IDCEC Course # 102821 Subject Code 5.8, WelfareAIA Course #000203 Provider #G391AIA Course #000203, Provider #G391

Dye Methods

© 2014The Carpet and Rug Institute

IDCEC approval 12/13/13 – 2/1/16

Registered Provider G391

The Carpet and Rug Institute is a Registered Provider with The American Institute of Architects Continuing Education Systems

This CEU is registered with the Interior Design Continuing Education Council (IDCEC) for continuing education creditsArchitects Continuing Education Systems.

Credit earned on completion of this program will be reported to CES Records for AIA members. Certificates of Completion for non-

(IDCEC) for continuing education credits. This credit will be accepted by the American Society of Interior Designers (ASID), International Interior Designers

AIA members are available on request.This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed

Association (IIDA) and Interior Designers of Canada (IDC). The content included is not deemed or construed to be an approval or endorsement by IDCEC of any materialit does not include content that may be deemed

or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, di ib i d l i i l d

or endorsement by IDCEC of any material or construction or any method or manner of handling, using, distributing or dealing in any material or product. Questions

l d ifi i l h d ddistributing or deal in any material or product. Questions related to specific materials, methods and services will be addressed at the conclusion

related to specific materials, methods and services should be directed to the instructor or provider. This program is registered for .1 CEU be add essed at t e co c us o

of this presentation.eg ste ed o . C U

(continuing education credit).”

Learning Objectives

At the end of this course, participants will be able to:At the end of this course, participants will be able to:■Distinguish between various types of dye methods■Explain the dyeing processes■Explain the dyeing processes ■ Identify the machines used for each method■Differentiate between pre dyed and post dyed yarn■Differentiate between pre-dyed and post-dyed yarn

processes■State the characteristics of each dye method■State the characteristics of each dye method

Color Creates Aesthetic Appealpp

Pre & Post Dyed Yarns

Pre-Dyed Yarns Post-Dyed YarnsPre Dyed YarnsBefore tufting

Post Dyed YarnsAfter tufting but before

backing/finishing

SOLUTION DYEING BECK DYEINGYARN DYEING PRINTINGYARN DYEINGMulticolor Yarn Dyeing Solid Color Yarn Dyeing

PRINTING

CONTINUOUS DYEING

Pre-dyed Yarn Processes

■Solution Dyeing■Solution Dyeing

■Yarn Dyeing

■Multicolor (Space) Dyeing

■Solid Color Yarn Dyeing

Solution Dyeing

■ Pre colored b man fact rer■ Pre-colored by manufacturer by introducing pigments into the molten polymer before extrusionextrusion.

■ Outstanding fade resistance and colorfastness

■ Used for a large percentage■ Used for a large percentage of commercial nylon, polypropylene and triexta

■ Colors limited to producer’s■ Colors limited to producer s palette.

Synthetic FibersExtrusion

Extrusion Process Diagram1. Blended polymers and1. Blended polymers and

colored pigments2. Spinnerettes3. Cooling tower4. Yarn take-up

And, once extruded, a fiber becomes a continuous filament.

Yarn Dyeing, Multicolor (Space) Dyeing( p ) y g

■Printing several colors onto a white or base dyed yarn■Printing several colors onto a white or base dyed yarn■When it’s tufted into carpet, flecks of multiple colors

appear at intervals in the carpetpp p■Types of space dyeing:■ Knit-de-knit■ Warp-sheet printing■ Continuous space dyeing

Yarn Dyeing: Multicolor (Space) Dyeing Examples( p ) y g p

Printed YarnWhite YarnPrint Rollers

or print heads

Printed YarnWhite Yarn

Space dyed yarn after heatsettingSpace dyed yarn after heatsetting

Knitted yarn tube printed on both sides, then deknitted

Characteristics of Multicolor (Space Dyeing)( p y g)

■ Produces a tweed effect which■ Produces a tweed effect which helps hide soiling

■ Aesthetics■ Color flexibility■ Approx 8 colors can be applied■ Approx. 8 colors can be applied.■ Used as an accent yarn■ More color punch and pop■ More color punch and pop■ Can coordinate with interior

furnishings like systems furniturefurnishings, like systems furniture and fabrics

Three Common Types of Solid Color Yarn Dyeingy g

Skein Pad Jet

Characteristics of Solid Color Yarn Dyeingy g

■Color flexibility■Color flexibility■Small dye lot capability■Lends itself to custom work■Lends itself to custom work

Solid Color Yarn Dyeing: Skein Dyeingy g

Skein Dyeing – Process of reeling yarn ontoSkein Dyeing Process of reeling yarn onto skeins and dyeing them in kettles

■ Used for nylon and wool■ Good for small and large lots of solid colors and custom colors

Solid Color Yarn Dyeing: Pad Dyeingy g

Pad DyeingPad Dyeing■ Process of applying dye liquor or paste to carpet or

knit tubingg■ Dye fixed by atmospheric steaming

Dye is added to knit tubing and then fixedtubing and then fixed by steaming to create a colored yarn.

Solid Color Yarn Dyeing: Jet Dyeingy g

Jet Dyeing with Knit-de-KnitJet Dyeing with Knit de Knit■ Process of using a sealed vat where the yarn (that has

been knitted into a sock in the knit-de-knit process) p )is dyed under heat and pressure

■ Provides excellent color saturation and uniformityy

Three Types of Post-Dyeing Methodsy g

■ Beck Dyeing

■ Printing

■ Continuous Dyeing■ Continuous Dyeing

Beck Dyeing

Beck Dyeing

■ Good color saturation and color uniformity

■ Excellent for custom colors

■ G d f ll d ti■ Good for small production runs

Digital and Jet Printing

■ All f i i l t f l■ Allows for precision placement of colors■ Enhances time to market for samples of new designs■ C d h d i■ Can accommodate short production runs

Continuous Dyeing

■ A high-speed conveyor operation feeds unbacked carpet (or greige goods) through a series of rollers

■ Dye is applied by foam or spray into the carpet fibers and then■ Dye is applied by foam or spray into the carpet fibers and then they are steamed and dried

■ Large dye lot capabilityg y p y■ Quick color changes possible■ Uses less water than beck dyeing■ Lower cost

Continuous Dyeing

1. Staging or preparation2 Pre-conditioning2. Pre-conditioning3. Dye Application4. Steamingg5. Washing6. Drying

In Summary

■Pre-Dyed Yarns are dyed before tufting.■Solution Dyeing■Solution Dyeing■Yarn Dyeing

■Multicolor Space Dyeing, Knit-de-knit, Warp-sheet and Continuous Space Dyeing

■Solid Color Yarn Dyeing, Skein, Pad and Jet

■Post Dyed Yarns are dyed after the tufting process■Post-Dyed Yarns are dyed after the tufting process but before backing and or finishing.■Beck Dyeing■Beck Dyeing■Printing: Rotary, Flat Bed, and Digital■Continuous Dyeing

For more information, visit carpet-rug.org or any carpet manufacturer’s website.

Bibliography

Aquafil USA, Inc., at http://www.aquafilusa.com, 2009“Carpet Basics,” The Carpet Site: An Online Consumers’ Guide to Carpet and Other Flooring Products,

http://www thecarpetsite com 2008http://www.thecarpetsite.com, 2008“Carpet Dye Methods and Pros,” The Carpet Buyers Handbook©, http://www.carpetbuyershandbook.com/carpet-

basics/dye-methods-and-professionals, 2008“Commercial Customers: Dyeing and Color Selection,” Carpet and Rug Institute at www.carpet-rug.org/commercial-

customers/selecting-the-right-carpet/dyeing-and-color-selection.cfm, 2009g g p y g ,CRI Model Specification for Commercial Carpet (downloadable pdf document) 2011 http://www.carpet-

rug.org/documents/Model_Specification_Commercial_Carpet.pdf CRI: The Carpet Primer, The Carpet and Rug Institute, 2002CRI: “Standard Commercial Test Methods,” 2008,“Dyeing Carpet by the Mill or Fiber Producer,” Bane-Clene® Corporation, http://www.baneclene.com/articles/carpet-

dyeing.html, 2007DyStar© Textilfarben at http://www1.dystar.com, 2007Floor Covering Weekly: The Industry’s Business News & Information Resource, http://floorcoveringweekly.com, g y y f , p g y ,

2012 Floor Focus Magazine, Floor Daily, http://www.floordaily.net/FloorFocus, 2012“Innovations Explained,” BASF: The Chemical Company, http://www.basf.com/group/corporate/en/innovation-

explained/index, 2009J&J Flooring Group, Images, 2013Shaw Industries, Contract Training Manual, 2011.Tandus | Centiva. Interview/information and Images. 2013

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IDCEC Course #102821Subject Code 5 8 Welfare

AIA Course #000203Provider #G391102821 Subject Code 5.8, WelfareProvider #G391102821