PRESENTATION on WATER-FREE PROCESSING

INTRODUCTIONDyes are coloured organic compounds that are used

to impart colour to various substrates. Indigo is the oldest known dye was used by the

ancients , Egyptians to dye mummy cloths. Generally dye is done with the help of water.World demand for dyes and organic pigments

increase 5.1% per year to more than 14 billion in 2004.

DIFFERENT TYPES OF DYES• Direct dye• Reactive dye• Acid dye• Basic dye• Disperse dye• Vat dye • Sulphur dye• Azoic dye

SUBSTRATES

WATER CONSUMPTION(KG/KG OF FABRIC)

COTTON 250-350

WOOL 200-300

NYLON 125-150

RAYON 125-150

POLYSTER 100-200

ACRYLIC 100-200

WATER CONSUMPTION BY

TEXTILE INDUSTRY

TOTAL WATER CONSUMED DURING WET PROCESSINGPROCESS WATER CONSUMED

PERCENTAGEBLEACHING 38%

DYEING 16%

PRINTING 8%

BOILER 14%

OTHER USES 24%

METHODS OF DYEINGDISCONTINOUS DYEING : Dyeing ,

washing , rinsing are processed to be done in different bath

CONTINOUS DYEING : All processes are done in same bath

DYEING PROCESS1) Dissolving of the dye2) Adsorption of dye3) Diffusion/Absorption4) Migration of dye particles5) After treatment

DISADVANTAGES OF DYEING WITH WATER

In Textile industries largest quantity of aqueous waste are discharged from dyeing process with strong colours and high BOD.

Waste contains high level of toxic chemicals. More chemicals causes aquatic life in danger.High amount of water is used for dyeing processing

and there may be shortage of water in near future. Waste water is responsible for soil pollution and

water pollution.

WASTE WATER REMEDIESIt is based not only in colour removal , but also in the degradation of dye molecules .THERE ARE THREE METHODS Physical method Chemical method Biological method

WATER FREE DYEING The innovative water free dyeing

technology consumes absolutely no water use less energy and fewer chemicals reduces emissions into the air .

This dyeing process twice as fast as water based dyes.

WATER FREE DYEING TECHNIQUES

Dyeing with super critical CO2Plasma dyeingFoam dyeingSublimation and transfer printingMicrowave dyeingNano particle dyeing

DYEING WITH SUPERCRITICAL CO2

Using supercritical fluid CO2, polyester and other synthetics can be dyed with modified disperse dyes.

When carbon dioxide is heated to above 31°C and pressurized to 74 bar, it becomes supercritical, a state of matter that can be seen as an expanded liquid, or a heavily compressed gas.

DYEING WITH SUPERCRITICAL CO2

Key Advantages of Supercritical Dyeing

Elimination of water consumption Elimination of wastewater discharges Wastewater treatment process eliminated Elimination of drying and dryer effluent Reduction in energy consumption Approximately 95% of CO2 can be recycled Dyeing time significantly reduced

PLASMA DYEING METHOD

•Plasma dyeing is a very surface sensitive method.

•It is a revolutionary way to carry dye to fabric and fabric surfaces.

•It is so advanced that it not only colors the yarn, but also thousands of filaments in each piece of yarn, yielding rich, brilliant colors. Penetration is complete

•It produces superior results compared to sublimation printing and conventional dyeing, but that is just the beginning of its advantages.

Glow Discharge

Corona Discharge

Dielectric-Barrier Discharge

Atmospheric pressure plasma technique .

Type of plasma dyeing

PRINCIPLE OF PLASMA DYEING

• If a textile to be functionalized is placed in a reaction chamber with any gas and the plasma is then ignited, the generated particles interact with the surface of the textile.

• In this way the surface is specifically structured, chemically functionalized or even coated with nm-thin film depending on the type of gas.

ADVANTAGES OF PLASMA DYEING PLASMA dyeing technology reduces

detrimental impacts on the environment. The result is more beautiful colors. Substantially less water and chemicals

discharged. Maximum color durability Producing luxuriously brilliant color. Soil-resistant, flame-retardant, Plasma treatment modifies the fiber surface

rather than its interior

FOAM DYEING• In case of foam dyeing, the main dyeing element is

foam. For that’s this dyeing is called foam dyeing.• A fabric is padded with a foam formed from an

aqueous solution of a dyestuff, a foaming agent and a carrier for the dyestuff and the padded fabric is maintained at elevated temperatures to fix the dye.

HORIZONTAL PADDING MANGLE

MATERIAL REQUIRED FOR COMMON FOAM DYEING

oWhite fabricoReactive dyesoSoda ash(fixer)oSynthrapoloSqueeze bottles to hold dyes

Sublimation and Transfer Printing

Sublimation and Transfer Printing described as a waterless coloration technology in that heat is applied via press, heated roll or calendar to sublime the disperse dyes and drive color into the interior of the fiber.

IT is done by way of explanation the design is printed onto a special sheet of release paper using sublimation ink which is then heat pressed onto the garment.

At a very high temperature and pressure the ink forms a gas which then permanently dyes the polyester content of the fabric.

sublimation technology is almost exclusively a polyester specific solution.

Sublimation and Transfer Printing• It’s possible to transfer an image from a release paper and bond the chemistry (or foil) to the surface of

the cotton through a heat activated binder system or similar.

• Inkjet technologies have been used to simulate the surface appearance of woven fabrics including

jacquards and yarn dyed shirting, given the issues outlined.

• Monochrome ribbons contain a black ink panel the same size as each page being printed, while color

ribbons contain panels for each color.

KEY ADVANTAGES

• Primarily suited to t-shirt printing or for small areas of decoration;

• Sublimation prints offer a soft hand and greater potential for printing larger fields of color;

• Printing faster than dye sublimation, • consumables (ribbon and paper) are less expensive.

Microwave dyeing

•The dielectric property refers to the intrinsic electrical properties that affect the dyeing by dipolar rotation of the dye and influences the microwave field upon the dipoles.•This is a terrific method of dyeing small amounts of fabric in the microwave using ‘Procion dyes’.

HOW TO DYE YARN IN A MICROWAVE

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HOW TO DYE YARN IN A MICROWAVE

After microwave dyeing

Dyeing With Nanoparticles:• The way of Textile coloration by Nano-tech. is very fascinating

as no dyeing and finishing will take place, which means no toxic chemicals, waste water and would consume less energy and resources to produce.

• For the Pigments found in butterflies (melanin's etc.) can be produced by Nano-technology in only yellow, orange-yellow, red, black, and brown colors.

• Green, blue and violet color comes from layers of nanoparticles separated by layers of air.

• This nanolayer is in a pattern of mosaic tiles, where each tile of pattern has different structural features as well as tiny gap among them for light refraction.

• The thickness of the layers changes the color we see.

Dyeing With Nanoparticles(Cont.):• Teijin Fibers Limited of Japan; produces Morphotex®, a first

optical coloring fiber that mimics morpho butterfly wings, by using interference to produce color without pigments or dyes.

• The fabric is produced from 61 layers of polyester or nylon in

alternative way, with 70nm thickness, and laminated.

ADVANTAGES OF WATERFREE PROCESSING

a) Energy saving b) Dyeing time savingc) High production rated) Water savinge) Pollution free environmentf) Reduces the toxic chemicalsg) Capital savingh) Easy processing as compare to conventional processing.

WATER FREE PROCESSING TECHNIC USED BY FOLLOWING COMPANIES

1-DYECOO TEXTILE (NETHERLAND)2-YEH GROUP (BANGKOK)3-ADIDAS4-HUNTSMAN TEXTILE

*In march 2008,DyeCoo Textile Systems is the world's first supplier of industrial CO2 dyeing equipment and is a leading innovator in CO2 dyeing technology and processes.

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