INTEGRATED TERM PROJECT

SUSTAINABLE DYES

SUBMITTED BY
SUBMITTED TO
OJASVI MAHAJAN
MR. NANDAKISHORE BARIK
BHASWATI PANDA
ASSNT. PROFFESSOR
NIFT BBSR
 INTRODUCTION
 Dyes represent a massive industry. Aware of the colour’s influence over
consumers, the textile and fashion industry explore this aspect in great detail,
spending massive amounts of energy and money in the pursuit for the perfect
colour.
 Dyeing matter possesses peculiar chemical properties that make it very distinct
from other materials.
 However, the extent usage of chemicals and water waste by the textile industry
is an emergent ecological concern.
 It is crucial to examine the possibilities of new substance or materials and
providing consumers with highly smart and eco-friendly products and materials;
creating goods or textiles.
 USAGE OF WATER
 Normally, two types of wasted water during dyeing.
 One is the dye bath, which contains the remaining dye as well as other
complex compounds that helped the bonding between colouring
substance and fibre.
 These residues and the amount of dye lost vary, depending on the type
of dye used and variations of pattern and colour combinations.
 The other type is the wash/rinse water, a procedure to remove any
excess dye present in the substrate.
 In addition to this, water is also needed to clean all the manufacturing
components involved in the process
 HIGH WATER AND ENERGY
CONSUMPTION
 Traditional dyeing processes use 5.8 trillion litres water p.a.
 10-20% dye remains after dyeing (plus other chemicals), leaving
potential for wastewater pollution.
 It is one fifth of the world's industrial water pollution (World Bank)
 391 billion kWh energy for dyeing processes
 Finally, textile dyeing produces 568 million metric tons of greenhouse
gases (GHG) annually, more than 94 million passenger vehicles emit
each year.
 WHAT IS DYEING?
 Dyeing is the process of adding color to textile products
like fibres, yarns, and fabrics.
 Dyeing is normally done in a special solution containing dyes and
particular chemical material.
 After dyeing, dye molecules have uncut chemical bond with fiber
molecules.
 The temperature and time controlling are two key factors in dyeing.
 There are mainly two classes of dye, natural and man-made.

 DIFFERENT TYPES OF DYES :

 Acid Dyes ,Direct Dyes, Azoic Dyes, Disperse Dyes, Sulphur Dyes,
Reactive Dyes, Basic Dyes etc.
 EFFECT OF DYEING ON ENVIRONMENT
 The greatest environmental concern with dyes is their absorption and
reflection of sunlight entering the water. Light absorption diminishes
photosynthetic activity of algae and seriously influence on the food chain.
 Dyes can remain in the environment for an extended period of time,
because of high thermal and photo stability. For instance, the half-life of
hydrolysed Reactive Blue 19 is about 46 years at pH 7 and 25 °C.
 Many dyes and their breakdown products are carcinogenic, mutagenic
and/or toxic to life. Dyes are mostly introduced into the environment
through industrial effluents.
 EFFECT OF DYEING ON HUMAN BODY

 Textile dyes can cause allergies such as contact dermatitis and

respiratory diseases, allergic reaction in eyes, skin irritation, and
irritation to mucous membrane and the upper respiratory tract.
 It is assumed that in the same way reactive dyes can bond with –
NH2 and –SH group of proteins in living organisms.
 A lot of investigations of respiratory diseases in workers dealing
with reactive dyes have been made.
 Certain reactive dyes have caused respiratory sensitisation of
workers occupationally exposed to them.
 TREATMENT METHODS
 PHYSICAL METHOD
Adsorption
Membrane Filtration
 CHEMICAL METHODS
Oxidative
Photo chemical
Ion exchange
 PHYSIO-CHEMICAL METHODS
Precipitation / coagulation
Flocculation
Permethrin removal
 NATURAL DYES
 Natural dyes are derived from natural resources and based upon their
source of origin, these are broadly classified as plant, animal, mineral, and
microbial dyes although plants are the major sources of natural dyes.

 Some natural dyes from plant origin are :

 Blue dyes- Indigo is the only important natural blue dye. This very important
dye popularly known as the ‘‘king of natural dyes’’ has been used from
ancient times.
 Red dyes- A variety of plants produce red dyes, including madder and
safflower .
 Yellow dyes - These are available from several plant resources like turmeric
and saffron .
 Black and brown- Black color can be obtained from many yellow and red
dyes by iron mordanting.
 ADVANTAGES DISADVANTAGE

 Natural dyes are considered to be eco- o Shade range of natural dyes is limited.
friendly as these are obtained from o It is not possible to produce the same
renewable resources. shade with a particular natural dye in
 These are biodegradable and the every dyeing operation.
residual vegetal matter left after o Only a few natural dyes possess
extraction of dyes can be easily fastness properties
composted and used as fertilizer. o While natural dye sources are
renewable, sustainability can still be
 Fabrics dyed with such dyes should
an issue for natural dyes because
offer good protection from ultraviolet
producing them require vast areas of
light.
land.
 COTTON DYEING

 Cotton comprises 45% of all fibres used within the global textile
industry, so a sharp reduction in water consumption would be a huge
process improvement for this sector.

 DRAWBACKS OF CONVENTIONAL DYEING PROCESS :

 Soil too alkaline to support crops.
 Kills aquatic life
 Difficult to remove from effluent
 The dyeing process is also antiquated and slow, causing it to be
unnecessarily expensive
 High energy consumption
 50% total cost dyeing procedure
 AN INNOVATION - COLOURZEN
 ColorZen is an innovative new technology that makes the dyeing process
significantly more efficient and sustainable, transforming the way cotton
is dyed.
 With ColorZen, enormous amounts of water and energy can be saved
during dyeing.

How does it work ?

 The conventional cotton and dye are like magnets that are both
negatively charged, repelling each other .
 But colourzen reverses the charge of the cotton, allowing the dye to
quickly and easily bond with it.
 And cotton no longer has to be treated with toxic chemicals and salts to
force it to accept color in dye baths .
 POLYESTER DYEING
 Polyester is the most used synthetic dye in the world.
 It is dyed with disperse dyes which are of low water solubility and are
suitable for dyeing hydrophobic fibres.
 Traditional aqueous process requires dispersing agents/surfactants and high
temperatures (typically 130 °C) under pressure

 SUPER CRITICAL CO2 DYEING

 CO2 dyeing process eliminates the need for water and processing chemicals
in the dyeing process of fabrics and also reduces energy consumption.
 This technology uses CO2 for dyeing polyester fabrics, and has already been
embraced by major brands such as IKEA and Nike.
 AURA HERBAL WEAR
 Aura uses herbal dyes for its fabrics, made from turmeric, castor oil and sea
salt that are chemical-free, non-toxic and recyclable.
 The process of herbal dyeing was developed through extensive research on
age-old dyeing methods practiced since the days of the Indus Valley
civilization. During this entire treatment only natural processes are used.
 Fabrics & Yarns used are certified organic cotton, natural cotton, silk, wool,
linen, jute, hemp etc. and their natural blends
 Aura uses only medicinally rich herbs, plant material, minerals & oils like,
turmeric, myrobalan, castor oil, sea salt etc. for dyeing fabric or yarn.
 To make the colors bright and fast, natural mordant such as myrobalan,
rhubarb leaves, oils, minerals, alum, iron vat etc. are used. They don’t use
heavy metal mordant like copper, chrome, zinc, tin etc.
DYECOO COMPANY- WATERLESS DYEING

 DyeCoo’s CO₂ technology is the world’s first 100% water-free and process
chemical-free textile processing solution.
 DyeCoo uses patented and industrial proven technology based on CO₂,
instead of water.
 When pressurized, CO₂ becomes supercritical (SC-CO₂), a phase between a
liquid and a gas, it gains a very high solvent power, allowing the dye to
dissolve easily.
 Short batch cycles, efficient dye use, no waste water treatment all
contribute to significantly reduced operating costs.
 The dyestuff penetrates deep into the fibres creating intense colours with
excellent quality characteristics.
 This process opens up new opportunities for the textile industry, to occur
closer to market, shorten lead times and disconnect from Earth’s most
valuable resource … water.
 DYSTAR COMPANY -
 The DyStar Group is a global market leader in colorants, chemicals and
services to the textile and apparel industry.
 It aims at reducing the energy, water and raw materials consumed for
every ton of production by 20% of 2011 levels by the year 2020.
 The same target applies to the waste, wastewater and greenhouse gas
emissions resulting from internal operations.
 CADIRA TECHNOLOGY
 The DyStar Group is a global market leader in colorants, chemicals and
services to the textile and apparel industry.
 In contrast to the standard process, Cadira process does not require a
separate reduction clearing process and thus saves more than 40%
chemicals, water and energy, according to the company.
 “The Cadira concepts considerably reduce process costs, water, waste
and energy consumption and machine utilisation.
 Cadira supports brands and retailers and their production partners in
their effort to save valuable resources and to reduce the carbon
footprint of their textile goods
 For eg. Cadira Polyester is additionally designed to reduce the
processing time in order to improve the utilization of the machinery. The
benefits of a full optimization through Cadira Polyester can be up to 58%
of productivity increase, according to the manufacturer.
 LAVA DYES
 Lava Dyes support a sustainable dyeing process due to lower energy
and water consumption.
 We can achieve bright shades and dark colors on denim.
 They also offer great possibilities in creating wash effects due to their
excellent decolourization with permanganate and accelerator.
 Coloration can be done at a low temperature and great light and wash
fastness can be achieved without pre-cationaisation or binders.
 SUSTAINABLE WOOL DYEING
 DyStar provides a full range of dyes to meet all requirements in the
dyeing of wool. – From high-quality and economical standard dyes to
innovative problem-solvers.

Supralan
 The cost effective all-round dye range
 A product range for reliable and economical dyeing of wool in all forms
for dyeing. The Supralan range comprises 1:2 metal-complex and acid
(milling) dyes. The dyes cover virtually the whole color spectrum.
Realan
 Metal-free dyes with very good wet fastness properties
 Reactive dyes for black and navy blue, brilliant shades and machine
washable wool. Realan dyes are gaining importance in wool dyeing and are
a focal point of research and development at DyStar.
 SPRAY DYEING TECHNIQUE
 A new way to dye denim in bulk using sprays instead of traditional dyebaths
is currently being used by select textile mills in India.
 It could significantly reduce the environmental impact of jeans production
worldwide.
 This new technology offers high flexibility for dyeing small lot sizes, reduced
water usage and effluent discharge lower impact on yarn in the dyeing
process and simplified recipe changes.

 Single Sided Functionality on face side of DENIM fabric

Natural LOOK through thin coating layers
Special handle and shiny look
Special Wash Down Effects
Economical and ecological wet on wet application
 ACHROMA COMPANY– SUSTAINABLE GREEN
JEANS
 Archroma has developed a more ecological denim dyeing process. Instead of
indigo, the Denim-Ox and Pad/Sizing-Ox processes use a new eco-friendlier
generation of concentrated sulfur dyes, Diresul RDT blue specialties.

 Producing one pair of jeans requires more than 2,500 gallons of water,
nearly a pound of chemicals and vast amounts of energy.
 The process, called Advanced Denim , can produce a pair of jeans using up
to 92 percent less water ,30 percent less energy, 87% less cotton and zero
water wastage than conventional denim manufacturing methods.
 Unlike conventional denim production methods, which require up to 15
dyeing vats and an array of potentially harmful chemicals, Advanced Denim
uses just one vat and a new generation of eco-advanced, concentrated,
liquid sulphur dyes that require only a single, sugar-based reducing agent.
 DOPE DYEING
 Dope dyeing is the process of incorporation of colorant into the polyester
melt during the spinning process.
WHY DOPE DYEING ?
 The cellulosic textiles industry consumes a large quantity of water in wet
processing operations like desizing, scouring, mercerising, bleaching and
dyeing during conversion of fibre to fabric.
 Dope-dyed viscose is one of the solutions in reducing environmental
pollution and wastewater discharges in the textiles industry.
 Greenhouse gas emissions are reduced up to 20 per cent by using spun-
dyed viscose, compared to the conventional dyeing of viscose.
 Wastewater generation is reduced up to 10 per cent and a significant
reduction is noticed in heavy metal concentrations in the effluent
generated by spun-dyed viscose.
 DYECAT PROCESS
 Catalytic process that allows colour to be integrated directly into
polyesters.
 Dye is introduced in polymerisation step and is chemically bonded
within polymer backbone
 Eliminates need for conventional dyeing
 Colour in fibre is generated at the same time the polymer is made
 Colours ‘locked into’ fibre providing a technically superior product
 No need for wasteful dyeing processes
 AIR DYEING TECHNOLOGY

 Air-Dye technology manages the application of color to textiles without the

use of water. It is today’s sustainable alternative to traditional dyeing and
decorating processes.
 Airflow is the key element of the technology, as air is an ideal transport
medium.
 Air-Dye technology also reduces detrimental impacts on the environment
because the dye is in the Fibre rather than on the Fibre.
 This process creates new design capabilities, including the ability to
contrast (or match) two sides of the same fabric with solids or prints.
 Energy savings of up to 40 percent.
 They produce permanent colouration.
 SALTLESS DYEING
 DyStar and Rota Spray are announcing a salt less dyeing solution for
the denim industry. This new technology is awarded important ECO
certificates and offers high flexibility for dyeing small lot sizes, reduced
water usage and effluent discharge lower impact on yarn in the dyeing
process and simplified recipe changes.

ADVANTAGES
 To elimination of salt as an electrolyte.
 To reduce the hydrolysis of dye molecules.
 To achieve maximum dye fixation.
 To improve the highest dye up-take
 To reduce low volume of water requirement during washing process
 To improve fastness properties and compare different fastness.
 To reduce the environmental pollution
 ACME’S DYEING MACHINE
 The company explains that it has developed the concept of forwarding fabrics by
mechanical force rather than water in the dyeing process.
 The machine is equipped with a conveyer drive system used to forward the fabric so
there is only the need for water for pipe circulation and fabric pick up.
 It has extremely low liquor ratio of 1:2.5 – 3.5 dependent on the fabric type being
processed. The method is said to save 65% of chemicals and energy used and
effluent is also reduced by 65%.
 The organization specializes in manufacturing a series of hi-tech low liquor ratio
dyeing machines that are currently used by many dye houses in more than 20
countries.
 All of the company’s products are worldwide patented, including in Japan, USA, UK,
Italy, Germany, Greece, Turkey, China, Thailand, Indonesia, Malaysia, Korea and
Taiwan.
THANK YOU