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Pad Dyeing with Reactive Dyes

Dr. Tanveer Hussain

Dean Faculty of Engineering & Technology
National Textile University Faisalabad.
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Dr. Tanveer Hussain

Pad dyeing methods with reactive dyes

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Reactive dye requirements for pad dyeing

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Powder and liquid dyes

Excellent solubility
Excellent bath stability
Low-to-medium substantivity, good compatibility
Good diffusion and levelling properties
Similar reactivity and rapid fixation
Unaffected by fixation time variations
High degree of fixation
Excellent washing-off properties
Good fastness level

Dr. Tanveer Hussain

CIBACRON C Dyes

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Dye solubility in the presence of alkali

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Dye solubility in the presence of alkali

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Degree of fixation

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Degree of fixation of CIBACRON C

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Bath stability in pad-batch

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Stability vs. bath pH

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Dye affinity & pad dyeing

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Pad batch process

Padding
X g/l dyes
1 g/l wetting agent
2 g/l sequestring agent

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Kuesters Contidos System

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Batching

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Changing pH during batching

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Merits & demerits of pad batch method

Merits

Demerits

Modest investment layout

Suitable for small and fairly large
batches
Very simple working conditions
Limited manpower required
Low energy consumption
Lower water consumption than
exhaust dyeing
Good penetration and level
dyeing
Good reproducibility
Suitable for dyeing knitgoods

Batch process
Higher dye consumption
than pad-dry-pad-steam
Moderate coverage of dead
and immature cotton

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Pad-dry-pad-steam process
Dye Pad

X g/l dye
1 g/l wetting agent
2 g/l sequestering agent
5-10 g/l migration inhibitor

IR pre-drying

To residual 30-35% moisture content

Drying

120C

Chemical Pad

250 g/l salt

15 ml/l Caustic Soda (36Be)

Steaming

60 seconds with saturated steam

Washing-off

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Pad-dry-pad-steam process
Merits

Demerits

Economical process for large

production runs
Still economical for fairly
small runs (>5000m) on
modern equipment
High colour yield
Very good appearance of the
dyed fabric
Good reproducibility
No detrimental influence on
light and/or chlorine fastness

Shade changes are time

consuming
Less suitable for dyeing
fabrics prone to migration
problems or difficult to dry
(pile fabrics)

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Pad thermo-fix process

Dye Pad

X g/l dye
1 g/l wetting agent
2 g/l sequestering agent
5-10 g/l migration inhibitor
20-100 g/l urea
10 g/l soda ash

IR pre-drying

To 30-35% residual moisture content

Drying

120C

Thermo-fixation

60 seconds as 160C

Washing-off
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Pad thermo-fix process

Merits

Demerits

Good colour yield on cotton

and coverage of dead cotton
Very good lab to bulk
reproducibility
Good batch to batch
reproducibility
Moderate soiling of
machinery
No need for a chemical pad
liquor

Not recommended for dyeing

regenerated cellulose
Possible specky appearance
of the dyed fabric
A negative influence on the
fabric handle is possible
Danger of yellowing of the
substrate
Lower light / chlorine fastness
level
The process requires urea

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Pad-steam process
Dye Pad

X g/l dye
1 g/l wetting agent
2 g/l sequestering agent
3 g/l thickener/migration inhibitor
60-90 g/l salt
10-30 g/l soda ash

Steaming

60-90 seconds in saturated steam

Washing-off
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Pad-steam process
Merits
Continuous method mainly
used for dyeing fabrics with
high liquor retention, such as
terry fabrics and corduroy,
because no intermediate
drying is required
No migration problems
Reduced energy costs
Good appearance of the dyed
fabrics
No detrimental influence on
fastness

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Demerits
Higher amounts of dye are
required to produce deep
shades compared to the
pad-batch or pad-dry-padsteam processes
Worthwhile for dyeing
deep shades when the
higher dye costs are at least
balanced by savings in
energy and gains in
productivity

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Pad humidity-fix process - Econtrol

Dye Pad

X g/l dye
1 g/l wetting agent
2 g/l sequestering agent
5-10 g/l migration inhibitor
20 g/l soda ash
Y ml/l caustic soda (36Be)

Drying/fixation

2-3 minutes at 120-130C, 25% RH (depending on

fabric weight)

Washing-off
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Pad humidity-fix process - Econtrol

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Pad humidity-fix process - Econtrol

Merits

Demerits

Low chemical and auxiliary

requirements
Suitable for dyeing viscose and
cellulosic blends
Good colour yield
Good appearance of the dyed
fabric
No need for a chemical pad
liquor or steamer
No detrimental influence on
fastness (light or chlorine)

Lower fixation level when

compared to pad-batch or paddry-pad-steam
For heavy weight fabrics IR predrying is necessary to control
migration and prevent surface
dyeing
Controlling the chamber climate
can be problematic, especially
when processing a mixture of
different fabric qualities
Lab shade matching requires
specialist equipment (e.g.
universal steamer, type DH/DHe
from Mathis AG)

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Continuous washing-off reactive dyes

Best washing conditions:

When substantivity of the dye is as low as possible

When diffusion rate as high as possible

Phase 1: Dilution or exchange

Removal of unfixed dye, alkali, auxiliaries & alkali

residues from the fabric surface.
Influenced by:
The number of bath changes.
The amount of water.
Turbulence, running speed and bath circulation.

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Continuous washing-off reactive dyes

Phase 2: Diffusion and desorption
Removal of unfixed dye, chemicals and alkali
residues from inside the fibre.
Influenced by:

Amount of unfixed dye and electrolyte content

Substantivity and diffusion rate of the unfixed dye
Time & Temperature
Liquor ratio (number of wash baths, turbulence)

Phase 3: Dilution & removal of diffused out dye

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Effect of washing temperature

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Effect of washing time

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Washing-off profile

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Washing-off profile

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Setting-up washing-off conditions

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