Polyester Microfibers:- Dyeing and Wet Processing

Microfiber

A synthetic fiber that is extremely soft, lightweight, breathable, durable and ultrafine. In fact, microfibers are two times finer than silk and one hundred times finer than a human hair. Microfiber is currently manufactured from acrylic, nylon, polyester and rayon.Ultra-microfibers on the market are even finer – some having thickness of just 1/200th the thickness of human hair!

Microfibres refer to staple fibres, or individual filaments within yarns, which have fineness less than 1 decitex ( 1 grams per 10,000 meters) and For any fiber to be classified as microfibre yarn, the weight per 10,000 metres of yarn (dtex) is divided by the number of filaments (f), the result must be below 1.
All about microfibers

Microfibers: Functional Beauty

Properties of Polyester Microfibers

1. Lightweight and flexible
2. 
   
   Good stability and shape retention
3. 
   
   Anti-wrinkle property
4. 
   
   Have a wicking ability that permits perspiration
5. 
   
   Comfortable to wear as they are more spongy
6. 
   
   Doesn't water stain - superior water repellency is available
7. 
   
   Woven or knitted into a very high quality fabric construction
8. 
   
   Formerly commenced as a polyester microfiber, today you can find nylon, rayon and acrylic microfibers too.
9. 
   
   Strong and durable, water repellent and wind resistant -so tightly woven, that the fabric can't be penetrated by wind, rain or cold
10. 
    
    Lightweight, resilient or resist wrinkling, have a comfortable array, preserve shape and resist pilling
11. 
    
    The positively charged microfibers draw dust; the tiny fibers are capable to enter the microscopic surface voids most materials
12. 
    
    Washable, dries quickly and also washable in at the water temperatures up to 200 degrees and their characteristics will remain intact.
13. 
    
    Electrostatic effect - Hair, lint and other dust particles are attracted and grabbed by the microfibers without lifting dust.
14. 
    
    The density of the material allowable it to grip six to eight times its weight in water hence high absorbing power capacity
15. 
    
    The attraction capability of the microfibers is so sound, even absorbs bacteria and germs - hence can be use as germ or bacteria free purpose
16. 
    
    The fabric consists of millions of small tiny conduits that carry oil and grease too.
17. 
    
    Benefits of microfibers
18. 
    
    Comfortable - very soft, texture like silk, lightweight
19. 
    
    Due to its fineness and superior fiber surface area making deep, rich and bright colors achievable
20. 
    
    Less "sweaty" in warm weather than usual synthetics
21. 
    
    Quickly cleanable - clean just with water
22. 
    
    Highly intense and shrink-resistant
23. 
    
    Presents insulation and breathability
24. 
    
    Change without help - to establish lovely drape
25. 
    
    Very fine - finer than the most precise silk
26. 
    
    More reusable for cleaning alternative - compared to other mops more efficient and long life

Dyeing of polyester Microfibers
Due to their fineness, the total surface area of microfibre yarn or fabric is far greater than ordinary fibres. Threfore

1.Due to its special structure ,micro fibers has much larger quantity of size ,oil agents and wax on warp yarns.

2.Since microfibres have very small interstitces, with consequent difficulties of size accessibility and duffusibility, desizing becomes quite difficult and costly.

3.Microfibres have greater absorption area resulting in a dyeing rate four times higher than that of normal, which can cause unlevelness in dyeing.

4.They also require more dyestuff than standard fibres to obtain the same depth of shade.
5.Larger external surface means an increase in number of threads exposed to light which, on destruction of dye, is expressed as lower light fastness rating.
6. Wash fastness and color fastness to rubbing is also poor.
7.Staple microfibres offer difficulty in carding.

The problems in wet processing of microfibers can be overcome by

1.Better knowledge about the size applied and optimum parameters during desizing operation.

To achieve satisfactory dyeing effects ,desizing and refining process must be done before dyeing and after desizing and refining , there should be no impurities left such as electrolyte, antistatic finishing agent , spin finishes and blot.

2.Pre-setting

Suitable pre setting conditions ( time ,temperature and tension) helps not only in stable dimensional stability ,softness but also better dyeing results.

3.Alkali weight reduction

Alkali weight reduction s to treat the fabric with concentrated alkali at high temperature.fber molecule hydrolyse under this condition and lose some weight with change in properties, thus space occurs between crossing points and rubbing resistance relative to slippage among yarns becomes small.Alkali weight reduction makes fabric soft, liveliness, limber and improved absorption.

2.Careful selection of the dyes.

Proper dye selection which are
1.Compatible
2.Having same exhaustion rates
3.Having high wash fastness properties.
4.Good migration and levelling properties
 eliminates problems regarding build-up and fastness properties.
Disperse dyes for polyester microfibers

3.Optimizing the dyebath conditions and dyeing cycle.


Optimised dyeing cycles can be worked out by controlling the temperature to account for the high rate of dyeing and to eliminate the risk of uneven dyeing.Chemicals and dyes to be added at, at least 10-20 deg.C lower temperature than normal polyester fiber dyeing. The additions of dyes must be progressive or devided at least into 4 parts. The heating rate must be slow from 40 deg C to 100 deg C. 10-20 min more holding time required at 130 deg C as compared to normal PES.


4.Proper selection of  Dyeing machinery.

The dyeing machine must have the required automation to fufil the requirements of microfiber dyeing such as microprocessor controlled dosing , proper and accurate heating rate control etc.


5.Proper selection of dyebath additives
such as
Levelling agents :- A strong levelling agent which shall start working at lower temperatures.
Dispersing agents :- Higher quantities of dispersing agents are needed because amount of dyes required are more to produce the desired depth.
Chelating agents:-
Anticreasing agents,Dyebath softners/Lubricants :- Because microfiber textiles are prone to creasing , therefore use off dyebath lubricants is must.

6.Proper aftertreatment of dyed goods.
Soaping :- In order to obtain satisfactory color effect , fabric should be soaped after dyeing .Soaping is the key process to achieve satisfactory dyeing results on polyester especially polyester / nylon microdenier fabric.


Reduction clear :-Good reduction clear process is needed to achieve satisfactory washing , rubbing and light fastness properties.
Washing :-Is required for neutralising and removing alkali after reduction clear treatment.
Softening, anti soil and antistatic treatment :-Because microdenier fiber easily stains and produces static charges, a hydrophilic ,antistatic and antisoil treatment besides softening is highly recommended to ensure fabric softness and comfortability.

Recommended Dyeing Cycle for polyester Microfibers

Dianix PLUS( Dystar) or Longsheng  is a new range of five compatible, level-dyeing dyes for reliable dyeing of medium and heavy shades, especially on microfiber and weight-reduced polyester, whether applied under mild alkaline conditions to control trimer, or under conventional acid conditions.
Dianix E-PLUS" for Pale Shades on Polyester Fabrics
Fashion application of polyester

Application of polyester Microfibres

Microfibers are most commonly found in polyester and nylon. Some rayon and acrylic micros are in production and available to consumers. Micros can be used alone or blended with conventional denier man-made fibers as well as with natural fibers such as cotton, wool, and silk.

In textiles

Microfibers are used in a variety of fabrics, but most commonly in dress and blouse weight garments. Suit jackets and bottom weights are becoming available. Look for micros in lingerie, rainwear, outdoor fleece and wind-resistant sportswear, as well as tents, sleeping bags, track and jogging suits. The strength of microfibers make them particularly adaptable to sueded or sandwashed finishes because of their extensive fiber surface area and the use of strong fibers like polyester and nylon. As a result, many microfibers simulate the appearance of sandwashed silk.

Other Main products for which microfiber are ideally suited:

• Microfiber Glass Cloth

• Duster/Multi-purpose Microfiber Cleaning Cloth

• Microfiber Scrubber

• Microfiber Kitchen Cloth

• Microfiber Optical & CD Cloth

• Microfiber Mops

• Microfiber Cleaning Sponge

• Microfiber Cleaning Cloths – Terry Cloths, Suede Cloths, Waffle-Weave Cloths

Microfiber Makes the Grade
http://www.tex.in/education/nextiles/fib/mic/mic.html
http://ygmfranchise.blogspot.com/2007/07/cleaning-tips-microfiber.html
http://www.microfibergreen.com/is-microfiber-green-product.html
http://www.norwexnow.com/microfiber%20science.html

 

Cotton Processing : Fiber to Fabric

COTTON, cool, soft, comfortable, the principal clothing fiber of the world. Its production is one of the major factors in world prosperity and economic stability.Cotton's popularity stems from the fiber's inherent benefits, such as tactile comfort (that is, a sensation of softness when touching cotton fabric), and an unsurpassed ability to accept and retain color. Cotton is a seasonless fiber--cool in the summer, insulating in the winter. It "breathes" and therefore keeps body moisture away from the skin. It launders beautifully.Its beauty and natural comfort make the world a better place. Can you imagine a world without cotton? It's often the first fiber we touch when we are born into the world… and it stays with us throughout our lives. Consumer demand clearly shows that people want cotton in their lives all year long because the comfort and strength that cotton provides is empowering.There is nothing fake about cotton. Cotton feels wonderful against your skin and we believe it is the healthiest of all fibers. Life can be hard, but cotton makes our lives easier. What would we do without cotton? Since cotton wrinkles, polyester was added to give it wash and wear properties for a busy world. In recent times, the consumer determined that polyester, although easier to care for, took away the cool from cotton and also added a "pilling" effect to cotton/polyester blends. Consumers now often request "100% Cotton".

cotton is known as for its friendly properties with environment and human body. Cotton is a natural fibre and donot have any hazardess effect as comparison to polyester.

Properties of the cotton
1.Cotton is entirely made up of cellulose.
2.It can also withstand high temperatures in water and tumble drying and remarkably can be bent as many as 50,000 times before breaking point.
3.It is soft and comfortable.
4.It absorbs perspiration quickly.
5.It has good colour retention.
6.It is also strong and durable.
7.It is very versatile, stable chemically, resistant to alkalis.
8.It is of moderate cost.
9.It is sunlight resistant. Handle is soft, cool to the touch.
10.Cotton has an incredible ability to absorb moisture up to 27 times its own weight in water.
Processing of Cotton
Textile – Fibre to Fabric Processing
Textile Raw Materials and Their Conversion Into Yarns; (The Study of the Raw Materials and the Technology of the Spinning Process) a Text-Book
1.Cultivation of cotton
How a cotton plant grows
2.Chemistry of cotton

Cotton is cellulose fiber. Cotton consists typically of 88-96% cellulose. A single molecule of cellulose consists of chain of millions of glucose molecules. Cellulose is natural polymer (C6H10O5)n. It is a polysaccharide. Glucose is a chemical compound in which C (carbon), H (hydrogen),and O (oxygen) are bounded together by covalent bonds (chemical bond).

physical and chemical properties of cotton
3.Ginning

The cotton gin is where cotton fiber is separated from the cotton seed.

Ginning and classing

Grades of cotton

Processability of cotton

Ginning process

The first step in the ginning process is when the cotton is vacuumed into tubes that carry it to a dryer to reduce moisture and improve the fiber quality. Then it runs through cleaning equipment to remove leaf trash, sticks and other foreign matter.

Ginning is accomplished by one of two methods. Cotton varieties with shorter staple or fiber length are ginned with saw gins. This process involves the use of circular saws that grip the fibers and pull them through narrow slots.
Cotton ginning Basics
Fiber quality aspects of cotton ginnning
Ginning machinery
Cotton ginning process video 1
cotton ginning video
4.Spinning
Mixing
Practice of Cotton Fibre Selection for Optimum Mixing
Cotton Mixing
Blow room
Process parameters in Blow Room
Carding
The blow room only opens the row material to flock whereas the card opens the flock into individual fibers. During this individualization process, coarse trash particles are removed in the licker-in zone and fine trash particles/ dust sucked away. The sheet of carded fibers is removed through a funnel into a loose rope like strand called a sliver.
PROCESS PARAMETERS IN CARDING
Combing
Combing process serves to improve the row material in production of medium, medium to fine and fine yarns. This in turn reflects into better yarn evenness, strength, cleanliness, smoothness and visual appearance. In the wool system, combed sliver is used to make worsted yarn, while cards sliver is used for woolen yarn. In cotton system, the term combed cotton applies to the yarn mad from combed sliver. The function of comber is:

• To eliminate pre-determine quantity of short fiber.
• To eliminate remaining impurities.
• To eliminate large proportion of naps.
• To form a sliver of maximum possible evenness.
Process parameters in combing
Drawing

The task of drawing process is to improve evenness over short, medium and especially long term level by straightening and paralyzing the fiber. In addition to this it also for blending of different fibers (Blending of Polyester / Cotton, Polyester / Viscose, Polyester / Wool Etc.) The drawing frame contains several pairs of rollers that rotate at successively faster speed. As the slivers pass through, they are further drawn out and lengthened, to the point where they may be five to six times as long as they were originally. In this process 4 to 8 carded or combed slivers are fed to the drafting arrangement.
Process parameters in Drawing
Roving

The main function of the roving is to attenuate the sliver. In this process draw frame sliver is fed to the drafting arrangement, which attenuate the sliver with a draft of between 5-20. The delivered strand is too thin to hold, which is strengthened by imparting twist immediately at the exit form the drafting arrangement. The twisted (rove) is finally wound on the bobbin, so that it is easy to transport to next process, stored and crelled on ring frame.
Process parameters in Speed frame
Ring Spinning
Spinning Machines (Machine Technology)
Air jet spinning
A spinning system in which yarn is made by wrapping fibers around a core stream of fibers using compressed air.
Air Jet Spinning of Cotton Yarns :- Read here
Compact Spinning
Ring spinning technology : Development in drafting system
open end spinning
Rotor spinning technology
PROCESS PARAMETER IN SPINNING
Production Technology and Applications of Nu-Torque™ Singles Ring Yarns
FAQ cotton spinning
5.Weaving
Basics of Weaving-1
Basics of Weaving -2
Basics of weaving-3
Basics of Weaving -4
The Weaving Book: Patterns and Ideas
Learning to Weave
 6.Knitting
A short history of knitting

Introduction to knitting
V-Bed machine technology
Circular machine technology
Warp knitting machine technology
V-Bed machine fabric structure and patterning
Circular knitting fabric structures and patterning
Yarn tension, cam forces and robbing back
Quality control in v-bed knitting
Graphical representation of warp knitted structures
Graphical representation of weft knitted structures
Quality control in circular knitting
Positive feeding on v-bed machines
Weft knitting quality control
Glossary
Advances in Knitting Technology

Knitting Technology: A Comprehensive Handbook and Practical Guide to Modern Day Principles and Practices
7.Dyeing and finishing
The dyeing of cotton in high-temperature dyeing machines (Technical circulars)
8.Applications : applications of cotton
10. All about cotton

Read About Cotton processing
1.Field to Fabric
2.Process of making cotton cloth
3.Process of.making Cotton Textiles step by step in brief
4. Cotton Textile Processing :-Sustainable solutions for a better future
5.Cotton manufacturing :-An article from 1900s
6.Story of cotton :- Step by step from seed to your wardrobe
7.Organic Cotton Manufacturing
8.Growing cotton : History and cultivation
9. Ring spinning Vs Compact spinning
10. Developments in Spinning
Manual: Sizing, Pretreatment, and Dyeing of Cellulosic Fibres
Dyeing of cellulosic fibres and related processesNew Spinning Systems (Manual of Textile Technology)

Jigger Dyeing Machines

About Jigger
Jigg or jigger dyeing machine is one of the oldest dyeing machine used for cloth dyeing operations. Jigger machine is suitable for dyeing of woven fabrics, up to boiling temperature without any creasing . Jigs exert considerable lengthwise tension on the fabric and are more suitable for the dyeing of woven than knitted fabrics. Since the fabric is handled in open-width, a jig is very suitable for fabrics which crease when dyed in rope form.
Some wovens are conveniently dyed on jigger are ,
a. Taffettas
b.Plain wovens
c.Satins
d.Poplins
e.Ducks
f.Suiting and Shirting material.
g.Sheetings etc.
but have limited application on fabrics which are tension sensitive such as crepes , flat crepes , knits , net fabrics and elastomeric warps etc.
Machine Description
The jigger machines have two main rollers which revolve on smooth bearings and are attached to with a suitable driving mechanism , which can be reversed when required. The fabric is wound on one of the main rollers and fed from the other. The fabric move from one roller to the other through the dye liquor trough located at the lower part of the machine . There are various arrangement of guide rollers at the bottom of liquor trough ,and during each passage the cloth passes around these guide rollers .
The concentrated dye liquor is usually introduced directly into the dyebath in two equal portions, which are added just before commencing the first and second ends. The liquor is agitated by the movement of the fabric through the dyebath. Several horizontal spray pipes are fitted across the full width of the trough in order to expedite fabric rinsing.
Live steam injected into the bottom of the trough through a perforated pipe across the width of the jig heats the liquor. Some modern jigs also have heat exchangers for indirect heating.
Covering the top of the jig minimizes the heat loss to the atmosphere, keeps the temperature uniform on all parts of the fabric and minimizes exposure of the liquor and the cloth to air. Minimizing exposure to air is important when using sulphur or vat dyes since these dyes can be oxidized by atmospheric oxygen.
A few meters of leading fabric, similar in construction to the cloth under process, is stitched to each end of the cloth batch , to allow the entire length of the fabric to pass through the dye bath during the dyeing process. When jig processing is completed, the fabric is run onto an A-frame via a nip or suction device to remove extraneous water during unloading.
Modern machines such as automatic and jumbo jiggers have full automation in drive , tension regulation and control , fabric speed and metering, smooth and jerk less stop and start , counters for number of turns , gradual and noiseless reversal, automatic temperature regulation and control etc.

Dyeing process on Jigger

The dyeing process on jigger is regarded as a series of intermittent padding operation followed by dwelling periods on the main roller , during which the dyeing action and diffusion takes place. The factors controlling the rate of dye absorption are:

1.The amount of interstitial dye liquor retained in the interstices of the fabric weave.

2.The exhaustion of the interstitial liquor in the dwell period between successive immersions.

3.The degree of interchange of liquor during one immersion (interchange factor).

In the dyeing on jigger machines the cloth revolves on two main rollers , The open-width fabric passes from one roller through the dyebath at the bottom of the machine and then onto a driven take-up roller on the other side. When all the fabric has passed through the bath, the direction is reversed . Each passage is called an end. Dyeing always involves an even number of ends. The dye bath has one or more guide rollers , around which the cloth travels , and during this immersion achieves the desired contact with the dye liquor. During this passage the fabric picks up adequate quantity of dye liquor , excess of which is drained out but still a good quantity is held in the fabric . During rotation of rollers this dye penetrates and diffuse into the fabric. The real dyeing takes place not in the dye liquor but when the cloth is on the rollers, since only a very small length of fabric is in the dyebath and major part is on the rollers . Therefore the speed of cloth during immersion in dye liquor has a very little effect on percentage of shade produced.

see video click here

Some critical problems related to the conventional jigger dyeing machines ( which are minimized in the modern day machines) The major problems are side-to-centre color variations, called listing, and lengthways color variations, called ending.

Other problems are

• Temperature control from side-to-side and end-to-end of the roll

• Tension control from end-to-end

• Constant speed control from end-to-end

• Prevention of creases

• Prevention of air

Limitations of jigger Dyeing

1.Jigs exert considerable lengthwise tension on the fabric and are more suitable for the dyeing of woven than knitted fabrics.

2.In textile preparation due to the swelling and dissolution of size, which makes the fabric slippery and unstable in roll form.

3The low liquor ratio makes washing-off difficult.

4.There is little mechanical action in a jig machine and it is less suitable where vigorous scouring is required before dyeing.

5.Moiré effects or water marks may arise on some acetate and nylon fabrics because of pressure flattening the structure of the rolled fabric.

New Developments in this Field

Click here

Read More About Jigger Dyeing
Jig Dyeing Machine
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Dyeing

HTHP Package Dyeing Machines

High Temperature Dyeing Machines (Guidance Note)
Package dyeing machines are the most widely used now a days for dyeing of almost all type of yarns ,due to economical ,automatic and accurate dyeing results. The term package dyeing usually denotes for dyeing of any type yarn wound on the compressible dye springs/perforated solid dyeing tubes or cones. Yarn dyeing in package form is done at high temperature and under high pressure ,with the packages mounted on hollow spindles .These spindles are fixed on the dyeing carriers ,which is inserted into the dyeing vessel after closing the lid of the machine ,the dyeing liquor is forced through the packages in two way pattern (inside to out and outside to in) and goes on circulating throughout the vessel and yarn. Heat is applied to the dye liquor to achieve the dyeing temperature, time –temperature and flow reversal are controlled through a programmer.

All operations from pre treatment to finishing can be performed in the same machine ,without taking out the material out of the machine.

A series of technical developments in the recent past has resulted into package dyeing machine being developed into a highly sophisticated dyeing equipment.

The main advantages of package dyeing over other yarn dyeing methods are

1.The material is dyed on cross wound packages ,therefore bigger unit weight( 1.2 kg -1.5 kg for cotton) in dyeing is possible. The bigger weight makes the process sequence from winding to end use economical due to less handling and less changeovers.

2.Economical dyeing due to lower liquor ratio, compact and enclosed dyeing vessels .different liquor ratio is possible in different process steps such as partial filling in washing and soaping and fully flooded in rinsing make the process economical.

3.More uniform dyeing is possible due to higher number of contacts at high and optimized flow rates .The automatic flow control through programmer in critical steps and depending upon the material permeability make the processing trouble free.

4.High temperature ,high pressure and high flow rates results into shorter dyeing cycles.

5.Due to complete automation ,the machines are less labor intensive.

6.Modern machines with partial loading spindles are more flexible for different size lots ,the air pad system allows to maintain the material to liquor ratio and automatic flow control system maintains the flow through the packages ,thus whether the machine is fully loaded ,partially loaded or half loaded ,the dyeing parameters remain the same and results into better reproducibility as well economical dyeing.

7.Bigger dye lots are possible by coupling or linking one ,two, three or even four similar machines. The machines after linking works as a single unit and same shade is produced as a single lot. The coupling allows to serve the bigger lots without going for such bigger machines .The use of coupled machines makes the market service more efficient.

8.Very less handling and damage to dyed substrate ,due to shorter dyeing cycles.

9.All operations from pretreatment to hydro extraction in single machine are possible.

10.The package dyeing machines are more versatile because almost all type of substrates can be dyed and almost all types of dyestuffs applications is possible.

11.The same machines can be used for multiple make ups such as yarn, fiber, tow ,tops, bumps and beams on suitable dyeing carriers.

12.Certain new developments and instrumentation allows to go to very high flow rates

( more than 50 ltrs/kg/minute) without channeling or damaging the yarns and shortening the dyeing cycles considerably. Most advanced machines are equipped with pH regulators and controllers and salt sensors to for achieving very reliable and reproducible results.

Main parts of the machines
1.Main kier or the main vat in which the actual dyeing is being carried out.
2.Expansion or addition tank
3.Stock or preparation tank
4.Main pump
5.Injector or dosing pump
6.Dyeing carrier
7.Sampling device
8.Back cooler in fully flooded models
9.Control panel
Working of Package Dyeing machines

The material to be dyed is wound on the dye springs, perforated plastic cheeses or steel cones and loaded in the carrier spindles ,which are compressed and bolted at the top to make a uniform and homogeneous dyeing coloumn. The liquor containing dyes chemical and auxilliaries is forced through with the help of pump, and circulated through the material from inside –out and is reversed periodically so that each and every part of the material get the same and uniform treatment. The dyeing cycle is controlled through a micro computer and different chemicals may be added through the injector pump or color kitchen at any stage of dyeing.

In case of fully flooded machines ,the liquor expands with the rise in temperature (approximately 5% volume increases from 30-130 degree centigrade temperature) is taken back in the expansion tank through a back cooler. This extra water is then again injected to the dyeing vessel through an injector pump. Expanded volume of the dye liquor is thus remains in continuous circulation in the system.

Any type of addition can be done to the machine through the injector pump, the quantity and time of injection can be controlled through the programmer.

In case of air pad machines ,the air above the liquor acts as a cushion ,which is compressed with the increase in liquor volume, the pressure is controlled by pre set pressure control valve .In air pad machines have an advantage ,that entire dye liquor participate in dyeing and dye exhaustion is perfect. In case some addition has to be done in air pad machines , if the machine temperature is less than 80 degrees ,the liquor is taken back by back transfer valve to addition tank ,and injected back to machine vessel. If the machine temperature is above 80 Degree then cooling has to be done to bring down the machine temperature.

Air pad technology is possible in all types of machines such as vertical kier, horizontal kier and tubular dyeing machines.

The material after dyeing is washed and finished properly in the same machine and taken out hydro extracted or pressure extracted in the same machine and dried subsequently.

Yarn Package Dyeing Machine Instruction :- Animated Video

The dyeing of cotton in high-temperature dyeing machines (Technical circulars)
Different type of Package Dyeing Machines are
1.Vertical Kier Dyeing Machines
2.Horizontal Kier Dyeing Machines
3.Tubular Dyeing Machines
The dyeing of viscose rayon with direct and vat dyestuffs in high-temperature dyeing machines (Technical circulars)

Vertical Kier Dyeing Machines

These machines have a vertical cylindrical dyeing kier, in which material loaded into carriers with vertical perforated spindles, is dyed .The machine could be fully flooded or air pad type .These are high pressure machines and suitable up to 1350C temperature dyeing.

Horizontal HTHP Dyeing Machines

These machines are similar to vertical type machines in which the cylindrical dyeing kier is in horizontal position. The dyeing carriers with vertical spindles are used in these machines, which are inserted into the machine via trolleys. These machines are erected at the ground level and hence do not need an overhead hoist as well as platform, thus making the dyehouse design and layout is simple .
See video here

Tubular HTHP Dyeing Machines

These machines may be of vertical or horizontal type ,and have one or many tubes acting as small dyeing vessels, each with a single individual spindle. The spindle is taken out of the tube ,loaded and then inserted back into it. These machines can be operated either fully loaded tubes or to partial loads by using dummies. Since all individual tubes in a machine are connected and serviced by a main pump, therefore it is also possible to operate as many tube as required and disconnecting others.

These machines can be erected at ground level and hence do not need a platform or hoist.

These machines are most flexible as for as the capacity variation is concerned ,without altering the material to liquor ratio.
Explore More
About Package Dyeing Machines Click Here
Dyeing Machine Controllers Click Here
Package Dyeing Machines Click Here 
Vat Dyeing in Package dyeing machines Click Here

Indigo Dyeing

Indigo is the primary color of blue jeans , it is an important dyestuff with unique shade of blue color.The dye gives a brilliant and eye catching blue color to the fabric. Indigo has a low affinity  for cotton ,therefore deep blue dyeings are only possible when and oxidation is done several times.The color partially penetrates the yarn , and imparts the surface blue color.The dye then fades gradually fades from the surface of the fabric naturally.

For Manufacturing process of Indigo click here

Natural Indigo

Indigo dye is an important dyestuff with a distinctive blue color. The natural dye comes from several species of plants.A variety of plants have provided indigo throughout history, but most natural indigo is obtained from plants in the genus Indigofera, which are native to the tropics. In temperate climates indigo can be obtained from woad (Isatis tinctoria) and dyer's knotweed (Polygonum tinctorum), although the Indigofera species yield more dye. The primary commercial indigo species in Asia was true indigo (Indigofera tinctoria, also known as Indigofera sumatrana). In Central and South America the two species Indigofera suffructicosa and Indigofera arrecta (Natal indigo) were the most important.

Properties of  Indigo

Indigo is an insoluble dye ,a dark blue crystalline powder, which has to be reduced with suitable reducing agents to make it soluble in water,Indigo works by a chemical reaction called oxidation reduction.Indigo does not dissolve in water. It must be reduced — i.e. the oxygen must be removed— in the presence of alkali by a reducing agent such as thiourea dioxide (thiox), sodium hydrosulfite, Zinc, or bacteria. Upon reduction, indigo becomes colorless and water soluble. In this state, indigo has a high affinity for cellulosic fibers and enters the open spaces of the fiber. The dyed fibers are then exposed to air, which oxidizes the dye molecule back to its insoluble form. The insoluble dye particles are trapped inside the fiber, coloring them permanently blue. Unlike most dyes, indigo forms a mechanical, not
chemical, bond.

A.Indigo is a dark blue crystalline powder that melts at 390°–392°C.
B.It is insoluble in water, alcohol, or ether but soluble in chloroform, nitrobenzene, or concentrated sulfuric acid.
C.The chemical structure of indigo corresponds to the formula C16H10N2O2.

 

Click for Complete Chemistry of Indigo

D.The naturally occurring substance is indican, which is colorless and soluble in water. Indican can easily be hydrolyzed to glucose and indoxyl.
E.Mild oxidation, such as exposure to air, converts indoxyl to indigo. 

F.Indigo is a frequency range of visible light, from 440 to 420 nanometers in wavelength, placing it between blue and violet.

Indigo dye

Indigo has despite many other blue dyestuffs kept his popularity. This by no doubt is achieved by the fact that Indigo has a number of properties which have in this combination not yet been achieved by other single dyestuffs.

The main properties are:


• Pleasant colour shade.


• Possibility to achieve by simple repeated dipping, deep marine blue shade.


• Possibility to dye cotton in cold dye bath.


• Competitive in price.

• Possibility to achieve an acceptable colour fastness and the exceptional advantage by repeated washing of fading colour, to keep the colour shade that always a clear, pleasant blue shade result.

Indigo Application
Three basic steps for indigo application are .

1.Dissolving the dye by reduction involving vatting and loosening up.

2.Dyeing from the vat.

3.Oxidising in the air.

Since indigo has a low affinity for cotton, deep blue dyeings are only obtained when dyeing and oxidising are repeated several times.

Dyeing Methods

Five major Indigo dyeing methods for the basic denim are

1- Indigo rope dyeing process


2- Indigo one sheet dye slashing

3- Indigo double sheet dyeing

4- Loop dye 1 for 6 (continuous dye slashing)

5- Loop dye 1for 6 with dyemer (continuous mercerization dyeing and sizing).

Indigo Dyeing on a 20 rope range 
Indigo Dyeing different systems
Indigo rope dyeing some important technical considerations
Dyeing with Indigo - Natural Fermentation Vat

The Blue Denim

Manufacturing Process Of Denim Enter Here
Manufacturing denims Click here
Denim Washing Process :-A step by step guide

New Developments In Indigo Dyeing

Improved system for denim dyeing Click Here
Indigogenius Denim Dyeing System click here


Read Articles on Indigo Denims
Indigo Dye facts Click here
All about developments of Indigo Click here
Garment Washing Techniques for cotton apparels Click here
A-comparative-study-of-different-stone-and-bio-stone-washing-of-denim Click here

Denim Finishes Click here
Bi-stretch denim manufacturing Click Here
Indigo Dyeing on a 20 rope range Click here
Modification on plain loom for Denim Click here
Notes on Yarn for Rope Dyeing in Denim Click Here
Denim Manufacturing Process- the presentation Click here

Proposed Inspection Process for Indigo Dyed Denim Click Here

Manufacturing Process of Denim Click here