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YARN PROCESS ING

Yarn Processing

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All about textile yarn processing

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Page 1: Yarn Processing

YARN PROCESSING

Page 2: Yarn Processing

Customer Needs• Optimum whiteness and absorbency in

pretreatment.

• Excellent level dyeing properties.

• Batch to batch reproducibility.

• An excellent wash-off and Fastness properties.

• CSP change within acceptable limit.

• Easy rewinding & knitting

Page 3: Yarn Processing

Technological Development• Rapid dyeing system (flow rate, flow direction)

• Packaging system

• Low liquor approach (cost, effluent, water)

• Drying system (RF drying)

• Automation and handling tech.( steam, washing)

• Proper selection of chemicals and dyestuffs

• Auto dispensing system (for Chemicals and dyes)

Page 4: Yarn Processing

Yarn processing

Hank Package

Page 5: Yarn Processing

Winding

• Winding system

• Winding angle

• Package traverse and diameter

• Winding density

• Package concentricity

• No ribboning

Page 6: Yarn Processing

Winding and pressing densitiesFibre Wind density

(g/l)

Press density

(g/l)

Weight

(kg)

Cotton 320 - 400 400 - 440 1.0 – 1.6

Co/ PES 340 - 360 420 - 460 1.2 – 1.6

Viscose 320 - 360 380 - 420 1.0 – 1.4

Wool 320 - 360 400 - 480 1.2 – 1.6

Wool/PES 320 - 360 420 - 500 1.4 – 2.8

Acrylic 320 - 360 380 - 420 1.2 – 1.4

PES 360 - 380 420 - 480 1.2 – 1.6

PES Filament

380 - 400 450 - 500 1.5 – 4.0

Page 7: Yarn Processing

Parameter requirements HankΩ Convert cone to Hank

of uniform densityΩ Hank weight should be 2-5 kgΩ Open structureΩ Suitable for delicate

yarn e.g. Silk

PackageΩ Density profile:

Type of winding Package edgeΩ Geometry:

Type of tube Package faceΩ Precision winding on s.s

spring of cylindrical package with suitable density (pressed 10%) is most economic one

Page 8: Yarn Processing

Cleaning of Dyeing Machine

• Boiling out

• Basic cleaning

• Cleaning of heat exchanger

• Boiling out pressure drier

Page 9: Yarn Processing

Boiling out of Dyeing M/C

Caustic Soda (38 oBe) – 10-15 gms/lHydrose – 3 gplVat RW Liquid – 1gplRun for 30 min at boil

Oligomer Removal

Chemicals 100 Kg M/C 200 Kg M/C 500 Kgs M/C

Water (lit) 750 1500 3000

Caustic Soda (Kg) 10 20 40

Zycol BCL Liq(kgs) 2 4 8

Oligo EM Liq (Kgs) 4 8 16

Hydros 2 4 8

At Temp 110 -1300C for 4 to 16 hrs

Page 10: Yarn Processing

Boiling out of Pressure Dryer

Trisodium Phosphate 2 gpl

Vat RW Liquid 1- 2 gplTreat for 20 - 40 min, at 50

oC

Drain

Rinse

Cleaning of Heat Exchanger

Descaling agent 50 – 200 ml/l

orGreenacid New Liq 500 ml/lLeave for 2 – 12 hrs at 25 oC

Rinse

Page 11: Yarn Processing

Process Scouring – Bleaching (Mercerization – optional)

Dyeing OBA Finishing Drying

Rewinding

Page 12: Yarn Processing

Cabinet Type Hank Yarn Dyeing Machine

1. Overflow

2. Dye Addition Tank

3. Spare Set of Sticks

4. Temperature Controller

5. Timer

6. Auto Reverser

Page 13: Yarn Processing

Rotating Arm Type Hank Dyeing Machine

Higher winding out put due to entanglement-free yarn treatment.

Mechanical mixing and heating of bath without disturbing the yarn.

Can be coupled for maximum flexible operation.

Page 14: Yarn Processing

1. Reduced yarn handling.

2. High and uniform rates of liquor circulation, leading to level application of dyes.

3. Low liquor ratios, giving savings in water, effluent and energy.

4. High temperature dyeing is possible.

Package Dyeing Machine

Page 15: Yarn Processing

Common Dyeing Problems• Heavy foaming and pump cavitation• Un-level dyeing with coupled machines• Dye spots and marks• Elimination of oxygen – during vat dyeing• Package deformation and yarn abrasion• Pressure and lustre marks on inner yarn layers• Leakage in the package column• Spinning oils and waxes• In-out variation

Page 16: Yarn Processing

2oC/min

Caustic &Bleaching Chemicals

40 oC

60 min15 min

95 oCDeaerating &Chelating agent

Drain

15 min

Washing, Neutralisation & PeroxideKilling

Scouring – bleaching Process

Page 17: Yarn Processing

Scouring - Bleaching

• Caustic soda Flakes 1.5 - 2.0 %• Hydrogen peroxide 1.5 – 6%• Scouring cum wetting agent 0.5 -1.0 %• Stabilizer 1/4th – 1/8th H2O2

• Chelating agent 0.5 -1.0%• Deaerating agent 0.3 - 0.5 % Treat at 95°C for 30-45 min

Page 18: Yarn Processing

NeutralizationGreen acid New liq 1 – 2gpl

orGreenacid BCN liq. For 15 – 20 min

Peroxide KillingSet the fresh bath at 45 – 55°C and pH 6.0 – 7.0 with the

Following and run the bath for 10-15 min

Ultrox EPN Premium Liquid 0.5 – 1.2 gms/lit

or

Ultrox EPN Supreme Liquid 0.5 –1.0 gms/lit

Page 19: Yarn Processing

Bio Application

Cotton scouring

Scourenze SBWB Pdr. Scourenze CBE New Pdr

Silk degumming

Silkenz DGM liq. Silkenz ENZ Liq.

Wool softening Greasenz BSW Liq. Greasenz PWE New Liq.

Page 20: Yarn Processing

40 oC

55 oC

60 min15 min

95 oC

Washing, Neutralisation & Peroxide Killing

2oC/min

2oC/min

Bio-scouring Chemicals

Bleaching Chemicals

Drain

Bio-scour Process

Page 21: Yarn Processing

Bio-scour Process Kleenox WLF Conc. – 1 gpl Descour New – 0.6 gpl at 40 oC. Raise the Temperature to 55 ‘C.Run for 15 minutes.

Add Caustic -1.2 gpl, Zystab C- 0.25 gpl , Peroxide - 2.5 gpl.

Raise the Temperature to 95’C, hold 1hr.

Drain. Hot Wash ,Neutralisation and peroxide Killing.

Page 22: Yarn Processing

Bio-scour Process Kleenox WLF Conc. – 0.5 gpl Descour New – 0.5 gpl Scourenze CBE – 0.3 gpl at 40 oC. Raise the Temperature to 55 ‘C. Run for 15 minutes.

Add Caustic -1.2 gpl, Zystab C - 0.25 gpl , Peroxide - 2.5 gpl. Raise the Temperature to 95’C, hold for 1hr.

Drain. Hot Wash ,Neutralisation and peroxide Killing.

Page 23: Yarn Processing

Parameter Evaluation - Bleaching

• Whiteness Index

• Absorbency• CSP (Count * Breaking Strength)

• RKM (length of yarn at which it breaks by its own weight)

• Levelling

Page 24: Yarn Processing

Scouring of 100 % PES

Greenscour CP Liquid or Kleenox LXI paste 0.5 –

2.0 gpl Zywet PDG/ Kleenox BAS 0.3 –

1.0 gpl Temperature: 70-80 °C Treatment time: 10-15 min Hot drain or cool upto 60 oC and add

dye for single bath scouring- dyeing. Soda is optional depending upon impurities.

Page 25: Yarn Processing

Dyeing Curve for HE Reactive Dyeing on Cotton

100 oC

30 oC

After treatment60 oC

10 40 100 160

Time (min)

Dye

SaltAlkali DrainAux.

1 oC/min

Page 26: Yarn Processing

Cotton Dyeing

Zywet PDG 0.3 - 0.5 gpl

Zycol SNE/ Zycol PCSN B 1.0 – 2.0 gpl

Krisil RLA Liq 0.5 – 1.0 gpl

Reactive dye X %

Glauber’s Salt 30 – 60 gpl

Soda/ Caustic depending on shade

Process as per dye manufacturer.

Page 27: Yarn Processing

Washing off

Zycol PCSN

Zycol PCSN B

Zycol PRSK

Zycol SNE

Add 1- 3 gpl washing off agent

Add Soda to adjust pH 7.5 – 8.0 and boil for 15 – 20 min.

Page 28: Yarn Processing

Dye Fixing

Hifix NFI

Hifix NFI conc

Zyfix R

Zyfix ECO

Add dye fixing agent 2.0 - 3.0 %

Treat at pH 5 - 5.5 and 60 - 70°C for 20 min.

Page 29: Yarn Processing

Dye

Auxiliary

30 oC

130 oC

60 oC1 oC/min

2 oC/min

15

80 oC

85 145

Drain

Time (min)

Dyeing Curve for Polyester

Page 30: Yarn Processing

Polyester Dyeing Disperse dye X%

Dispa Hot 0.5 – 1.0 gpl

Krisil AB Liquid/

Krisil RK Liquid 0.3 – 1.0 gpl

Zycol BCL (100% textured PES) 0.5 – 2.0 gpl

Adjust pH to 4.5 - 5.0 with Dymax PI/ Greenacid New Liquid/ Dymax NDA, dye at 130oC for 45 - 60 min depending on shade.

Page 31: Yarn Processing

Reduction Clearing

Neutraclear RC Liquid 0.5 – 1.0 gms/lit

Dispa AST pdr 2.0 – 4.0 gms/lit

Treat at 70 - 80Oc for 15-20 mins

Page 32: Yarn Processing

Dyeing curve for Vat dyeing on Cotton

Aux

30 oC

Drain

2oC/min

60 oC

Dye

15 min 75 min

After treatment

Time

Page 33: Yarn Processing

Vat Dyeing on Cotton Dye X % Caustic Soda 5.0 – 12 gpl Sodium Hydrosulphite 3.0 – 9.0 gpl Krisil VL Extra 0.5 –1.0 gm/lit Dyeing Temperature 50- 600C Oxidation with Oxidant VS Pdr/ Zynec VS 0.3

gm/lit at 45 – 500C for 10 – 20 min. Soaping with Zyclean ITC

Page 34: Yarn Processing

Wool/ Silk Dyeing Set the dye bath at 50 - 60OC and pH 3.5 - 4.5

with acetic acid Dye X % Glauber's Salt 5.0 - 10 % Krisil SMK Liquid 1.0 - 2.0 % or Krisil SE Super liq. 0.4 – 0.75% Run for 10 min, Add pre-dissolved dyestuff

and raise the temperature to boil, run for 45 – 60 min. rinse and dye fix with Greenclear DM/ zyclean SNE

Page 35: Yarn Processing

Nylon Dyeing Krisil LPA Liquid 4.0 - 2.0 % Glacial Acetic acid 1.0 - 2.0 % boil for 20 - 30 mins. cool to 50- 60OC. Adjust pH to 6.0 with liquor ammonia and add. Krisil LAN Liquid/ 1.0 - 4.0 % Krisil SMK Liquid Run for 5-10 mins. Add pre-dissolved dyestuff, raise to 95oc and

hold for 60- 90 mins. Cool, rinse and fix with Hifix N6

Page 36: Yarn Processing

Fastness Test

Cotton PES Wool Silk Nylon

Water • • • •

Washing • • •

Crocking • • •

Chlorine •

Post-mercerisation •

Light • • • • •

Dry-cleaning • •

Sublimation •

Perspiration • • • •

Test Substrate

Page 37: Yarn Processing

Finishing Softeners

– Zylon CS Liquid – Ultima XT Plus– Innersof MW Liquid – Rosil MTS– Zylon NS– Inovasof VTS Delux liq.– Magma CI paste– Zylon SFC– Zylon CHMK Lubricants/ Antistat

– Lubril HDR Paste– Zylube SDC Liquid– Hydrostat BM Liquid– Hydrostat Liquid– Lubril VRL New Liquid

Page 38: Yarn Processing

WAX EMULSIONS

PE WAX HARD WAX HARD & SOFT WAX

Lubril PE`` Lubril SDC Lubril PG Liq Lubril WX Liq.Lubril HDPN

WAX EMULSIONS

Page 39: Yarn Processing

Fabshield UV- 50 Plus Liquid

• Prevent fabric from UV/ IR radiation.

• Applied on Polyester and its blend during dyeing.

Disperse dye X %

UV 50 Plus 2 – 3%

Krisil AB 0.5 – 1.0 gpl

Dispa Hot Liq. 0.5 – 1.0 gpl

At 130 oC for 30 to 60 min

Page 40: Yarn Processing

OBA for Full White Cellulosics Polyester Rosba BBN Conc. Pdr Rosba MS Liq. Rosba NBS Liq. Rosba MMO L

Liq Rosba VGS Liq. Rosba MO Liq.

Polyamide WoolRosba UNO Rosba WSNRosba NCO

AcrylicRosba OBA Liq.

Page 41: Yarn Processing

Hydro-Extractors

Centrifugal Hydro-Extractors Only unbound moisture comes out.

Reduce final drying time as well as drying efficiency

Page 42: Yarn Processing

Residual Moisture after Hydro-extraction

Material Moisture (%)

Cotton 50 - 60

PES Textured 8 - 10

PES (with softener) 28 - 32

Viscose 65 – 70

Wool 30 – 40

Linen 80 – 8

Polyamide 10 – 15

Acrylic 10 – 15

Page 43: Yarn Processing

Residual Moisture content for blend

Co/PES: 65/35

Co with residual M.C of 60 %

PES with residual M.C of 15 %

Residual M.C of Blend:

(65X60) + (35X 15)

100

= 44.25%

Page 44: Yarn Processing

Typical cycle time in Pressure dryerMaterial Drying Temp.

(oC)Drying cycle

(Min)

Cotton (Vat dyed) 120 - 140 60 - 70

Cotton (Reactive dyed)

100 - 120 60 - 90

Cotton (Bleached) 90 - 120 70 - 90

Wool 90 - 110 70 – 80

Wool/ PET 100 - 120 60 - 70

PET 100 - 120 20 – 30

PET/Co 110 - 130 50 - 60

Page 45: Yarn Processing

Hank Yarn Drying MachineContinuous Dryer suitable for 54", 72" and 90" hank length of various materials like Cotton, Wool, Silk etc.

The yarn is carried on stainless steel carrier rods and the heating media is steam or hot oil circulation.

The dryer is highly energy efficient. Variable airflow and machine speed.

Page 46: Yarn Processing

Can operate at maximum efficiency and dry yarns at low temperatures. (80 oC in the case of cotton).

The 'second generation' RF with 'intelligent vacuum' ensure very low drying temperatures (approximately 65 oC) and with smaller generators.

Package Yarn Drying Machine

Page 47: Yarn Processing

Right First Time Approach

• Process water quality• Selection of dyes/ auxiliary• Liquor ratio• Auxiliary dosage• Steam quality• Bleaching bath stability• Liquor Circulation• Winding parameters and

pressing density

• Temp (Process/ steam)• pH and Dwell time • Liquor circulation/ flow rate• Effective washing off• Residual peroxide killing• Proper neutralization• Number of contacts with

liquor

Page 48: Yarn Processing

Problems in ProcessingCSP down 1. Oxy-cellulose formation 2. Residual peroxide 3. Higher alkali/ peroxide 4. Over dryingShade variation 1. Poor absorbency/ whiteness 2. Improper washing off/ dye fixing/ RC 3. Residual peroxide/ alkali after pretreatment 4. Improper reduction/ oxidation of vat dyes

Page 49: Yarn Processing

Problems in Processing

Unlevel dyeing 1. Water quality 2. Density of hank/ package 3. Liquor flow rate / direction (I/O: Co/PE 3-4 kg & Wool: 2-2.5) (O/I: 0.5 kg less of I/O) 4. Improper penetration of dyes/ auxiliaries 5. Residual alkali/peroxide after bleaching 6. High affinity of dyes towards fibre 7. Improper reduction/ oxidation of vat dyes

Page 50: Yarn Processing

Preventive Action

Remove entrapped air and increased penetration properties: Zywet PDG liq.

Residual peroxide killing using enzymes: Ultrox EPN Premium, Ultrox EPN Supreme

Reduce water hardness and chelate out dissolved metal ions: Zyquest AS, Chelate D, Kleerix PER liq.

Page 51: Yarn Processing

Preventive Action

• Use good scouring cum wetting agent: Kleenox PSF/BAS/WLF Conc./LFAF

• Dye bath conditioner as levelling and alkali shock absorber: Zycol PCSN B, Zycol SNE, Zycol PR-SK liq.

• Suitable levelling agent: Krisil RLA, Krisil AB, Krisil VL Extra, Krisil LAN

Page 52: Yarn Processing

Preventive Action

• Use suitable washing off agent Zycol SNE/ PCSN/ Vat 100, Neutraclear RC

• Use dye-fixing agent like Hifix NFI Conc. Zyfix R.

• Choice of suitable OBA and softening agent preventing yellowing.

• Proper Hydro extraction prior to drying.

Page 53: Yarn Processing

POLYESTER YARN DYEING PROBLEMS

UNEVEN DYEING, RING FORMATION, DARK LIGHT AREAS

• USE LEVELLING AGENT - ZYCOL BCL• SET PROGRAM AS PER CTZ• USE SPECIAL DISPERANT - DISPA PDA1• CHECK DYE DISPERSION• ENSURE SOFT PACKAGE

Page 54: Yarn Processing

POLYESTER YARN DYEING PROBLEMS

COLOUR SPOTS, DEPOSITS INSIDE CHEEESE

• USE HIGHER LIQUOR RATIO• CHECK WATER QUALITY - ZYQUEST /

DISPERSANT• SHORTEN DYEING CYCLE• ADD DYE AT HIGHER TEMPERATURE• USE SPECIAL DISPERSANT - DISPA PDA1

Page 55: Yarn Processing

POLYESTER YARN DYEING PROBLEMS

POOR REPRODUCIBILITY, TONAL VARIATION

• CHECK WATER QUALITY• USE pH BUFFERS - GREENDYE OLN• PRACTICE CHECKING pH OF DYEBATH• SELECT DYES WITH SIMILAR EXHAUSTION BEHAVIOUR• CHECK MERGE NOS OF BASE POLYESTER• USE SPECIAL DISPERSANT - DISPA PDA1• SYNCHRONISE LAB - PRODUCTION DYEING CHEMICALS /

SYSTEMS• FOLLOW GOOD INDUSTRIAL PRACTICES

Page 56: Yarn Processing

OLIGOMER

• SMALLER CHAIN LENGTH OF POLYESTERDIMER, OLIGOESTER, CYCLIC TRIMER

• POWDERY DEPOSIT• 0.1 - 1 % DURING PES MANUFACTURE• MIGRATES AT HIGH TEMPERATURE• IS MESSY AND COMBINED WITH

HARDNESS FORMERS, MAKES MACHINE INEFFICIENT DUE TO CHOKING AND DEPOSITION

Page 57: Yarn Processing

PROBLEMS CAUSED BY OLIGOMER

• FILTERATION EFFECT• POOR PUMP PRESSURE• CHOKING OF SPINDLES• HEAT LOSS, VARIATION OF TEMP.

RISE• DULLER SHADES• DUSTING DURING CONING• DEPOSITS ON MACHINE PARTS

Page 58: Yarn Processing

NEW CONCEPTS INTRODUCED

• FOCUS ON UTILITIES AND MACHINE PERFORMANCE

• APPLICATION OF KNOWLEDGE

• OLIGOMER DEPOSITS

• YARN BRIGHTNESS - MADE A REALITY

Page 59: Yarn Processing

INFLUENCE OF ACIDS AND pH BUFFES ON REDUCTION SENSITIVITY OF DISPERSE DYES IN SOFT WATER AT pH 8

ADJUSTED WITH

DYEINGS CARRIED OUT IN PRESENCE OF WOOL AT 105 OC WITHOUT FORMALDEHYDE ) • ACETIC ACID pH - 5• FORMIC ACID pH - 5• SULPHURIC ACID pH - 5• (NH4)2SO4+ACETIC pH - 5

ACID

• (NH4)2SO4 +FORMIC pH - 5

ACID

• (NH4)2SO4 + SULPHURIC pH - 5 ACID

• DYMAX PI pH - 5

• GREENDYE OLN pH - 5

• AZO COLOURS REDUCED• AZO COLOURS REDUCED• AZO COLOURS REDUCED• SOME AZO COLOURS

REDUCED• FEW AZO COLOURS

REDUCED

• SOME AZO COLOURS REDUCED

• NO EVIDENCE OF COLOUR REDUCTION

• NO EVIDENCE OF COLOUR REDUCTION

Page 60: Yarn Processing

COMMON MISCONCEPTIONS IN DYEING POLYESTER WITH DISPERSE COLOURS

• REQUIREMENT OF DISPERSING AGENTS

• REQUIREMENT OF LEVELLING AGENTS

• REDUCTION CLEARING

• pH OF DYEBATH- WHY ?

• SCOURING

• COMBINATION OF COLOURS

• DIFFUSION ACCELERANTS

• TEMPERATURE > 130 OC

• RAPID DYES / RAPID DYEING / RATE OF RISE OF TEMPERATURE

• SHIFTING OF CRITICAL TEMPERATURE ZONE

Page 61: Yarn Processing

COMMON COMPLAINTS IN DYED POLYESTER YARN WITH DISPERSE COLOURS

• POOR RUBBING FASTNESS

• COLOUR FADING

• POOR WASHING FASTNESS AFTER FABRIC FINISHING

• STAINING/ TINTING OF ADJACENT PORTION OF FABRIC AT STENETRING STAGE

• POOR BRIGHTNESS

• R/C, GOOD DISPERSANTS,

CHECK WITH COLD DMF• CHECK LIGHT FASTNESS,

ANOMALOUS OR CATALYTIC FADING

• THERMO / THERMAL MIGRATION

• SUBLIMATION FASTNESS, OVER SATURATION, APPLY SOLID SOLUTION THEORY

• APPLY “ COLITZ “

Page 62: Yarn Processing

“COLITZ” RECOMMENDATIONS

• COMPLETE MACHINE CLEANING

• PREVENTIVE CLEANING• REMOVAL DURING - DYEING

AND REDUCTION CLEARING ( GRITACOL IO, OLIGO EM )

• ENSURING HYDROLYSIS WITH INCREASED CAUSTIC IN R/C

• PREVENTING HARDNESS FORMERS WITH - ZYQUEST /DISPERSANT BRANDS

• OLIGOMER BINDING IN FINISHING

• APPLICATION OF CRITICAL TEMPERATUR ZONE (CTZ)

• RATE OF RISE OF TEMPERATURE IN CTZ CONCEPT TO INCREASE PRODUCTIONS

• RATIONALISING HOLD TIMES• DYESTUFF SELECTION FOR

TONE ON TONE DYEING - IMPROVISING THE RAPID DYES CONCEPT

• USE OF SOLID SOLUTION THEORY FOR DYEING POLYESTER

Page 63: Yarn Processing

GROUPING OF SHADES - INCREASED PRODUCTION , REDUCED COST OF UTILITIES AND CHEMICALS

MAIN GROUP

DIFFERENT HOLD TIMES/DIFFERENT PROGRAMMES

1. LIGHT 2. MEDIUM 3. DARK 4. HEAVY DARK

SUB GROUP

SEPARATE PROGRAMMES & CHEMICAL ADDITIONS

• THE BLUE 183 GROUP• THE BLUE GSL GROUP• THE BLUE SR / SBK GROUP• GENERAL GROUP

Page 64: Yarn Processing

OUR STAR PRODUCTS FOR BRIGHTER DYEINGS

• OLIGO EM

• GRITACOL IO

• Dymax PI/NDA

• RAPID GE

• A REVOLUTIONARY PRODUCT FOR OLIGOMER REMOVAL

• OLIGOMER DISPERSANT CUM LEVELLING AGENT

• BUFFER, DESIGNED FOR HARD WATER

• ECONOMICAL, ECO-FRIENDLY CARRIER

Page 65: Yarn Processing

OUR STAR PRODUCTS FOR BRIGHTER DYEINGS

• LUBRIL HDR

• ZYCOL BCL

• DISPA PDA-1

• GREENCLEAR DM

• OLIGOMER BINDING AND MULTI PURPOSE FINISHING AGENT

• VERSATILE LEVELLING AGENT

• STATE OF ART DISPERSING AGENT

• REDUCING AGENT WITH DISPERSING AND SURFACTANT PROPERTY

Page 66: Yarn Processing

EFFECT OF LEVELLING AGENTS

• BLANK• GRITACOL IO• ZYCOL BCL• RAPID GE

EFFECT OF LEVELLING AGENTS

0

10

20

30

40

50

60

70

80

90

100

20 30 40 50 60 70 80 90 100 110 120 130 130 130TIME / TEMPERATURE

% E

XH

AU

ST

ION

Page 67: Yarn Processing

CTZ - critical temperature zone

Definition• 80 % of any colour exhausts

onto the fibre in the CTZ• The temp zone below and

above the CTZ does not contribute to uneven dyeing

• Temp control in CTZ based on diffusion rate, machine, MLR, fabric & liquor flow produces fault free dyeing

• CTZ shifts to the right as the depth increases

• Selection of dyes

CTZ

0

50

100

150

time /temperature

% e

xhau

stio

n

Page 68: Yarn Processing

Cellulosic PretreatmentZywet PDG liq.

Zywet DDC liq

Zywet LF 100 liq.

Nofoam NS Super liq.

Kleenox PSF

Kleenox WLF Conc.

Kleenox LFAF

Zyquest AS

Zyquest AS Super

Kleerix PER

Scourenze CBE New Pdr

Scourenze SBWP Pdr

Zystab A

ZystaB C

Zystab REV

Greenacid New Liq.

Ultrox EPN Premium

Ultrox EPN Supreme

Chelate D

Greenpol A

Page 69: Yarn Processing

Cellulosic Dyeing• Kleerix DOC Spl.• Zycol PCSN B• Zycol PR-SK• Zycol SNE• Krisil RLA• Krisil RLA Classic• Krisil VL• Krisil VL Extra

• Krisil CHN• Sulphubrite Liq• Oxidant VS• Zynec VS Pdr.• Hifix NFI Conc.• Hifix NFI Super• Zyfix R• Zyfix ECO

Page 70: Yarn Processing

Finishing

– Zylon CS Liquid

– Ultima XT Plus

– Innersof MW Liquid

– Zylon CHMK

– Magma CI paste

– Zylon NS

– Inovasof VTS Delux liq.

– Lubril HDR Paste

– Zylube SDC Liquid

– Lubril VRL New Liquid

– Lubril PE Liquid

– Lubril HDPN Liquid

– Zylon NYN Liquid

Page 71: Yarn Processing

PES Finishing

• Hydrostat BM liq.

• Hydrostat liq.

• Ultima XT Plus liq.

• Innersof MW liq.

• Lubril HDR paste.

• Lubril PE liq.

• Lubril HDPN liq.

• Lubril WX liq.

Page 72: Yarn Processing

PES Pretreatment

• Cleenpur ALF New liq• Cleenpur ALF SP liq• Greenpol A liq.• Greenscour CP liq.• Enrich R liq• Kleenox SW liq• Kleenox TEP liq• Kleenon LXI paste

• Nofoam ND liq.• Zywet LF 100 liq.• Zyquest AS liq.• Zyquest AS Conc. liq.• Zyquest AS Super liq.• Chelate D liq.• Kleenon CSR liq.• Kleenon NSH liq.

Page 73: Yarn Processing

PES Dyeing• Dymax NDA liq.• Dymax P liq.• Greenacid New liq.• Gentrate EN 200 liq.• Rapid GE liq.• Dispa PDNS liq.• Dispa PDA liq.• Dispa WS liq.• Dispa HOT liq.• Barel KB liq.

• Barel SPN liq.• Gritacol IO liq.• Krisil AB liq.• Krisil RK liq.• Zycol BCL• Zycol EDA liq.• Neutraclear RC• Greenclear DM liq.• Zycol CW liq.• Lubril HDR liq.