PC ORANGE COLOR DYEING PROCESS

Polyester/Cotton (PC) Orange Dyeing Process: A Comprehensive Guide

Introduction

Dyeing polyester/cotton (PC) blended fabrics requires a meticulous process to achieve vibrant, uniform colors while ensuring environmental compliance and fabric quality. This article outlines a professional dyeing process for achieving an orange shade on a 50% polyester/50% cotton fabric with a GSM of 160, using a sample order of 5 kg. The process adheres to Oekotex standards, employs a liquor ratio of 1:20, and is conducted on Machine No. 5 with a total volume of 100 liters. The following sections detail each stage of the dyeing process, including chemical dosages, temperatures, and durations.

Polyester Part Dyeing (135°C x 60 Minutes)

The polyester component of the PC blend is dyed first due to its hydrophobic nature, requiring high-temperature disperse dyes. The process is carried out at 135°C for 60 minutes to ensure optimal dye penetration and fixation.

Chemicals and Dosages

Acetic Acid (0.5 g/L, 50 g): Adjusts the pH to optimize dye uptake and prevent hydrolysis of disperse dyes.

Cross Color PLD (0.6 g/L, 60 g): A leveling agent that ensures even dye distribution on the polyester fibers.

Uniferol Buffer S (1.0 g/L, 100 g): Maintains pH stability throughout the high-temperature dyeing process.

Taicron Yellow SP-RST (0.5%, 25 g): Primary yellow disperse dye contributing to the orange shade.

Taicron Red SP-2RT (0.2%, 10 g): Red disperse dye to achieve the desired orange hue.

Process

The fabric is loaded into the dyeing machine at a 50% load capacity. The bath is prepared with the specified chemicals and dyes, and the temperature is gradually raised to 135°C. The process runs for 60 minutes, allowing the disperse dyes to penetrate the polyester fibers effectively. A gradual cooling phase follows to prevent thermal shock to the fabric.

Reduction Clearing (90°C x 20 Minutes)

Post-dyeing, reduction clearing removes excess disperse dyes from the fabric surface to enhance color fastness and prevent staining of the cotton component.

Chemicals and Dosages

Caustic Soda (2.0 g/L, 200 g): Provides an alkaline environment to facilitate dye reduction.

Sodium Hydrosulfite (2.0 g/L, 200 g): Acts as a reducing agent to clear unfixed dyes.

Process

The bath is heated to 90°C and maintained for 20 minutes. This step ensures that any residual disperse dyes are solubilized and removed, preparing the fabric for the cotton dyeing stage.

Neutralization (60°C x 20 Minutes)

Neutralization is performed to remove residual alkalinity and prepare the fabric for subsequent processes.

Chemicals and Dosages

KLEERIX NAC LIQ GREEN Acid (1.0 g/L, 100 g): Neutralizes the alkaline environment, bringing the pH to a suitable range for further processing.

Process

The bath is set to 60°C for 20 minutes, ensuring complete neutralization of the fabric.

Semi-Bleaching (98°C x 45 Minutes)

Semi-bleaching enhances the whiteness of the cotton component, improving the vibrancy of the subsequent reactive dyeing.

Chemicals and Dosages

Kappawet BOS (1.0 g/L, 100 g): A wetting agent to ensure uniform penetration of bleaching chemicals.

RON LUBE PLUS C (0.5 g/L, 50 g): A lubricant to reduce fabric abrasion during processing.

KAPPACOM EIS (1.0 g/L, 100 g): A stabilizer to control peroxide activity and prevent fiber damage.

Kappazon H 53-250 (0.4 g/L, 50 g): A bleaching auxiliary to enhance the process efficiency.

Hydrogen Peroxide (50%) (2.0 g/L, 200 g): The primary bleaching agent for the cotton component.

Caustic Soda (2.0 g/L, 200 g): Provides the alkaline environment necessary for peroxide activation.

Process

The bath is heated to 98°C and maintained for 45 minutes. This step whitens the cotton fibers, preparing them for reactive dyeing while preserving fabric strength.

Hot Wash (70°C x 10 Minutes)

A hot wash removes residual bleaching chemicals to prevent interference with subsequent processes.

Chemicals and Dosages

Kappawet BOS (0.1 g/L, 10 g): Ensures thorough wetting and removal of impurities.

Process

The fabric is washed at 70°C for 10 minutes to clean the surface and prepare for neutralization.

Neutralization (60°C x 15 Minutes)

Neutralization removes residual alkalinity from the bleaching process.

Chemicals and Dosages

KLEERIX NAC LIQ GREEN Acid (0.5 g/L, 50 g): Neutralizes residual alkali.

PK-20 (0.5 g/L, 50 g): Assists in pH stabilization.

Process

The bath is maintained at 60°C for 15 minutes to ensure a neutral pH, critical for the enzyme treatment.

Enzyme Treatment (55°C x 60 Minutes)

Enzyme treatment removes surface fuzz and improves the fabric’s hand feel by bio-polishing the cotton component.

Chemicals and Dosages

MEGA PK2 (0.1%, 5 g): A cellulase enzyme for bio-polishing, enhancing fabric smoothness.

Process

The treatment is conducted at 55°C for 60 minutes, optimizing enzyme activity while preventing fiber damage.

Cotton Part Dyeing (60°C x 60 Minutes)

The cotton component is dyed using reactive dyes to achieve the orange shade, complementing the polyester dyeing.

Chemicals and Dosages

Dekol SNS (1.0 g/L, 10 g): A sequestering agent to prevent dye aggregation.

KAPPACOM EIS (0.5 g/L, 50 g): Stabilizes the dyeing bath.

RON LUBE PLUS C (0.5 g/L, 50 g): Reduces friction during dyeing.

Sunfix Yellow S3R 150% (1.0%, 50 g): Primary yellow reactive dye.

Sunfix Red S2B (0.5%, 25 g): Red reactive dye to achieve the orange shade.

Glauber’s Salt (50 g/L, 5000 g): Promotes dye exhaustion onto the cotton fibers.

Soda Ash (12 g/L, 1200 g): Fixes the reactive dyes by creating an alkaline environment.

Process

The dyeing is performed at 60°C for 60 minutes, ensuring uniform dye uptake and fixation on the cotton fibers. The high salt concentration aids dye exhaustion, while soda ash facilitates covalent bonding of the reactive dyes.

Cold Rinse (40°C x 10 Minutes) and Hot Rinse (80°C x 10 Minutes)

Rinsing removes unfixed dyes and chemicals, improving color fastness.

Process

A cold rinse at 40°C for 10 minutes is followed by a hot rinse at 80°C for 10 minutes to thoroughly clean the fabric.

Neutralization (60°C x 15 Minutes)

Neutralization ensures the removal of residual alkalinity from the reactive dyeing process.

Chemicals and Dosages

KLEERIX NAC LIQ GREEN Acid (0.75 g/L, 75 g): Neutralizes the fabric pH.

Process

The bath is maintained at 60°C for 15 minutes to achieve a neutral pH.

Soaping (95°C x 20 Minutes, 2 Cycles)

Soaping removes unfixed reactive dyes, enhancing wash fastness.

Chemicals and Dosages

Setawash SB (1.0 g/L, 100 g): A soaping agent to remove unfixed dyes.

Process

The fabric undergoes two soaping cycles at 95°C for 20 minutes each, ensuring excellent color fastness.

Fixing (40°C x 15 Minutes)

A fixing agent enhances the wet fastness of the reactive dyes on the cotton component.

Chemicals and Dosages

Kappafix GG 100 (3.0 g/L, 300 g): A cationic fixing agent to improve dye retention.

Process

The fixing process is conducted at 40°C for 15 minutes, ensuring the dyes are securely bonded to the cotton fibers.

Finishing by Padding

The final finishing step imparts softness and stabilizes the fabric pH.

Chemicals and Dosages

KLEERIX NAC LIQ GREEN Acid (0.5 g/L, 50 g): Maintains a slightly acidic pH for fabric stability.

Softsil Nano (20 g/L, 2000 g): A silicone-based softener for a smooth, soft hand feel.

Process

The fabric is padded with the finishing chemicals, dried, and cured to achieve the desired softness and handle.

The described dyeing process for a 50% polyester/50% cotton fabric achieves a vibrant orange shade while adhering to Oekotex standards. By carefully controlling chemical dosages, temperatures, and process durations, the procedure ensures excellent color uniformity, fastness, and fabric quality. This method is suitable for small-scale sample production (5 kg) and can be scaled up with appropriate adjustments to machine capacity and liquor ratios. The use of eco-friendly chemicals and precise process controls makes this an efficient and sustainable approach to PC fabric dyeing.

Date+A4:H41	03-Apr-16		Customer	Oekotex CII		Load	50%
Color	ORANGE		Order #	Sample		Reference	Swatch
Fabric	Polyester/Cotton (PC)		GSM	160		Machine	No.5
Quantity	5 Kg		Liquor Ratio	1:20		Volume	100
Polyester Part Dyeing  135 C x 60 Mins
Chemicals			Dosage	Quantity in grams
Acetic Acid			0.50 g/l	50
Cross Color PLD			0.60 g/l	60
Uniferol Buffer S			1.0 g/l	100
Taicron Yellow SP-RST			0.500%	25
Taicron Red SP-2RT			0.20%	10
Reduction Clearing  90 C x 20 Mins
CAUSTIC SODA			2.0 g/l	200
Sodium Hydrose			2.0 g/l	200
Neutralization 60 x20 Mins
KLEERIX NAC LIQ GREEN Acid			1.0 g/l	100
Semi- Bleaching 98 C X 45 Mins
Kappawet  BOS			1.0 g/l	100
RON LUBE PLUS C			0.5 g/l	50
KAPPACOM  EIS			1.0 g/l	100
Kappazon H 53-250			0.40 g/l	50
Hydrogen Peroxide ( 50%)			2.0 g/l	200
Caustic Soda			2.0 g/l	200
Hot Wash 70 C X 10 Mins
Kappawet  BOS			0.10 g/l	10
Neutralization
KLEERIX NAC LIQ GREEN Acid			0.5g/l	50
PK-20			0.5g/l	50
Enzyme Treatment  55C X 60 Mins
MEGA PK2			0.100%	5
Cotton Part Dyeing 60 C X 60 Mins
Dekol SNS			1.0 g/l	10
KAPPACOM  EIS			0.5 g/l	50
RON LUBE PLUS C			0.5 g/l	50
Sunfix Yellow S3R 150%			1.00%	50
Sunfix Red S2B			0.50%	25
Glauber's Salt			50 g/l	5000
Soda Ash			12g/l	1200
Cold Rinse 40 X 10 Mins, Hot Rinse 80 C X 10 Mins
Neutralization 60 C X 15Mins
KLEERIX NAC LIQ GREEN Acid			0.75g/l	75
Soaping 95 C X 20 Mins (2X)
Setawash SB			1.0 g/l	100
Fixing 40 C x 15Mins
Kappafix GG 100			3.0 g/l	300
Finishing by Padding
KLEERIX NAC LIQ GREEN Acid			0.5 g/l	50
Softsil Nano			20 g/l	2000