NEX-GEN DYEING SYSTEM

Textiles is the highest water consumer industry compared to other industries. Many asian countries like China, India, Pakistan, Bangladesh, etc are experiencing a phenomenal growth in textiles. This has resulted in heavy demand of water. On the other hand, water scarcity is increasing and many governments are putting restrictions regarding effluents. Installation of reverse osmosis plants or microbial effluent treatment plants is becoming necessary. Because of this, the wet processing cost per kilogram of substrate is increasing and the competitiveness is at stake. To counter this, processors are looking for avoiding some steps or combining some processes not only to save water but also energy and time. To help this, Zytex (India) Pvt. Ltd has developed a novel process for dyeing of cotton knit and yarns. This process is especially suitable for dyeing medium to dark shades with reactive dyes. The main ingredients of this system are; A) Diwet Plus :- It is a non-ionic, non-foaming wetting agent. Because of its zero foaming nature, it is ideal product for soft flow and cheese dyeing machines. It is APEO free. B) Lubmax Ultra :- A polymeric anticreasing agent. Its non-ionic nature makes it compatible auxiliaries used in wet processing of textiles. We recommend to use it during NexGen dyeing of knit fabrics for avoiding crease marks. C) Polyclean SP :- It is the main ingredient of the system. This is a special polymer developed to clean cotton. It has ability to remove dirt, minerals and other impurities present in raw cotton and keep them in suspension form. It also exhibits excellent dispersing and leveling properties. The main features of the system are; a. It is a one bath two step process b. Shortens the process cycle c. Omits hash treatment such as boiling with caustic d. Saves Water, Time and Energy The process for dyeing cotton knits and yarns with Nex-Gen dyeing system is as follows;

In the first step, grey cotton material is treated with DIWET PLUS, LUBMAX and POLYCLEAN SP. The treatment is carried out at 600 C for 30 min. In this process, natural impurities present in cotton such as alkaline earth metals, heavy metals, dirt and hydrophobic materials are removed from cotton and kept in suspension form. The pH of the treatment is slightly acidic. In the second step, dyeing with reactive dyes is carried out in the same bath without draining. Before starting of dyeing, pH must be checked and adjusted as per requirement of the dyestuff. The dyeing is carried out in normal manner with salt and alkali additions. After completion of the dyeing, soaping and dye fixation is carried out as usual. Normal Process
120
Scouring

Nex Gen Process

Dyeing

100
Dyeing Pretreatment
Salt 2

80 Temp ( 0C)

Alkali in proportions

Dye Salt 2

Alkali in proportions

Hot Wash
Salt 1

60
Dye

Drain & Wash Neutralisation Off Cold Wash

Salt 1

40

Drain & Wash Off

20

0 0 20 40 60 80 90 100 120 130 140 160 180 200 220 240 260 Time (min.)

Process Step 1 : a. Diwet Plus b. Lubmax c. Polyclean SP LR 1:8 to 1:10 600 C 1 gm/l (Non-ionic wetting agent) 1 gm/l (Anti-creasing agent) 2 gms/l 30 min

Do not drain the bath! Step 2 : a. Reactive dyestuff b. Salt c. Alkali X gms/l (single or mixture of dyes) Y gms/l (as per requirement) Z gms/l (as per requirement)

Continue dyeing as per recommendations from dyestuff manufacturer. After completion of dyeing, drain, rinse, neutralize, rinse and soap. Let us discuss advantages of this system to processors. Let us take an example of a medium size unit producing 5 tons of knits/yarns per day with 2 tons medium to dark shades, 1 ton bleach and 2 tons light shades. Nex-Gen system is suitable for medium to dark shades. Normally the liquor ratio is 1:8. If the processor uses Nex-Gen system for dyeing his 2 tons material per day, he saves; a) Water equal to 2 drains i.e. 16000 liters per day, saving in cost and conserving environment. b) 16000 liters per day less effluent load on ETP, saves cost. c) Saving in steam required to heat 8000 liters water from 60 to 98 degrees, saves energy and cost. d) e) f) Saves time equal to 70 to 90 minutes per batch i.e. increase in productivity. 60 min less machine run, savings on electrical bill. Better softness than normal process, improved handle. The above benefits clearly show that Nex-Gen system is very much beneficial to processors for dyeing medium to dark shades on cotton knits and yarns. If this system is

further attached with processes to shorten after dyeing cycles, the whole process will result in a very substantial savings of water, energy and time. **************************************************