVE

100 120 140 160 180 200 220 240 260 280 300 320

Time in minutes

737 XL Programmable Micro Processor Controller

N S

T 737 XL Programable Controller

OrgaTEX Dye house - Central Computer System

T 737

Plant Main Frame

(not part of our supply)

Liquid Chemicals

Dye Stuffs

Powder Chemicals

T 737 T 737 HUB

T 737

Dye house Floor

Dye house Office

t t
SN

Fabric / Yarn Store

T 737

t t
SN

T 737

Server

Colour Matching

Dye Store

Agent for Australia

Agent for New Zealand

DKSH Group
Melbourne, Australia

Marinco, Chemcolour
Auckland, New Zealand