FOAM DYEING TECHNOLOGY

FOAM DYEING
In case of foam dyeing, the main dyeing elements is foam. For thats
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. The advantages of the process
include improved dye prefixation, improved migration of the dye into
the fiber, higher color yields in the fabric even after relatively short
dyeing times and improved dimensional stability of the dyed fabrics.
Foam is a dispersion of a gas in a liquid. Here the liquid is generally
water and the gas is generally air but it may also be an inert gas. This
is familiar as fort on beer shaving foam etc.

Foam Dyeing

TYPES OF FOAM:

REQUIREMENTS OF FOAMING AGENTS:

1. It should generate foam readily.
2. It should offer a good wetting capability.
3. It should exert fast an uniform wetting action.
4. It should show little or no effect on color fastness.
5. It should be compatible with other products of the finishing
mix.
6. It should be least effect ed by water hardness.
7. It should not cause yellowing of white materials.
8. It should be easily stabilized.
9. It should be capable of producing various bubble sizes to
meet specific requirements.

FOAM DYEING PROCEDURE:

1. Pre-wash the fabric in Synthrapol. This removes any oils or dirt
that might be on the fabric and gives you better dye results.
2. Dissolve one cup soda ash in one gallon of hot water. Soak the
fabric in the soda ash solution for 5-10 minutes, wring lightly and
hang dry.
3. Dissolve your dye powders (2 tsps. for colors without an *, 4 tsps.
for colors with one *, 8 tsps. for colors with two *) in a small amount
of warm water, stirring into a smooth paste. Stir in 1/2 cup lukewarm
water. For reds and colors containing red, filter the dye solution
through a coffee filter or piece of silk to remove difficult to dissolve
particles. Add 1/2 cup shaving cream to the filtered dye solution, and
then pour this mixture into the squeeze bottle.
4. Dilute about half a can of shaving cream with a cup of water in a
large mixing bowl. Whisk the mixture until well blended and thick
and creamy. Pour mixture into the tray until about an inch deep.

FOAM DYEING PROCEDURE:

5. Squirt the dye/shaving cream mixture over the shaving
cream/water mixture in the tray in any pattern you wish. Use a
comb, chopsticks, or any tool to swirl and spread the dye into any
pattern desired.
6. Place a piece of the prepared fabric on the surface of the
shaving cream and dye pattern. Remove any air bubbles by
pushing down gently with a tool or a gloved hand.
7. Allow the fabric to sit on the surface of the dye/shaving cream
for 5 minutes, and then remove fabric by lifting carefully. Place on
a flat surface shaving cream side up and allow to sit for 2 to 24
hours to develop the dye. The piece needs to remain moist for
the activation to take place.
8. Rinse fabric in cool running water to remove the soda ash, and
then increase temperature to hot. Continue to rinse until water is
almost clear, then wash in hot water and Synthrapol to remove
any excess dye. Dry, press and voila!

Methods of foamapplication:
(a) horizontal padder;
(b) doctor coating, roller coating and flow coating;
(c) pressure or vacuum application;
(d) transfer (double-sided)

Kiss-coating system
Morrison reverse roller
Knife-over-rollercoating system
MonfortsVacu-foam system

The Stork RSF (Rotary Screen Foam)system is illustrated in figure.

The foamfrom thefoam generator is suppliedto achamber (A), which
is formed by twostainless steel blades.Theupperblade(B)has a tip
of synthetic material and ispressed against the rotary screen (C) by
airbellows (D). The lower blade (E) ispressed against the rotary
screen by acombination ofmechanicalpressureandhydrostatic foam
pressure

Foam vs. Emulsion:

Foam
1) It is the dispersion of a gas in a
liquid
2) Unstable
3) Foaming agent used.

Emulsion
1) It is a mixture of two immixable
liquid
2) Comparatively more stable than
foam.

3) Emulsifier
used.
#Emulsifier is a special chemical
used to mix
oil &
water.
#Optical Brightening agent is used for white dyeing.

FOAMING AGENT:
Sancowad Foamer NT (Clariant), Nekanil LN (BASF).
1. Generate foam readily
2. Wide range of wetting technology
3. Fast & uniform wetting action
4. Little or no effect on color fastness
5. Compatible with other products
6. Least affected by water hardness
7. Least affected by temperature
8. Do not cause yellowing of white
9. Tend itself to be easily stabilized
10.Capable to comply with specific requirement.
Foam is a medium only like water in regular wet processing
technology. Foam only replace water, other processing materials will
be there for processing.

ADVANTAGE:

1. Low material, water for low m:l ratio

2. Low Waste
3. Eco-friendly
4. Energy Saving

CLASSIFICATION:
It can be classified in following categories:

Dispersion foam: It is produced by the introduction & mixing

of gas from an external source into a liquid phase. E.g.
Dispersion

Tank

in

textile

[fig].

It is used in textile processing.

Condensation foam: It is formed from the generation of a

gas within the liquid, either by chemical reaction or by physical
change. E.g. [fig]

COLLAPSE OF FOAM:

Inter lamellar liquid drains out of spherical foam cells.

The lamellae grow thinner, exchange of gas or breakage of

lamellae, small bubbles aggregates to foam bugger bubbles
until finally the foam collapse.

#Salt brings dye on surface of fabric

#Soda fixes dye.
#Linear Process/Application: Main chemicals like NaOH, NaCl,
Dye
#Progressive Process/Application: Auxiliary chemicals

FOAM GENERATION:
Continuous foam application technique flow chart is as follows:

FOAM EVALUATION CRITERIA:

Blow-Ratio: The blow ration expresses the volumetric ration of liquid to f

Range of application: 1 : 8 1 : 15
Bubble Size: Range: 0.1 0.3 mm dia
Homogeneity: Constant sizes.

Ionic Nature:
1 ) Anionic Surfactants which has more foaming power, not very
sensitive to temp change, used for cotton & polyester.
2 ) Non-ionic: Foaming power less than anionic. Foaming power
reduced by temperature and addition of electrolytes.
3) Cationic: Unused.

Drop Escape Time: This is the time that elapses before the first
drop of liquid emerges from the foam.
Range: 45 90 cc. Uneven application, possibility of
less
Half Life period: It is the time taken for one half of the liquid in a
definite volume to drain. Range: 4 -60 min

FOAM APPLICATION SYSTEM:

There are several types of foam application system.

Such as-

HORIZONTAL PADDING MANGLE:

APPLICATION WITH A COATING BLADE:

Here, foam collapse with squeeze roller. This process is called VALCHEM pro

Application with Coating Blade and collapse with

suction nozzle:

In this case, foam is applied using coating blade while they are
collapsed using a suction nozzle action on the back of substrate.
This is developed by United Ranchants & Ram Factures

Foam application by pressure Nozzle:

This process is developed by Gaston county & union carbide. It is called FFT pro

Application with rotary screen printing:

This process is developed by MITTER. They are suitable for carpets.

Two Sided foam application with transfer roller:

In this case, two sided foam application is done by using transfer roller
and dosage shots. This is developed by KUESTER. It is called Janus
minifoam applicator.

Foam Application with indirect doctor blade:

Here, foam application is done by indirectdoctor blade dosage and foam

collapse is controlled by vacuum cylinder suction. It is developed by
MONFORTS.

Advantage & Disadvantage of foam

finish/technology:
Advantages

Disadvantages

1) Save water

1) Investment cost is more.

2) Save chemicals (0 20%

2) Skilled man power is required

minimum)
3) Save cost
4) Reduce water pollution
5) Save energy
6) Faster production
7) Printing do not need thickener
8) Wet on wet
9) Two sided application is

3) Application limited, only for

cotton and polyester
4) More attention required.