Inovation in Dyeng- This

Innovations in Innovations in DyeingDyeing

Mr. Thomas Mende

IFC International Conference March 2005

We are your experienced partner!

Dyes

Machinery

Chemicals

Water

Man Power

Energy

Dyeing Components

It has been estimated that in a standard cotton dyeing process

Bleaching, washing and rinsingUSESUSES

* 70% of the total time

* 80% of the water

* 90% of the energy

0

100

200

300

400

500

600

1:15 1:12 1:10 1:8 1:8 1:5

litre

s/kg

Total water per kg of fabric

Process water

Cooling water 30 °C

‘eco master

IImpact of Liquor Ratiompact of Liquor Ratio Cooling and Process WaterCooling and Process Water

Average Steam consumption per kg fabricBased (MCT)Reactive Dyeing

1:15 1:12 1:10 1:8 1:8 1:5

12.08

9.58

7.91

5.96

4.133.30

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00 ‘eco master’

WITH HEATRECOVERY

Impact of Liquor RatioImpact of Liquor Ratio Steam ConsumptionSteam Consumption

5.000 kg day Reactive Dyed Cotton = 1.650.000 kg/year fabricaverage salt used 60 grms/litre

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

SALT

1.980

1.485

990792

495

0

400

800

1.200

1.600

2.000

1:20 1:15 1:10 1:8 1:5

Liquor Ratio

To

nn

es

of

salt

pe

r ye

ar

Impact of Liquor RatioImpact of Liquor Ratio Chemical UsageChemical Usage

1:5 1:6 1:7 1:8 1:9-10 1:10-12 1:14-15

92.5%89.8% 87.0%

70.5%61.0%

53.2%49.0%

0%

20%

40%

60%

80%

100%

120%Reactive Dyeing 80°C

Matching Standard M&S = 0.8

Impact of Liquor RatioImpact of Liquor Ratio Right First TimeRight First Time

New Innovations in dyeing

• new funtions• RINSEtronic

RINSEtronicRINSEtronic

RINSEtronic automatically calculates the correct rinsing producedure to arrive at a bath residual

salt content of less than 1g/lonly necessary to enter the salt concentration & the

dept of shade in the dye program

Result :

• Shorter cycle time

• Lower water consumption

• Reduced effluent

RINSEtronicRINSEtronic

Old system RINSEtronic system

2 to 5% reactive dye stuff

variable

New Innovations in dyeing

• new funtions• RINSEtronic• pH-TRONIC / pH-FiT

pHpH--TRONICTRONICA system for pH controlled dyeing.

The function pH-TRONIC enables pH adjustment following the pH-gradient and at the same time setting the required machine temperature.The control system consists of a pH measuring point and a chemicals dosing unit, which incorporates a dosing valve for linkage to an existing pressure

ring main or alternatively equipped with appropriate dosing pumps.

Result :

• Higher First Time Right rate

• Easy handle of pH

• New / different dye procedure (especially in PA dyeing)

• pH measure and regulating system for pH controlled dyeing

• Stationary or mobile• Re-cooler

pHpH--TRONICTRONIC

pHpH--FiTFiTA system for pH controlled dyeing with a fully automated

cleaning and calibration of the pH-electrodes.The modern pH-FiT Fuzzy-integrated-Technology enables pH adjustment

following the pH-gradient and at the same time setting the required machine temperature.

The control system consists of a pH measuring point and a chemicals dosing unit, which incorporates a dosing valve for linkage to an existing pressure

ring main or alternatively equipped with appropriate dosing pumps.

Result :

• Higher First Time Right rate

• Easy handle of pH

• no operator needed for cleaning and calibration of the probes

• New / different dye procedure (especially in PA dyeing)

• pH measure and regulating system for pH controlled dyeing

• Fully automated calibration of the probes• Stationary or mobile• Re-coolerDeveloped by DyStar, SETEX and Thies

pHpH--FiTFiT

New Innovations in dyeing

• New funtions• RINSEtronic• pH-TRONIC / pH-FiT

• ECD - Electrochemical Dyeing of VAT

Comparison of Dyeing Processes

A) Standard Vat Dyeing Process B) Indirect Electrochemical Dyeing Process

Dyebath

dyedfibre

Dyestuff(oxidised)

Dyestuff(reduced)

e -

Reducingagent

Saltwastewater

Dyebath

Dyestuff(oxidised)

Dyestuff(reduced)

dyedfibre

Cathode

e -

Mediator (red.)

Mediator (ox.)

Fe 2+

Fe 3+

Developed by DyStar (formerly BASF)

Electrochemical Dyeing with Indanthren® DyesDyeing Curve 2 (All-in-Process)

Redox potential[mV]

Temperature[°C]

Cell current[A]

20 °C

-200 mV

60 °C

Time

Dyeing phase IDyestuff reduction

Dyeing phase IILevelling(equilibrium of exhaustion)

Fillingtheapparatus

45 A

9 A

Addition ofdyestuff

Leuco potential of the dyes

-930 mV

-920 mV

Controlrange

Developed by DyStar (formerly BASF)

Electrochemical Dyeing ProcessScheme: Package dyeing range

dye bathregenerated

dyestuff

dyeing rangeelec-trolysiscell

Electric*supply

liquorused

filtration

dyestuff waste

measurement of redox potential

Developed by DyStar (formerly BASF)

Electrochemical Dyeing Process

Consumption of Process Chemicals in an Indanthren® Exhaust Dyeing Process: IN Process, 100 kg CO, LR 10:1

EC-Reduction 0.3 - 4% Dithionite 0.3% Dithionite 2% Dithionite 4%ReductionDepth of shade Conc. Amount Conc. Amount Conc. Amount Conc. Amount

DyeingMediator 13.6 g/l 2 050 g - - - - - -

Dithionite - - 3 g/l 3 000 g 5 g/l 5 000 g 8 g/l 8 000 g

Caustic soda 32 ml 2 100 g 14 ml 6 160 g 19 ml/l 8 360 g 24 ml/l 10 560 g

Reduct. clearingDithionite - - - - 2 g/l 2 000 g 2 g/l 2 000 g

Caustic soda - - - - 2 ml/l 880 g 2 ml/l 880 g

Total amount 4 140 g 9 160 g 16 240 g 21 440 g

Saving 55 % 75 % 80 %

Water in thedyeing process 150 l 1 000 l 2 000 l 2 000 l

Only process chemicals considered;Discharge in the EC technique approx. 15% of the liquor volume.

Savings in Chemicals and Water

Developed by DyStar (formerly BASF)

Electrochemical Dyeing Process

• Product savings

• Less chemicals with special safety requirements

• Maximum process reliability through control of the redox potential

• Existing dyeing machines can be retrofitted

• Unsurpased environmental compatibility

• Reduction of water and waste-water costs through recycling

• Waste-water limits easily achieved

• Better fastness properties

Advantages

Developed by DyStar (formerly BASF)

ecoeco--bloc quattrobloc quattro

New Innovations in dyeing

• New funtions• New dyeing machines

ecoeco--bloc X bloc X „eco bloc quattro“„eco bloc quattro“

Dye up to 4 colours at a time in one machineDye up to 4 colours at a time in one machine

• Kier combinations1 + 1 + 1 + 1 = 4 colours2 + 2 = 2 colours3 + 1 = 2 colours4 = 1 colour

• 4 or 6 packages per kier• „batch reduction“

Total capacity 11 to/batch

New Innovations in dyeing

• New funtions• New dyeing machines

developed by:

&

HTHT--Jigger TiroJigger Tiro

• Woven fabric

• All exhaust dyeing processes

• Fabrics with low length wise stretch

• Very light to very heavy qualities

• Special treatments (open width scouring)

• All substrates

• Crease sensitive fabrics

• Impermeable fabrics

• Varying batch sizes

• Large fabric widths

HTHT--Jigger Tiro (Application range)Jigger Tiro (Application range)

• Fabric tension: 5 to 70 kg/cm²• Speed: 10 to 150 m/min• Fabric width, max. 3800 mm• Roller width, max. 4000 mm• Roller diameter: 270 mm• Roller batch dia.: 1000 or 1230 mm (dependent on the type of m/c)• Fabric height: 365 or 475 mm (dependent on the type of m/c)

HTHT--Jigger Tiro (Technical details)Jigger Tiro (Technical details)

Technical Advantages:• A Fabric Rope Controller automatically calculates the r.p.m. ensuring exact fabric

speed and tension providing excellent dye penetration. Automatic sampling point selection.

• Direct drive of the main rollers by frequency controlled motors with brake current return provide a considerably shorter braking distance compared with hydraulic drives.

HTHT--Jigger Tiro (Technical advantages)Jigger Tiro (Technical advantages)

• Automatic dosing of dyes and auxiliaries depending on the fabric length passing through the bath provides excellent reproducibility.

• High efficiency external pump unit and heat exchanger ensure controlled and even flow throughout the system.

• Constant dyeing conditions in the economical trough for varying batch sizes(55-100% loading capacity; water meter required).

HTHT--Jigger Tiro (Technical advantages)Jigger Tiro (Technical advantages)

• Loading/unloading device for crease-free loading/unloading of the fabric (Option)

HTHT--Jigger Tiro (Further options)Jigger Tiro (Further options)

New Innovations in dyeing

• New funtions• New dyeing machines

ecoMasterecoMaster

• Multi Contact Dyeing

• CCR CCR Combined Cooling and Rising

• 100% Stock tank

• Power drain & fill

• Automatic filter

• Water meter

• Liquor Ratio 1:5

• pH FiT

• Analogue Dosing

• Analogue levels

• Vario chamber

• RINSE RINSE tronic

ecoMasterecoMasterFeaturesFeatures

Multi Contact Dyeing & rinsingusing dual nozzles

Liquor ratio 1:4.5 - 1:5

RINSEtronic –rinsing system reduces process time and water consumption

Winch speed up to 400 m/min

Liquor ratio reduced by new sump and pump configuration

Standard step filter

ecoMasterecoMaster

eco-soft PLUS ecoMaster

Process water (25°C. 60 °C) 46 litres 34.5 litresCooling water 0,00 0,00Effluent 44 litres 32 litresSteam 2.24 kg/kg 1.92 kg/kgElectrical Power 0.1 kW 0.12 kWTime 5.8 hrs 4.83 hrs

New Innovations in dyeing

• New funtions• New dyeing machines

soft TRD DS XLsoft TRD DS XL• Especially suiteable for surface

senstive and light weight fabrics

• Double rope design

• Liquor ratio starts from 1:8

• Fabric speed up to 600 m/min

• Operating temperature up to 140°C

• 1-4 chambers per machine. Option of chamber isolation and coupling of two machines

• Chamber configurations2 x 75 kg = 150 kg/tube2 x 100 kg = 200 kg/tube2 x 125 kg = 250 kg/tube2 x 150 kg = 300 kg/tube

soft TRD DS XLsoft TRD DS XL

• new internal chamber design ⇒ lower liquor ratio

• compact machine design ⇒ minimal floor space requirement

• short fabric circulation and ‚flooded‘ fabric transport ⇒ gentle handle of fabric

New Innovations in dyeing

• New funtions

Developed by:

&

LuftLuft--roto plusroto plus

• New dyeing machines

LuftLuft--roto plusroto plus

A joint development by Thies and DyStar

• Round machine ==> reasonable liquor ratio

• Rotating fabric chamber ==> smooth fabric transport

• Air drive ==> minimised mechanical stress==> improved opening and therefore better folding of

the fabric==> gentle plaiting into the fabric chamber==> flexible application

LuftLuft--roto plusroto plus

A joint development by Thies and DyStar

• 100% Stock tank ==> faster bath changes==> possibility of preparation of the next dye bath==> low set-up times

• CCR Function ==> cooling water used as rinse water ==> very good cleaning effect==> saving of rinse baths

• Rapid drain ==> pump operation during bath change==> time savingLuftLuft--roto plusroto plus

• New dyeing processesprovide access to

• New funtions• New dyeing machines

New Innovations in dyeing

Conventional processConventional process

Te mp.-time -curve

0

10

2030

40

50

6070

80

90

100

110120

130

140

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320

time in min.

Tem

p °C

LR 1:6LR 1:6 LR 1:6

A B C

A x g/l auxiliariesx g/l salt

B x % dyestuff

C x g/l Alkali

Consumption dataConsumption data

Consumption data:Process water: 50 - 60 l/kg Cooling water: 0,0 - 0,5 l/kgSteam: 4,5 - 5,5 kg/kg Electricity: 0,08 - 0,1 kWh/kg

Te mp.-time -curve

0

10

2030

40

50

6070

80

90

100

110120

130

140

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320

time in min.

Tem

p °C

LR 1:6LR 1:6 LR 1:6

A B C

Conventional process

Enhanced dyeing processEnhanced dyeing process

Te mp.-time -curve

0102030405060708090

100110120130140

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210

time in min.

Tem

p °C

LR 1:4,5 LR 1:3,7 LR 1:4,5

A B C

A x g/l auxiliaries

B x % dyestuff1/2 amount of salt

C x g/l Soda1/2 amount of salt

Consumption data:Process water: 28 - 35 l/kg Cooling water:1,4 - 1,8 l/kgSteam: 3,3 - 4,0 kg/kg Electricity: 0,16 - 0,22 kWh/kg

Developed by &

Te mp.-time -curve

0102030405060708090

100110120130140

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210

time in min.

Tem

p °C

LR 1:4,5 LR 1:3,7 LR 1:4,5

A B C

Enhanced dyeing process Consumption dataConsumption data

- 40 % no saving- 30 % no saving

Plant AutomationPlant Automationfor for

Fully or semi automated yarn dye houses Liquid chemical dispensing & supplyDye stuff dispensing and dissolvingBulk powder dispensing & deliveryDye house Management and MonitoringHeat recoveryWater recyling

• Volumetric dosing of Liquid Chemicals

• Modular extension 10, 20 .......

• Low level inlet

• Integrated manual dispensing option

• Low maintenance

Liquid ChemicalsLiquid Chemicals

Liquid ChemicalsLiquid Chemicals

• Option of varying capacities- 20 to 80 products

• Dust Extraction system

• One or more scales

• Automatic product retrieval

• Interface to OrgaTEX

Powder DyesPowder Dyes

CAPACITIES- 100, 200, 300, 600 litres

OPTIONS :- Hot water preparation station- Water blending valve

Powder DyesPowder Dyes

Weighing & Dissolving

Weighing

TIME TEMPERATURE CURVE

0

20

40

60

80

100

120

140

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320

Temp °C

Time in minutes

N S

•

737 XL Programmable Micro Processor

Controller

T 737 XLT 737 XL Programable Controller Programable Controller

OrgaTEXOrgaTEX Dye house Dye house -- Central Computer SystemCentral Computer System

Dye house Floor

Fabric / Yarn Store

Dye StoreN St

tt

N St

tt

Plant Main Frame(not part of our supply)

HUB

Dye house Office

ColourMatching

Dye StuffsPowder

Chemicals

Server

T 737

T 737

T 737

T 737

T 737T 737

LiquidChemicals

Agent for Australia

DKSH GroupMelbourne, Australia

Agent for New Zealand

Marinco, Chemcolour

Auckland, New Zealand