SUMMARY OF

Smith 1986 Pad Batch Dyeing

2.b.ii Electro1ytes:Smith 1986 Pad Batch Dyeing:HE STATES THAT Same as section from Identification and Reduction 3.2 . . . Smith 1986 on pad/batch fiber reactive dyeing of fiber reactives on cotton. It covers the same technical area (pad-batch) as Stone 1979, but this review focuses mainly on P2 aspects. The pad batch system addresses several of the major problems for cotton dyers in the future. They are covered in other parts of the outline, ie j 4. Dyeing, 2.a.v Water Conservation, and 2.b.i Color Residues in Textile Dyeing/Printing Wastewater. This information is also very appropriate for 3.j Process alternatives. This section should be substantially included in the document. Same information under all headings noted above.

2.a.v Water Conservation:Smith 1986 Pad Batch Dyeing:HE STATES THAT Same as section 3.2 from Identification and . . . Smith Reduction 1986 on pad/batch fiber reactive dyeing of fiber reactives on cotton. It covers the same technical area (pad-batch) as Stone 1939, but this review focuses mainly on P2 aspects. The pad batch system addresses several of the major problems for cotton dyers in the future. They are covered in other parts of the outline, ie 2.b.ii Electrolytes, 4.j Dyeing, and 2.b.i Color Residues in Textile Dyeing/Printing Wastewater. This information is also very appropriate for 3.j Process alternatives. This section should be substantially included in the document. Same information under all headings noted above.

2.b.i Color Residues in Textile Dyeing/Printing Wastewater:Smith 1986 Pad Batch Dyeing:HE STATES THAT Same as section 3.2 from Identification and Reduction . . . Smith 1986 on pad/batch fiber reactive dyeing of fiber reactives on cotton.It covers the same 1979, but this review focuses technical area (pad-batch) as Stone mainly on P2 aspects. The pad batch system addresses several of the major problems for cotton dyers in the future. They are cove in other parts of the outline, ie 2 .b. ii Electrolytes, 2. a.v Water Conservation, and 4.j Dyeing. This information is also very appropriate for 3.j Process alternatives. This section should be substantially included in the document. Same information under all headings noted above. 4.j Dyeing:Smith 1986 Pad Batch Dyeing:HE STATES THAT Same as section 3.2 from Identification and Reduction . . . Smith 1986 on pad/batch fiber reactive dyeing of fiber reactives on cotton. It covers the same technical area (pad-batch) as 1979, but this Stone reviewfocusesmainlyonP2aspects.Thepadbatchsystem addresses several of the major problems for cotton dyers in the future. They are covered in other parts of the outline, ie 2.b.ii Electrolytes, 2.a.v Water Conservation, and 2.b.i Color Residues in Textile Dyeing/Printing Wastewater. This information is also veryappropriatefor 3.j Processalternatives.Thissection should be substantially included in the document. Same information under all headings noted above.

3.j Process a1ternatives:Smith 1986 Pad Batch Dyeing:HE STATES THAT Same as section 3.2 from Identification and Reduction... Smith 1986 on pad/batch fiber reactive dyeing of fiber reactives on cotton. It covers the same technical area (pad-batch) as Stone 1979, but this review focuses mainly on P2 aspects. The pad batch system addresses several of the major problems for cotton dyers in the future. They are covered in other parts of the outline, ie 2.b.ii Electrolytes, 2.a.v Water Conservation, and 2.b.i Color Residues in Textile Dyeing/Printing Wastewater. This information 4 is also very appropriate for . j Dyeing. This section should be substantially included in the document. Same information under all headings noted above.

A "

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Pad B a t c hD y e i n go fC e l l u l o s i cF i b e r s The pad batch ( c o l d ) method of d y e i n gc e l l u l o s i c s

i s h a r d l y a new

concept [26-301. applications.

I t h a sb e e nu s e dq u i t es u c c e s s f u l l yi n

a wide v a r i e t y of

I n many ways, it is one the of

most r e l i a b l e and e a s i e s t - t o -

c o n t r o l methods a v a i l a b l et o d a yf o rc e r t a i na p p l i c a t i o n s .S t r a n g e l ye n o u g h , however, it has n o tc a u g h t C o n t i n e n t a l Europe o r i n C h e m i c a lI n d u s t r i e s .

To q u i c k l y summarize t h e pad b a t c hm e t h o d ,p r e p a r e df a b r i c

on i n t h i s c o u n t r y t o t h e e x t e n t t h a t

i t i s used i n

England, where i t was f i r s t developed by I m p e r i a l

is impregnated

w i t h l i q u o rc o n t a i n i n gp r e m i x e df i b e rr e a c t i v ed y e s t u f f l i q u i d is squeezedout boxes,andcovered on t h em a n g l e ;t h ef a b r i c

and a l k a l i ; e x c e s s

is b a t c h e d o n t o r o l l s o r i n
C02 from a i r o r

w i t h p l a s t i cf i l mt op r e v e n ta b s o r p t i o no f two t ot w e l v eh o u r s

e v a p o r a t i o n of water, t h e ns t o r e df o r
The goodscan

(see Figure 3.2-1 1.

on

be washed o f f i n a n y

of severalconventionalways,depending

e q u i p m e n ta v a i l a b l ei nt h e The method

mill. it o f f e r ss e v e r a ls i g n i f i c a n t

is i n t e r e s t i n g b e c a u s e

a d v a n t a g e s ,p r i m a r i l yi n

its s i m p l i c i t y n d p e e d . r o d u c t i o n a s P

of between

75

and 150 y a r d s a minute,depending

on t h e c o n s t r u c t i o n

andweight of speed can

of thegoods make t h e up.

involved , i s commonly r e p o r t e d .I nf a c t ,t h i sk i n d limitingfactor

the wash-off

f a c i l i t i e s , which may n o t be able t o k e e p

O t h e rb e n e f i t si n c l u d ee s s e n t i a l l ye l i m i n a t i n gt h e

need f o r s a l t o rc h e m i c a l and p o l l u t i o n

s p e c i a l t i e s from the dyebath, w i t h a s s o c i a t e d r e d u c t i o n i n c o s t s o u r c er e d u c t i o n . A n o t h e rf a c t o rt h a th a sg e n e r a t e de n t h u s i a s mf o r f l e x i b i l i t y , compared t o a c o n t i n u o u sr a n g e .E i t h e r done, and i n many c o n s t r u c t i o n s .F r e q u e n tc h a n g e so fs h a d e

pad batch is i t s wovens o rk n i t sc a n be

are no problem,

, -

PAD/ BATCH

- BEAM STORAGE

AND WASH-OFF UNIT

F i g u r e 3.2-1

Pad/batch

beam s t o r a g ea n d

wash o f f u n i t

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because eactives emain r r

water s o l u b l e , making c l e a n u p easy.

T h i sf i t s

many

s i t u a t i o n s well, e s p e c i a l l y when v e r s a t i l i t y i s r e q u i r e d . systemcanrunthe u s u a l l yr u n

The pad b a t c h

same c o l dd y e i n gf i b e rr e a c t i v ec o m b i n a t i o n s

that are

on p a c k a g ed y e ,j i g s ,
be donewithbecks,

beams, b e c k s , j e t s andotherequipment.

Washing-off can

beams, c o n t i n u o u se q u i p m e n to ro t h e r

a v a i l a b l em a c h i n e s . S t u d i e s [301 have blendsconservesenergy, shown t h a t p a db a t c hd y e i n gf o rc o t t o n ,r a y o na n d

water, dyesandchemicals,laborandfloorspace.
beam wash-off

Water consumptionforpadbatchdyeingwith
t w o . g a l l o n sp e r

is t y p i c a l l y u n d e r

pound of dyed f a b r i c , compared t o t y p i c a l l y 20 o r more on

a t m o s p h e r i cb e c k sf o rt h e

same f i b e rr e a c t i v e

dyed shades. Energy consumption f a b r i cf o rb e c k s

Chemical u s e ,

is s i m i l a r l yr e d u c e d
t ou n d e r

from a b o u t 9000 BTU's p e r pound dyed of

2000 BTU's per pound f o r padbatchwith

beam washing.

and a s s o c i a t e d BOD and COD l o a d i n g sf o r 80% compared to tmospheric a

becks.

waste streams, can be reduced up t o

Labor osts c

are a l s o e d u c e d . r

For

example, t w o workers per s h i f t c a n d y e week. I ng e n e r a l ,t h eq u a l i t y

200,000 pounds of

f a b r i cp e rf i v e - d a y

ofpadbatchdyeings

is much b e t t e r t h a no t h e r
3 .?-, '.I 3. I.--I1 ,

d y e i n gs y s t e m s .S p e c i f i c so fc o s ts a v i n g s and 3.%III.

are shown i n T a b l e s

Pad b a t c hd y e i n g sr e q u i r eh i g h l yr e a c t i v e" c o l dd y e i n g "f i b e r Examples brand of names of such colors

r e a c t i v ec o l o r s .

are:

A t l a f i x CX Cibacron F

(Atlantic)
( C i b a Geigy ) (C&K)

. Intracron

Levafix E ( A )

(Mobay 1

f
Comparison of Annual Operation Cost Conventional Exhaust Dyeing 100% Cotton (19 b e c k s ) 193,050 lbs ./week or 9 , 6 5 2 , 5 0 0 lbs./annum $256,360
$272,000

Cold Dyeing R e a c t i v e s on Cotton Pad/Batch/2 Bern. Wash-of f Stands

Production ( 1 20 h r . wk/ 50 wks ./annum
193,050 lbs ./week

or 9 ,652,500 lbs ./annum

Labor Costs

$79,560

Fuel Costs ( E x t r a Drying)

i ater
COS

ts

$ 8,700

$ 98,500

Dye Costs
(Varies, see Table 111)
,

Chemical C o s t s

Salt Alkali

0 $19,112 $207,672

$337,840 82,820

$1,047,520

Table 3 I -I I . '

Capital Investment

[ 30 1

c o s t ConmarisonofPad-BatchwithBecks CostComparisonofPad-BatchwithBecks Pad BatchDyeingSystem: Dye Pad f o rK n i t s 2 Beam Wash-off Stands I n s t a l l a t i o n estimated t o be 30% ( i n c l u d e s pad e n t r y ,p a d d e r , 2 beam wash-off d y e / a l k a l i pump, 10 beams, r o t a t i o ns t a n d , c r a d l el e t - o f fs c r a y
$ 160,000

48,000

stands,
$ 208,000

ExliaustDyeing100%CottonOnly: 19 AtmosphericBecks 1 000 pounds c a p a c i t y e a c h $30,000 each Cost I n s t a l l a t i o ne s t i m a t e dt o

be 30%

$570 ,000 $171 ,000

$741,000

77
Table 3 .l-III

T y p i c a l Dye C o s tf o rP a d - B a t c hv st h e Color Powder Blue Dark Red B r i g h t Yellow B r i g h t Red BrightBlue L i g h t Blue Dark Green Navy

Same Dyes on

Becks [+/pound1

Pad-Batch
30 50 35

Beck-Dyed
40 63 50 75 70 58 70 53

48
55 37

46
30

All t h ea b o v ec o s t s are f o r d y e i n g o n l y ( f o r 100% c o t t o n ) , n o ti n c l u d i n gp r e p a r a t i o n . All of t h e .beck-dyed c o s t s are c o l dr e a c t i v e .I n cases where beck would the dye be d i r e c t , pad-batch would p r o b a b l yc o s t more. Beck dyeing w i l l probably c o s t less.

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Drimarine K

. Procion
Remazol

( Hoechs t

One key t os u c c e s s f u lu s e

.of t h es y s t e m

by t h ed y e r

is pH c o n t r o l .

While

a l l r e s p e c t i v ed y e s
be i d e a l i n

are n o t a l l e q u a l l y s e n s i t i v e ,

a pH of10.5

t o 1 1.5 w i l l pH may
be

most cases f o r 1 2 hourbatching.

An i n c r e a s ei n

n e c e s s a r yt oi n c r e a s er e a c t i o n

r a t e f o rs h o r tb a t c h

times ( 2 t o 4 h o u r s ) .
o fd y e i n gc e l l u l o s eh a s

Extensive work i n d e v e l o p i n g t h e been done by Cotton Incorporated

pad batchsystem

[27-301.

Some of t h ef o l l o w i n gi n f o r m a t i o n

was 'developedby

them i n a c t u a l p l a n t e x p e r i e n c e . p a db a t c hd y e i n gc o n s i s t so f :

Equipment f o r t h e
1

Padding unit

The p a d d i n gu n i ts h o u l dh a v et h en e c e s s a r yc o n t r o l sf o rh a n d l i n gt h et y p e

o ff a b r i ct h a t

i s t o be dyed on t h eu n i t .I n

case of k n i tf a b r i c s ,t h ep a d d e r

m u s th a v ea d q u a t eg u i d i n g ,d e c u r l i n ga n ds p r e a d i n ge q u i p m e n tt oh a n d l et h e knitin open width form. This w h i c ht e n dt oc u r l

is e s p e c i a l l yi m p o r t a n t
when l e n g t h w i s et e n s i o n

on s i n g l e k n i t

and warp The be

k n i tf a b r i c s

is a p p l i e d .

p a d d e rs h o u l da l s oh a v es u i t a b l ep r e s s u r ec o n t r o l st oa l l o wt h en i pt o c o n t r o l l e dc o n s i s t e n t l y . A n o t h e rd e s i r a b l ef e a t u r e
A d e f l e c t i o nr o l lp a d d e r

may be advantageous.

is a small dyetrough.This
amount of

is i m p o r t a n tt oa c h i e v e
" t a i l i n g " , and a l s o t o from beginning t o

good dye l i q u o rt u r n o v e r ,t om i n i m i z et h e

a v o i dr e a c t i v ed y eh y d r o l y s i sw h i c hm i g h tp r o d u c es h a d i n g

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t h ef a b r i cr u n .

A dye trough

of t e ng a l l o nc a p a c i t yo r

less i s u s u a l l y

recommended. thebatcherunit
,

A d e q u a t es p e e dc o n t r o l sw h i c hc o n t r o lt h ep a d d e ra n ds y n c h r o n i z e

are a b s o l u t e l y n e c e s s a r y . a q u a l i t yd y e i n g ,u n i f o r mf r o ms i d et os i d ea n d
The f a b r i cs h o u l d end t o

I no r d e rt oo b t a i n

e n d ,t h ef a b r i c

must be u n i f o r m l yp r e p a r e d .

be scoured

and/orbleachedwith

a r e s i d u a l p of 7 o r s l i g h t l y H

less.

I t s h o u l dc o n t a i n

no r e s i d u a l a l k a l i , s t a r c h , k n i t t i n g
w i l l interferewith

o i l s o ra n yo t h e rf o r e i g ns u b s t a n c e

which

the e v e n n e s so fa b s o r b e n c yo rt h es u b s e q u e n tc o l o r f a s t n e s s

o ft h ef a b r i c .

The f a b r i c s must w e t o u tr a p i d l y

and uniformly must and make up dye

be

uniformlypreparedanddried.

I t is a d v a n t a g e o u st o

lots of

f a b r i c s which were p r e p a r e d t o g e t h e r t o a v o i d p o s s i b l e s h a d e v a r i a t i o n w i t h i n t h ed y el o t . Pad b a t c hd y e i n gg i v e s s t y l e s .F o re x a m p l e ,f a b r i c s much l o w e rd e f e c tl e v e l st h a nr o p ed y e i n g of v a r y i n g h i c k n e s s u c h t s on many

as 100% rayon jacquard

by

t a b l e c l o t h s are d i f f i c u l t t o p r o c e s s i n r o p e exhaustmethods on b e c k s u s i n g d i r e c t d y e s .

f o r mw i t h o u ts t r e a k i n gi fd y e d

The b e a u t yo ft h ep a db a t c hs y s t e mu s i n gt h eh i g hr e a c t i v i t yd y e s

is t h a t

a g r e a td e a lo ft h ed y ef i x e si n

30 m i n u t e s ,a n dt h ed i f f e r e n c ei nd e p t h

betweenonehourandeighthours

is n e g l i g i b l e i n

many shades.This

is one

r e a s o nf o rt h eu n u s u a ld e g r e eo fs h a d er e l i a b i l i t ya n d t h ef a b r i cn e a rt h ec o r e of t h et a k e - u pr o l l

i s importantbecause
on and l a s t

is o b v i o u s l yf i r s t
layers.

o f f ,a n dh a sa c t u a l l yb a t c h e dl o n g e rt h a nt h eo u t e r Becauseofthe

low p h y s i c a la f f i n i t yo ft h e s ec o l dd y e i n gr e a c t i v e s ,t h e y
a padding

work e x t r e m e l y well f o r a l l c o n t i n u o u s o p e r a t i o n s t h a t i n c l u d e s e q u e n c e .C o l o ry i e l d( e x h a u s t i o na n df i x a t i o n )t e n dt o i n a l o n gl i q u o r , compared w i t hh i g ha f f i n i t yd y e s t u f f ss u c h

be lower when dyeing

as v a td y e s .
A

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w o r t h w h i l ei n c r e a s ei nf i x a t i o nc a n t h e t a b l e below i l l u s t r a t e s u s i n g group--in

be a c c o m p l i s h e di n

a s h o r t e rl i q u o r ,

as

a t y p i c a ld y e
22.

of t h e low s u b s t a n t i v i t y

t h i s case, CI ReactiveYellow

Liquor-to-goods
%

ratio

30:l
20% 265%

20:l 27% 170%

1O:l
40%

5:l 53% 38%

2l : 68%
7%

1 :1
73%
"

0.6: 1 75%
"

Dye f f ilx y d u le

color ased Incre v a l u eu s i n g

82%

1 : ratio

The a d v a n t a g e so ft h i sr a p i df i x a t i o na n ds t a b i l i t yo fs h a d e when compared t oo t h e r n o r m a lr o u t i n e methods. In j i g and beck dyeing, example, for the

are obvious

is t oc o n t i n u ed y e i n g ,s h a d i n gi fn e c e s s a r y ,

until the c o r r e c t

c o l o r is o b t a i n e d .

Dyehouse o p e r a t o r sa r es e e nc o n s t a n t l yc u t t i n gs w a t c h e s when t h ed y e r
is s a t i s f i e dw i t ht h ec o l o r ,

o f f the goods f o ri n s p e c t i o n .E v e n

i t may be t h a t a l l f i x a b l ec o l o rh a sn o tr e a c t e dw i t ht h ec l o t h ,

so t h a te a c h are i n e v i t a b l e .
With

batch must

be t r e a t e di n d i v i d u a l l y ,

a n ds h a d ev a r i a t i o n s

pad batch,however,experiencehas

shown t h a ti fp a d d i n ga n db a t c h i n g

temperatures are p r o p e r l yc o n t r o l l e d ,r e p r o d u c i b i l i t yo fs h a d e outs tanding. There is s t i l l a n o t h e rb e n e f i to ft h i sr a p i df i x a t i o n . p o i n tp e r h a p s ,a n de a s i l yo v e r l o o k e d ,b u tt h e r e from l a bt op r o d u c t i o ns h a d e s .

is

I t is a minor

is a l m o s t 100% r e p r o d u c i b i l i t y
may be home d e s i g n ,b u t

The pad batchsystem

i t must f e a t u r ea c c u r a t ei nm i x i n ga n dm e t e r i n g .

T o tanks h o l dd y e s t u f fa n d w
a

alkalisolutions

which are f e d t o The mix

a mix and d i s p e n s i n g mechanismwith a pump t ot h e

pad u n i t .

p r o p o r t i o n i n gd e v i c e .

is t h e nf e dv i a

By

employing a h o l l o wd i s p e n s e r ,

i t i s p o s s i b l et ok e e pt h ep a s s a g et h r o u g hw h i c h

the f a b r i cp a s s e s

less than inch one wide. This keeps the

volume of

liquor

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very low, a b o u te i g h tg a l l o n so r
so t h a t dyedecomposition

less a n di n s u r e st h er a p i dt u r n o v e r a minimum.

of l i q u o r

i s k e p tt o

T h i s i s , of c o u r s e ,i m p o r t a n t
the s t a b i l i t y of

b e c a u s ea d d i n gt h ea l k a l it oi n c r e a s er e a c t i v i t ya l s oa f f e c t s t h ei q u o r . l
(See F i g u r e 3.1-2.)

I nw o r k i n gw i t hp l a n tp r o d u c t i o n

pad b a t c h u n i t s , t h e f o l l o w i n g f o u r

p o i n tc h e c k l i s th a sb e e nh e l p f u li na v o i d i n gp r o b l e m s :
1.

Keep good a l k a l i c o n t r o l m e t e r i n gt e c h n i q u e s .

by i n s u r i n ga d e q u a t em i x i n ga n d / o r

2.

A d j u s te x h a u s td y er e c i p e sf o rp a db a t c h d a t a on l i q u o rr a t i o s . r a t i os h o r t ,a n dt h e Keep the immersion

by k e e p i n g a c c u r a t e
long, t h el i q u o r

volume low i n the pad. p a db a t c hr e l i a b i l i t yh a s

3.

Have good p r e p a r a t i o n .A c t u a l l y , reachedthepointwhere

it can be used as a check on t h e i t can

preparation. f omething oesn't ook ight, ost ften Is d l r m o be t r a c e d t o m i s t a k e s i n p r e p a r a t i o n .

4 .

Keep good t e m p e r a t u r e c o n t r o l , e s p r c i a l l y a v o i d d y e i n g h o t

f a b r i cf r e s h

from p r e p a r a t i o n .

Feed c o l df a b r i ct ot h ep a do r During very weather, hot

keep

e l s e t h et e m p e r a t u r e
t h e mix c o o lw i t h

w i l l rise.

a c o o l i n g water j a c k e t o r

use ice i n t h e

mix.

S i n c e many mills t h a th a v ea g r e e m e n t sw i t hm u n i c i p a l on some formulabased of t h e e f f l u e n t , t h e on t h ec o n t e n t

sewagesystemspay

of BOD, COD o ro t h e ru n d e s i r a b l ec o n t e n t s

padbatchmethodemployingcoldreactives

is a l s o
do n o t

a t t r a c t i v e from t h ep o l l u t i o ns o u r c ea b a t e m e n ts t a n d p o i n t .R e a c t i v e s r e q u i r er e d u c i n go ro x i d i z i n ga g e n t s , r e q u i r eu s e of massiveamountsof
as do v a t so rs u l f u r s .R e a c t i v ed y e s

s a l t when employed i n b e c k s , b u t i n t h e
no s a l t a t a l l .

pad

batch method, c o l d r e a c t i v e s r e q u i r e
"

SMITH/B-TC.0

5-33586.0

CHAP-3.0

18/08/86 08.23.56

PAGE 13

The useof

chemical s p e c i a l t i e ss u c ha sl u b r i c a n t s ,l e v e l i n ga g e n t s ,

a n t i m i g r a n t s ,f i x a t i v e s ,d e f o a m e r sa n do t h e rs p e c i a l t i e s dyeing i s u s u a l l yn o tr e q u i r e d . washing-off.
S m a l l amountsofdetergent

by the pad ba,tch

are u s e di n

In summary, e x c e l l e n tr e s u l t sh a v eb e e no b t a i n e d
( c o l d )s y s t e mu t i l i z i n gh i g hr e a c t i v i t yd y e s . benefits :
1.

w i t h thepadbatch

Dyers have experienced

many

Low c a p i t a l o u t l a y
Low e n e r g y r e q u i r e m e n t s

2.

3.
4.

High p r o d u c t i o n s p e e d Reduced l a b o rr e q u i r e m e n t High c o l o r y i e l d O u t s t a n d i n gr e p r o d u c i b i l i t y E x c e l l e n tp e n e t r a t i o n ,a n dl e v e l i n gc h a r a c t e r i s t i c s R a p i df i x a t i o n S u b s t a n t i a lo v e r a l lc o s ts a v i n g s( d y e s ,c h e m i c a l s ,l a b o r , water, etc. 1 R e d u c t i o ni n

BOD, COD and p p r o b l e m s i n e f f l u e n t . H

5.

6.
7.
8.

9.

10.

A t t h e i ri n c e p t i o ni n1 9 5 6 ,f i b e rr e a c t i v e s

were n o t e df o rt h e i r

e x c e p t i o n a l l yb r i g h ts h a d e s . The shaderange

However, t h e a n g e a s n c r e a s e d r a m a t i c a l l y . r h i d muted t o n e s aimed a t s h a d e s t h a t direct,sulfur and vatdyes.

now i n c l u d e s new dyesof domain of

p r e v i o u s l y were c o n s i d e r e dt h e Reactiveshavegiven

a good account o ft h e m s e l v e si nt e r m so ff a s t n e s sa n d

economy a g a i n s t t r a d i t i o n a l b r i g h ti n d e e d .

classes of d y e s ,a n df u t u r ep r o s p e c t sa p p e a rv e r y