Remazol Ultra RGB

Remazol Ultra RGB
The new generation of

Reactive dyestuffs for deep shades
Remazol Ultra Yellow RGBN Remazol Ultra Orange RGB Remazol Ultra Red RGB Remazol Ultra Carmine RGB Remazol Navy RGB
Bio-data
Name: Roland Schamberger
Title: Dipl. Textile Engineer

Age: 37 years
1988-1990 Training in a Textile lab and Knitted fabric dyehouse in Germany 1992-1995 Study leading to Textile Engineer with focus on Environmental Technology in Textile Industry at Textile college in Mnchberg (Germany) 1995-1996 Project study on pollution of wastewater in German Printing Factory 1996-1997 Additional education for Quality- and Environmental Management at DEKRA Academy 1998-2001 Lab Manager and Deputy Dyehouse Manager in a German Dyehouse
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7Q3-3534sro.ppt/pf 28. August 2007 -2-
Bio-data
Since 2001
Technologist in Global Technical Marketing and Textile Solutions DyStar Textilfarben GmbH & Co KG at
Responsible for:
International Support of Reactive Dying in Exhaust Application New product launch phase of new Remazol dyes Technical Marketing of Remazol dyes Internal and External training for Reactive dyes in Exhaust Application
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SDC International Conference Mumbai 2007
Outline of Presentation
Economical selection for dark shades Remazol Ultra RGB dyes in Exhaust application Remazol Ultra RGB dyes in CPB and Continue application Fastnesses Conclusion
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Warm reactive dye technology
The Market for Reactive Dyes:

Levafix CA Levafix E/EA/EN/ Remazol Specialities Remazol Ultra RGB
Fastness Dyeing performance Total cost of production
Warm reactive dyes
Fastness Dyeing performance Total cost of production
Remazol Remazol A
Fastness Dyeing performance Dyes cost Total cost of production
Exhaust CPB Continuous
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The Remazol Ultra RGB dyes at a glance
1%
3%
6%
Remazol Ultra Yellow RGBN

Strong, low photochromic Yellow component for deep ternary shades with good fastness properties.
Remazol Ultra Orange RGB

Strong build-up, dull Orange for bordeaux, dark brown and olive shades. Dischargeable
Remazol Ultra Red RGB

Cost effective and tinctorially strong Red with excellent build-up behaviour for medium to deep shades. Perfect wash-off properties. Very homogenous dyeing behaviour in combination with Remazol Ultra Yellow RGBN and Navy RGB.
Remazol Ultra Carmine RGB

Tinctorial strong Red. Highest possible build-up for deepest red and brown shades. Outstanding wash-off properties. Dischargeable.
Remazol Navy RGB 150%

Cost effective Navy with very good build-up behaviour for medium to deep shades. Basis for colour constant recipes. Dischargeable.
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The Remazol Ultra RGB supplementary dyes
1%
3%
6%
Remazol Golden Yellow RGB conc.

Cost-effective yellow for trichromatic shades. Dischargeable.
Remazol Blue RGB

Blue component with higher lightfastness when small quantities of blue shading components are required. Dischargeable.
2%
4%
7%
Remazol Deep Black RGB

Economical strong build up Black with good Fastness properties. Dischargeable.
Remazol Deep Black GWF

Remazol Deep Black GWF combines flexibility in application with highest fastness performance. The new dischargeable Deep Black meets the most stringent fastness specifications to fulfils the highest retailer/brand and market requirements. It can be used in exhaust, CPB and in all continuous application processes. Dischargeable.
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Remazol Ultra RGB: Flexibility in shading

Ultra Yellow RGBN Ultra Orange RGB
Further components in the Remazol RGB range:

Ultra Red RGB
Navy RGB 150%
Remazol Golden Yellow RGB conc Remazol Red RGB Remazol Ultra Carmine RGB Remazol Blue RGB Remazol Deep Black RGB
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Remazol RGB: Economical selection for all deep ternary shades

Golden Yellow Orange Red Bordeaux Navy Dark Brown Forest Green Dark Olive
Remazol Ultra Yellow RGBN Remazol Ultra Orange RGB Remazol Ultra Red RGB Remazol Ultra Carmine RGB Remazol Navy RGB 150%
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x x x x x x
x x
x x
x x
x x x x
x x x
x
Development of Best Available Technology for reactive dyeing of cellulose fibres
High build up in exhaust application

Key to avoiding dye overload is to form the covalent bonds with the cellulose fibre at an applied percentage of dye where the fixation graph is steep. The rate of fixation levels off with saturation of the available sites in the fibre
Cellulose
fixation hydrolysis
Water
Dye
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7Q3-3534sro.ppt/pf 28. August 2007 - 10 -
Build up of Remazol UltraCarmine RGB and Remazol UltraRed RGB vs. C.I. Reactive Red 239
Remazol UltraRed RGB Remazol UltraCarmine RGB C.I. Reactive Red 239 (140% )
7 6
Colour intensity value
5 4 3 2 1 0 0 1 2 3 4 5
dye conc. [% ]
10
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Significant less dye is needed to achieve the required depth of shade

dye conc. [% ] 12 11 10 9 8 7 6 5 4 3 2 1 0 1/3 SD
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0.9 % 0.7 % 0,47% 2.5 % 1,24% 2,28% 4.0 %
>12%
dye conc. [% ] 10 9 8
C. I. Reactive Yellow 176 (133% ) Remazol UltraYellow RGBN Remazol Ultra Orange RGB
not achievable
C. I. Reactive Red 239 (140% ) Remazol Ultra Red RGB Remazol Ultra Carmine RGB
8.3%
7 6
6.0 %
5 4 3 2 1 0
1.9% 1.0% 0.7% 0.6% 1.3% 2.1% 3.8% 3.2%
1/1 SD
2/1 SD
1/3 SD
1/1 SD
2/1 SD
Best Available Technology - Exhaust

Significant less dye is needed to achieve the required shade
Dark Brown
Remazol Golden Yellow RGB conc. 1.7% Remazol UltraRed RGB 0.9% Remazol Navy RGB 150% 0.8%
- 47%
C. I. Reactive Yellow 176 (133%) C. I. Reactive Red 239 (140%) C. I. Reactive Black 005 (133%)
3.9% 1.5% 1.0%
total: 3.4%
total: 6.4%
Ultra RGB Technology
C.I. Reactive
% Dye required for Dark Brown shade exhaust application

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Cost
Remazol Ultra RGB

Due to high strength and build-up, significant less salt is needed Reduces costs in purchasing, warehousing and handling
Dark Brown
-40%
100 g/l salt
60 g/l salt
100 g/l salt
100 g/l salt
Remazol Ultra RGB

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Commodities
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Cost
Remazol RGB
The reduction of salt requirements leads to significant cost savings per year Reduce salt consumption of up to 30% at a LR of 10:1 with new Remazol Ultra RGB dyes
Example
Normal salt consumption of a dyehouse with commodity products 60 g/l salt:
Savings
Salt consumption with Remazol Ultra RGB 45 g/l salt:
10 t fabric/day 100,000 l water x g/l salt

240 working days/year =
6 t salt/day*
1,440 t salt/year*
4.5 t salt/day**
1,080 t salt/year**
1.5 t salt/day
360 t salt/year
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Exhaust application
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Remazol Ultra RGB: Flexible in exhaust application

Application process
Basic recipe:
Basic recipe
x % 1 g/l 1 g/l Remazol Ultra RGB Sera Lube M-CF Sera Wet C-NR
Standard process (e. g. Cotton knit)
Detailed Information see pattern card
Temperature rise (e. g. no dosing equipment)
Basic recipe:
x % 1 g/l 1 g/l
Remazol Ultra RGB Sera Lube M-CF Sera Wet C-NR
Detailed Information see pattern card Basic recipe: x 1 1 % g/l g/l Remazol Ultra RGB Sera Lube M-CF Sera Wet C-NR
Migration process (100% Viscose, yarn package)
Detailed Information see pattern card
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Homogeneous on-tone build-up

NaCl Dye 20 25 C M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 Soda ash 10 10 10 10 10 10 10 10 10 60 C
on-tone build-up
Remazol Ultra Yellow RGBN Remazol Ultra Red RGB Remazol Navy RGB 150%
Reactive Yellow S-3R Reactive Red S-2B Reactive Navy S-G
off-tone build-up
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Remazol Ultra RGB

Up to 25% reduction in dyeing time
Standard
competitor recommendation
Salt Auxiliaries 60C 10
Dyes
Mixed alkali
45' 80 min
time saving
Remazol Ultra RGB

DyStar recommendation homogeneous dye combination rapid process
30 min!
Salt Mixed Auxiliaries Dyes alkali 60C 10 45'
50 min
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Remazol Ultra RGB

Excellent wash-off properties can increase productivity
optical density at 525 nm
700 600 500 400 300 200 100 0 1st rinsing (50 C) neutralisation (50 C)
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4% Remazol UltraCarmine RGB C. I. Reactive Red 239
Saving:
1 soaping bath
1 2 3 4 5
Rinsing baths of bulk trials with Remazol UltraCarmine RGB
1st soaping bath (95 C)
2nd soaping bath (95 C)
rinsing (80 C)
rinsing cold
Remazol Ultra RGB

The reduced dyeing time leads to potential cost savings of high productivity
Benefits from reduced processing time per batch

Example
Production with commodities
3 batches *6 h 10';**5 h 40' Savings
Production with Remazol RGB 17 h/day** 1 h 30'/day
18 h 30'/day*
240 working days/year
4,440 h/year*
4,080 h/year**
360 h/year
360 h : 5 h 40'/per batch
63 batches more/year
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Total colour difference dE

delt aE 10%overf ill
Remazol Ultra Yellow RGBN Remazol Ultra Red RGB Remazol Navy RGB 150% NaCl Soda ash NaOH 50% Liquor ratio Procedure
% 1.25 % 1.56 % 0.67 g/ l 60.00 g/ l 5.00 ml/ l 1.7 1 : 10 60 C Isothermal
+Liq rat io -Liq rat io
1,50 1,00 0,50 0,00
10%underf ill 20%overf ill
+5 C
20%underf ill
-5 C
- salt
+ 15' - 15' +Soda ash
+ salt -Soda ash
delta E
1 0%overfill
C. I. Reactive Yellow 176 C. I. Reactive Red 239 C. I. Reactive Black 005 NaCl Soda ash NaOH 50% Liquor ratio Procedure
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% 2.5 % 2.2 % 1.5 g/ l 100.00 g/ l 5.00 ml/ l 2.0 1 : 10 60 C Isothermal
+Liq ratio -Liq ratio +5 C -5 C +1 5' -1 5'
1 ,50 1 ,00 0,50 0,00
1 0%underfill 20%overfill 20%underfill - salt +salt -Soda ash
+Soda ash
close
Excellent lab to bulk and pilot to bulk reproducibility

Remazol Ultra Yellow RGBN Remazol Ultra Red RGB Remazol Navy RGB 150% % % % 1.98 1.08 0.72 NaCl Soda ash Liquor ratio 70 g/ l 17 g/ l 1:8
Process
M achine
kg
Pass/ Fail [dE]

against control CM C 2 : 1
Sample
Thies EcoSoft
Salt/Auxiliarie s 60C 10 ' Dye Alkali
80 5 5
Control 0.4 0.2
10 '
60 '
Thies MiniSoft Thies MiniSoft
Alkali Salt/Auxiliarie s 60C Dye 25C 10 ' 10 ' 1C/min 60 '
Lab process
(Temp-rise Alkali 1 add. at 60C)
0.6
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Speed Security
Remazol RGB
"Right-First-Time" performance in exhaust dyeing can deliver significant cost savings of high productivity Increase the RFT with Remazol RGB up to 10%
Example
Production capacity with commodites Production capacity with Remazol RGB
Additional production
batches/day = x 200 kg/fabric =
3.0 batches/day
3.3 batches/day
0.3 batches/day 60 kg fabric/day 14.4 t fabric/year
600 kg fabric/day
144 t fabric/year*
* = with a one rope machine
660 kg fabric/day
158.4 t fabric/year*
* = with a one rope machine
x 240 working days/year =
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Continuous application
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Remazol Ultra RGB: Flexible in padding application

Application process
Basic recipe:
Basic recipe
x g/l 2 g/l Remazol Ultra RGB Sera Wet C-AS
Cold Pad Batch (CPB)
fabric
alkali dyestuff winding and dwelling Washing off
Alkali system according to climate conditions and/or preference
padding
Basic recipe:
Pad Dry Pad Steam (PDPS)
x g/l 10 g/l 2 g/l 5 - 10 g/l Chemical pad: 250 g/l 20 g/l 3-6 ml/l
Basic recipe: x g/l 10 g/l 2 g/l 5 - 10 g/l 20 g/l 3.5 14 ml/l
Remazol Ultra RGB Sera Gal M-IP Sera Wet C-AS Sera CON M-LU salt soda ash caustic soda 50%
Remazol Ultra RGB Sera Gal M-IP Sera Wet C-AS Sera CON M-LU soda ash caustic soda 50%
Econtrol
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Significant less dye is needed to achieve the required shade

Dark Brown
84.3 g/l
-39%
51.8 g/l
C. I. Reactive Yellow 176 (133%) C. I. Reactive Red 239 (140%) C. I. Reactive Black 005 (133%) 54.0 g/l 19.3 g/l 11.0 g/l Remazol Ultra Yellow RGBN Remazol UltraRed RGB Remazol Navy RGB 150% 22.0 g/l 22.0 g/l 7.8 g/l
C. I. Reactive
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Remazol Ultra RGB

Robustness in Cold Pad Batch

Standard: Remazol UltraYellow RGBN Remazol UltraRed RGB Remazol Navy RGB 150% 4 g/ l 24 g/ l 10 g/ l Silicate NaOH 50% batching time 50 m/ l 14 ml/ l 12 h
1
as standard but 16 h batching
2
as standard but 24 h batching
3
as standard but 17 ml/l NaOH 50%
4
as standard but 16 h batching but 17 ml/l NaOH 50%
delE delC delH 1 0.05 2 0.16 3 0.14 4 0.04 5 0.11 6 0.31 7 0.18 8 0.13 -0.01 0.03 0.06 0.10 0.02 0.09 0.23 0.09 0.03 0.05 0.06 0.03 0.05 0.01 0.02 0.05
5
as standard but 24 h batching and 17 ml/l NaOH 50% M&I TMTS EXH CEL
6
as standard but 20 ml/l NaOH 50%
7
as standard but 16 h batching and 20 ml/l NaOH 50%
8
as standard but 24 h batching and 20 ml/l NaOH 50%
Advantages of Remazol Ultra RGB in pad application Good lab to bulk reproducibility in cold pad-batch:
Microwave 8 min
Drying cabinet 30 min, 50C
Drying cabinet 10 min, 70C
Standard
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Fastness
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(1) (2) (3) (4)
Light fastness (B02) Perborate light fastness (M&S, C9A) Wash fastness (M&S C10A) Fastness to Chlorine 10 ppm
3.0% Remazol Ultra Yellow RGBN
(1) (2) (3) (4)

0.6% 2.4%
4-5 pass 4-5 4

2.4% 0.6%
(1) (2) (3) (4)

1.2% 1.8%
3-4 pass 3-4 4

0.6% 1.8% 0.6%
(1) (2) (3) (4)
4-5 pass 4-5 4

1.8% 1.2%
(1) (2) (3) (4)

1.8% 1.2%
3-4 pass 4 4
1.2% 1.2% 0.6%
(1) (2) (3) (4)
3-4 pass 4 3-4

0.6% 1.2% 1.2%
(1) (2) (3) (4)
4-5 pass 4-5 4-5

1.2% 1.8%
(1) (2) (3) (4)

2.4% 0.6%
3-4 pass 4 4
1.8% 0.6% 0.6%
(1) (2) (3) (4)
3-4 pass 4 4
1.2% 0.6% 1.2%
(1) (2) (3) (4)
3-4 pass 4 3-4

0.6% 0.6% 1.8%
(1) (2) (3) (4)
4-5 pass 4-5 4-5

0.6% 2.4%
(1) (2) (3) (4)
4 pass 4 4
2.4% 0.6%
(1) (2) (3) (4)
3-4 pass 4 4
1.8% 1.2%
(1) (2) (3) (4)
3-4 pass 4 4
1.2% 1.8%
(1) (2) (3) (4)
4 pass 4 4
0.6% 2.4%
(1) (2) (3) (4)
4-5 pass 4-5 4-5

3.0% Remazol UltraRed RGB
3.0% Remazol Navy RGB 150%
(1) (2) (3) (4)
4 pass 4 4
(1) (2) (3) (4)
4 pass 4 4
(1) (2) (3) (4)
4 pass 4 4
(1) (2) (3) (4)
4 pass 4 4
(1) (2) (3) (4)
4 pass 4-5 4-5
(1) (2) (3) (4)
4 pass 4-5 4
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Fastness comparison
Commodities
Yellow 176/Red 239/Black 005
Light fastness (B02) Perborate light fastness (M&S, C9A) Wash fastness (M&S, C10A) Fastness to chlorine 10 ppm
Remazol Ultra RGB

Ultra Yellow RGBN/Ultra Red RGB/Navy RGB 150%

1 1-2 2 2-3 3

3-4 3-4
4 4-5 5

M &S C9A pass pass pass pass pass pass fail fail fail fail fail fail fail fail fail fail fail fail fail fail fail 1 1-2 2 2-3 3

4-5 5 M &S C9A pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass
3-4 3-4
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Conclution
Benefits offered by Remazol Ultra RGB technology

Reduced costs
Less dyestuff
Less water
Cost
Less energy Reduced stock costs
Higher productivity
Speed
Shorter production cycles Right-First-Time performance Robustness
Standardisation limits
Shade reproducibility Standard fastness requirements Eco-compliance
Security
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Remazol Ultra RGB

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Remazol Ultra RGB

The new generation of

Name: Roland Schamberger

Title: Dipl. Textile Engineer

M&I TMTS EXH CEL

7Q3-3534sro.ppt/pf 28. August 2007 -2-

M&I TMTS EXH CEL

7Q3-3534sro.ppt/pf 28. August 2007 -3-

SDC International Conference Mumbai 2007

M&I TMTS EXH CEL

7Q3-3534sro.ppt/pf 28. August 2007 -4-

Warm reactive dye technology

The Market for Reactive Dyes:

Warm reactive dyes

Fastness Dyeing performance Total cost of production

Fastness Dyeing performance Dyes cost Total cost of production

Exhaust CPB Continuous

M&I TMTS EXH CEL

7Q3-3534sro.ppt/pf 28. August 2007 -5-

The Remazol Ultra RGB dyes at a glance

Remazol Ultra Yellow RGBN

Remazol Ultra Orange RGB

Remazol Ultra Red RGB

Remazol Ultra Carmine RGB

Remazol Navy RGB 150%

The Remazol Ultra RGB supplementary dyes

Remazol Golden Yellow RGB conc.

Remazol Blue RGB

Remazol Deep Black RGB

Remazol Deep Black GWF