PABNA TEXTILE ENGINEERING COLLEGE

PROJECT REPORT ON

Application of Reactive Dyes in Major Textile Industries in Bangladesh and Technical Deficiency of Reactive Dye
BASIS OF

FAKIR APPARELS LTD. BSCIC SHILPA NAGARY, FATULLAH; NARAYANGONJ

SUPERVISING TEACHER

SHIB SHANKAR CHAKRABORTY

HEAD OF THE DEPARTMENT WET PROCESSING TECHNOLOGY PABNA TEXTILE ENGINEERING COLLEGE SHALGARIA, PABNA.

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PREPARED BY Md. SHADAT HOSSEN ROLL NO. 070006 SESSION 2006-2007

CONTENTS
Chapter No. 01 02 03 04 05 06 07 08 Name of the topics Acknowledgement Title Project Abstract Introduction Raw Materials Marketing Analysis Importance of The Survey Reason of using Reactive dyes in major textile industry in Bangladesh Methods of Dyeing Cotton Goods with Reactive Dyes Technical Deficiency of Reactive Dyes, Causes and Remedies of Technical Deficiency Conclusion Pag e No.

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Chapter 1

Acknowledgement
Acknowledgement

It is glee to come to an end of the industrial attachment. It was a long two month program and in this long journey, we like to give our heart-felt endeavor to the honorable Principal of Pabna Textile Engineering College whose advice and suggestions have led us to a successful end of the training. We also want to express our gratitude and appreciation to Mr. SHIB SHANKAR CHAKRABORTY (Head of the department of the fabric wet processing Technology) & also our supervising teacher for their encouragement, valuable suggestion, and guidance and decision which able to help to do this Industrial attachment successfully. Their directions have taken us to our destination. We are really lucky that we have got such a teacher without whom; this training may not end as it did. Pabna Textile Engineering College is serving the nation with her education, building successful engineers. At the same time, arranging Industrial attachment is an academic function of Textile Engineering. We want to express our deepest appreciation, sincerest gratitude to our respected teacher Md. Abdul Based Miah (Principal of Pabna Textile Engineering College)

DATE: 15-12-10

MD. SHADAT HOSSEN

Chapter 2

Title:
Application of Reactive dyes in major textile industries in Bangladesh &technical DIFECIENCY OF REACTIVE DYE

Chapter 3

PROJECT ABSTRACT

The use of reactive for Dyed products has dramatically increased over the last 50 years. Reactive dyes are now used to produce multiple products. Reactive coloring components are inert into materials which are adhered to the base substrate by the application of soda ash which act as fixing agent. The main goal of our project is to provide information about the reason of using reactive dyestuff in major textile industry in Bangladesh, different methods using in our industry for cotton dyeing with reactive dyes, technical deficiency of reactive dyes during dyeing & causes and remedies of deficiency of reactive dyes. During reactive dyeing there is a rule of using different amount of soda ash with fixed amount of salt & auxiliaries. In case of dyeing of cotton with reactive dyes alkali pH should be correctly maintained as during dyeing more electrolytes required for exhaustion and alkali for fixation.

However the rubbing fastness and hand feel properties of dyed fabric depends on the amount of soda ash. When we use fewer amounts of soda ash then hand feel is good but rubbing fastness is not good. And when we use more amounts of soda ash then rubbing fastness is good but hand feel is not good.

Chapter 4

INTRODUCTION
With the evaluation of the wet processing industries the use of the reactive dyes in the most of the industries increases day by day. As a result to complete the project it is has become a part to discus about the evaluation or growth of the wet processing industries in Bangladesh. Now the number of the wet processing industries and finishing industries in Bangladesh is 193 which are totally export oriented according to the survey of the BTMA which has been provided into their we address. But the interesting matter is that with the growth of the textile wet processing mills the number of the employee is not increasing. This is because of to reduce the cost and increase the quality the modernization of the machine is also increasing which reduce the number of worker in wet processing industries. But what is the actual number of the worker in wet processing industries has not been found due to the lack of proper survey in this sector.

Our project work was estimated as: APPLICATION OF REACTIVE DYES IN MAJOR TEXTILE IN BANGLADESH & DEFICIENCY OF REACTIVE DYE:
The project work is interesting as well as lengthy but we must admit that we had to really work hard and it helps us a great deal to know about whole procedure of reactive dyeing on dyed fabric. Though reactive dyeing products exhibit intrinsic characteristics which make them suitable for multiple products application but reactive dye has it main problem with hydrolysis while dyeing as a result wastage of the reactive dye increase and it become difficult to match the proper

The objects of project are:

Knowing the source of textile raw materials of wet processing and cost. To mention the reasons of using reactive dyes in major textile industry. To study on the application of reactive dyes

To learn about the technical deficiency of reactive dyeing. To study the causes and remedy of deficiency of reactive dyeing.

 Chapter 5

RAW MATERIALS
Raw material is a unique substance in any production oriented textile industry. It not only plays a vital role in case of continuous production & for high quality fabric but also it is related to the profit of the industry.

Types of raw material

The basic raw materials used in wet processing industries are: Fabric Dyestuffs Chemicals & auxiliaries. Names & source Fabric:
Different types of fabric treated in namely Single Jersey Single jersey with Lycra attachment Polo pique Back pique Rib Fabric Fleece

FAKIR APPARELS LTD. dyeing section are

Dyestuffs:

Dye

Brand name
Bezactive Ciba Dychufix Kemafix

Origin/source
Bezema , Switzerland Ciba , Switzerland Hubei Hwalle dyestuff Ind.co. Jaychem,India Dystar , Germany Dystar, Germany India Jaychem,India Dyestar , Germany Solarfine , Taiwan Solarfine , Taiwan

REACTIVE DYE

Levafix Procion Jackazol Kemazol Remazol Solazol Solacion

Chemicals:
Brand name Novolube Jet Bluton BVB1 Cibacel DBC Cibafix ECO Cibafluid C SandocleanPCLF Permacol FA Novostone CR Cotton white T Cyclanon E Cyclanon ECO Jinlev RLF349 Eulysin S Felosan NOF Uvitex EBF Jinlev CL-225 Oxalic caid Palegal FA-8 Respumit BU Permacol SQ Na thiosulphate Uniperol O Uvitex EVF Uvitex 2B Mollan129 Acetic acid Reduction HCS Mollan130 Bluton 2B Type Anti creasing agent Violet tone brightener Sequestering agent Fixing agent Anticreasing agent Detergent Stabilizer Enzyme Redder tone brightener Fixing agent Reduction cleaning agent Dispersing agent pH buffer in PET dyeing Detergent Whitening agent Levelling agent for reactive dye Iron remover Levelling agent for disperse dye Antifoaming agent Sequestering agent Peroxide killer Washing agent for PET dyeing PET brightener Yellow tone brightener Soapinging agent pH controller Reduction cleaning agent Sequestering agent Whitening agent Source Techna,Italy CHT,Germany Ciba,India. Ciba ,Switz. Ciba ,Switz. Clarient,Germany Techna,Italy Techna,Italy CHT,Germany BASF,Germany BASF,Germany Geigy,Taiwan BASF,Germany CHT,Germany Ciba ,Switz. Geigy,Taiwan BASF,Germany BASF,Germany Techna,Italy BASF,Germany Ciba, Switz. Ciba ,Switz. Rota,dystar Geigy,Taiwan Rota,dystar Ciba,India

Remark
The list is for the time of our industrial attachment. It varies according to the availability of the material & their price. The price has not been supplied to us due to their secrecy act. The annual requirement was not available & is a record of the procurement department.

Chapter 6

MARKETING ANALYSIS
Consumer of the products:
FAKIR APPARELS LTD. is a 100% export oriented industry. All the goods produced in this
industry are exported into various foreign countries. Name of the main buyers of the products of the industry are given below:

1. TOM TAILOR 2. S. OLIVER 3. H&M 4. POINT ZERO 5. GAP 6. G-STAR 7. AHLENS Importing countries:
The countries which are importing goods from Beximco knitting Ltd are given below:

U.S.A GERMANY SPAIN TURKEY RUSSIA JAPAN SWEDEN THAILAND SCOPE OF MARKETING:
As the life style of the people is changing and to keep face with that life style people of the world is seeking for high quality of product at the same time at a low cost. In this case we are lucky to have all the opportunity for the buyer at a low price. As e result our market is spreading all over the world. Now we are not competing with China, Thailand, India which was one time impossible to imagine. We are now not only exporting the knitted products but also the woven is being exported

Marketing Strategy:
Marketing strategy is a very important factors to sale the products to the buyer. In FAKIR APPARELS LTD. mainly senior marketing officers, merchandiser deals with buyer. There are some fixed buyers of the industry. The buyers give their orders continuously all over the year. The marketing officers and by both side understanding the rate and the order quantity are fixed. Duties& responsibilities of marketing officer: The main duties and responsibilities of a marketing officer are given bellow:

To prepare cost sheet by dealing with the buyer. To take different steps by discussing with the high officials and merchandiser. To maintain a regular & good relationship between commercial officer & merchandiser. To maintain a regular communication with the buyers & buying houses. Communicate with the new buyer. Display the criteria of the products.

Actually the responsibilities & duties of marketing officer begins from getting order of buyer & ends after receiving goods by the buyer. So he should be always smart, energetic & sincere.

Remarks:
FAKIR APPARELS LTD. has a well learned marketing & merchandising team. They always communicate with the buyers. The marketing section also looks for the quality & quantity buyers.

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Chapter 7

IMPORTANCE OF THE SURVEY

The main goal of our project is to provide information about the reason of using reactive dyestuff in major textile industry in Bangladesh, different methods using in our industry for cotton dyeing with reactive dyes, technical deficiency of reactive dyes during dyeing & causes and remedies of deficiency of reactive dyes. As these topics are very sensitive for dyeing industries, it is very much important to make a survey. It will be very helpful not only for our studying period but also for our future career. This survey also has these importances: 1. To mention the reason of using reactive dyes in major textile industry. 2. To study on the application of reactive dyes. 3. To learn about the technical deficiency of reactive dyeing. 4. To study the causes and remedy of deficiency of reactive dyeing.

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Chapter 8

Reason of using Reactive Dyes in Major Textile Industries in Bangladesh

Maximum textile industries in Bangladesh are based on cotton knit fabric and reactive dyes are easily applicable to cellulose fibres. Other associated reason as follows: 1. Reactive dyes are soluble in water. 2. They have very good light fastness with rating about 6. 3. The dyes have very stable electron arrangement and can protect the degrading effect of ultra-violet ray. 4. Textile materials dyed with reactive dyes have very good wash fastness with rating about 4-5 due to strong covalent bonds formed between fibre polymer and reactive group of dye. 5. Reactive dyes give brighter shades and have moderate rubbing fastness. 6. Dyeing method of reactive dye is easy. It requires less time and low temperature for dyeing. 7. Reactive dyes are comparatively cheap. 8. Fixation occurs in alkaline condition. 9. Reactive dyes have good perspiration fastness with rating 4-5. 10. It has a wide range of shade

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Chapter 9

Methods of Dyeing Cotton Goods with Reactive Dyes

REACTIVE DYE :
Reactive dye react with the fibres mainly react with cellulose fibres e.g. cotton, jute, bast fibres, viscose, flax. It can be applied to protein fibres e.g. wool & silk. Reactive dye contains reactive group and this reactive group makes covalent bonds with the fibres and becomes the part of the fibre. The general formula of reactive dye as follows: D-X-Y Here D->Chromophore of dye post X->Bridge Y->Functional group D-X-Y + Fibre ->D-X-Y-Fibre Covalent bond Reactive dyes water soluble D-F + Cell-OH ->Dye-F-O-cell D-F + H-OH ->Dye-F-OH Hydrolysis

Properties:
1. 2. 3. 4. 5. 6. Anionic in nature. Soluble in water. Form strong covalent bond Better wet & light fastness. Have better substantivity. Dyeing is carried out at alkaline condition.

Influencing factors:
1. 2. 3. 4. 5. PH Temperature. Conc. of electrolyte. Time. Liquor ratio.

REACTIVE DYEING FOR SENSITIVE SHADE AT 60oC

Dyeing: Anticreasing Agent (.5 g/l) Leveling Agent (1 g/l) A. Acid ( .2 g/l) Dyes (According to Shade %) G. Salt (According to Shade %)

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Soda Ash (According to Shade %)

60min at 60OC,
Neutralization (Dyeing): A. Acid (1 g/l)

10min at 40-50OC,
Soaping: Soaping Agent (.5 g/l)

Dyeing curve:
Sequestering Agent Color Dosing Leveling Agent Linear (30min) 600C 500C 10min 50min

Bath drain 350C PH +Hardness Check 20min 30min 10min 10min Salt (15min) 1 g/l Soda Rest Soda (30min) (60min) 350C Cold wash

HOT BRAND REACTIVE DYEING: DYEING AT 92oC: Process steps: Dyeing:

Anticreasing Agent (.5 g/l) Leveling Agent (1 g/l) A. Acid ( .2 g/l) Dyes (According to Shade %) G. Salt (According to Shade %) Soda Ash (According to Shade %)

60min at 80OC, PH = Above8 (Always)

Neutralization (Dyeing): A. Acid (1 g/l)

10min at 40-50OC,
Soaping: Soaping Agent (.5 g/l)

20min at 70-80OC,
Fixing & Softening: Fixing Agent (.5 g/l)

15min at 40OC,
A. Acid (.5 g/l)

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Softener (1.5 g/l)

20min at 40OC,
Bath Drain

Dyeing curve:
Sequestering Agent Color Dosing Leveling Agent Linear (30min) 60 C 500C 10min
0

800C 40min 50min Bath Drain

350C PH +Hardness Check

20min

30min

10min

10min Rest Soda (60min)

350C Cold wash

Salt (15min) 1 g/l Soda (30min)

N.B: The temperature increase at the grade 10C/min because its an important matter to avoid the shade variation in dyeing

DARK COLOR DYEING WITH REACTIVE DYE AT 600C

Dyeing: Anticreasing Agent (1.5 g/l) Leveling Agent (1 g/l) A. Acid (.2 g/l) Dyes (According to Shade %) G. Salt (According to Shade %) Soda Ash (According to Shade %)

60min at 60OC,
Neutralization (Dyeing): A. Acid (1 g/l)

10min at 40-50OC,
Soaping: Soaping Agent (.5 g/l)

20min at 70-80OC,
Fixing & Softening: Fixing Agent (.5 g/l)

15min at 40OC,

A. Acid (.5 g/l) Softener (1.5 g/l)

20min at 40OC,
Bath Drain

Chapter 10
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Technical Deficiency of Reactive Dyes, CAUSES AND THEIR REMEDIES

Hydrolysis is the main problem in dyeing with Reactive dyes. Only 60 to 70 percent dyes are absorbed in Reactive dyeing. There are also many causes of technical deficiency of reactive dye. Those are described below: Hydrolysis of reactive dyes: Under alkaline condition, reactive dyes react with the terminal hydroxyl group of cellulose. But if the solution of the dye is kept for long time, its concentration drops. Then the dye react with the hydroxyl group of water .The reaction of dye with water is called Hydrolysis of reactive dyes.

Factors which affect the hydrolysis of the reactive dye: 1. Salt concentration: When the cellulosic textile material is sink into water it convert into negetive charge or anionic charge. But the reactive dye is also convert into anionic charge. So the surface of the cellulosic material repel the dye molecules. To overcome the problem we use electrolite material like salt. It hepls to netralize the negetive ion over the textile material and helps the reactive dye ion to fix on the surface of the materail. As a result If we increase the concentration of the salt hydrolysis of the reactive dye will decrease. 2. pH: if the pH of the medium increase hydrolysis of the reactive dye also increase. This is for, reactive dye ionised more in alkaline medium and as a result it react with hydroxyl group of the water. 3. Temperature: With the increase of temperature hydrolysis of the reactive dye increases.

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4. Substantivity: With the increase of the substantivity hydrolysis of the reactive dye increase. 5. Reactive group of the reactive dye: Hydrolysis of the reactive dye depends on which group does it bears. Vinyl sulphone dye hydrolyize more than the Triazinyl group. Hydrolysis of water: Hydrolysis of the water is also a cause of the technical deficiency of the reactive dye. Remidies of the hydrolysis of the reactive dyes: The highest absorption of the reactive dye is about 70%. To minnimize the more lose of the reactive dye we should maintain proper liquor ratio, proper time and temperature. Even the pH of the emdium is also an important factor to avoid the more wastage of the reactive dye.

Faults and their remedies for the technical deficiency of reactive dyes:

There creates many problems and defects in dyed fabrics when dyeing with Reactive dyes due to technical deficiency. Some defects may be remedied by some process. Those are described below: Defect: Colors are not fast to washing, Abrasion; Staining in the fabric when transporting from place to the other, water marks on the fabric Remedy : Wash the fabric with soap and soda ash at right temperature. Adding sequestering agent will yield good results. Treating with Ammonia will also give good results. Defects in the fabric due to Printing- Need to take out full color Remedy: Treat the dyed fabric with Sodium Hydrosulphite with 5-10 gm Sodium Hydrosulphite at 75 deg C for 30-45 minutes. Add 5-7 gms Caustic Soda for even removal of colors. The color becomes light yellow or brown after removal. Wash it thoroughly with soap. The color can also be removed by solution of Sodium Hypochlorite. Treat the fabric with a sodium hypochlorite solution ( 3-5 gms Chlorine) for 20-30 minutes. Keep the pH between 9-10. The fabric is treated with Acetic acid after removal of color to remove chlorine and to neutralize the fabric. The fabric can be re-dyed after removal of color Defect: Bleeding in colors during washing, abrasion

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Remedy: Boil the fabric with caustic, Treat the fabric with Hydrogen Peroxide ( 5-10 gpl, 60-70 deg C) to make the color fast.

Defect: The fabric has been dyed in darker shade, uneven dyeing Remedy: To take out color from the fabric treat it with caustic for 45-60 min at 70 deg C. Thereafter treat the fabric with 10-20 gpl Acetic Acid for 40-60 min at 80-85 deg C. Defect: Uneven dyeing, marks of water, marks of colors Remedy: Wash the fabric in soap and re-dye in a darker shade Defect : The fabric has become stiff and rough after dyeing Remedy: Finish after adding right softener Defect: Color staining of fabric, uneven dyeing Remedy: Re-dye the fabric in darker shade. Defect: Color staining in fabrics of darker shade, uneven dyeing. Remedy: Dye the fabric in Sulphur black. Caution: Please treat a small length fabric to check the effectiveness and any harmful effects before commencing a full treatment.

Defect: Color staining of fabric, uneven dyeing Remedy: Re-dye the fabric in darker shade. Defect: Color staining in fabrics of darker shade, uneven dyeing. Remedy: Dye the fabric in Sulphur black. Caution: Please treat a small length fabric to check the effectiveness and any harmful effects before commencing a full treatment.

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Chapter 12

Conclusion
Obviously the project work we have discussed has many other arguments but as far as we believe the presented view to a large extent is one that has a predominant role in our textile sector especially in REACTIVE DYEING & thus has the ability to influence our thoughts. REACTIVE DYEING is truly an important dyeing phenomenon for cellulose materials & ranks as the major contribution to the progression of any textile dyeing industry. Dyeing parameters have a great influence on reactive dyeing which have described in my report. It was really an important subject & also innovative one. I have tried my best to express the topics properly. The project work has given us a special interest & has been arranged as a presentation of the application reactive dyes in cotton dyeing. I think anyone can research in future about this topic which will enrich our textile knowledge. Any absolute conclusion is impossible but waiting the pros & cons Im certain that my position is a tenable one.

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