Professional Dyeing Process for Cotton/Viscose/Elastane Single Jersey Fabric
Introduction
The dyeing process for blended fabrics, such as Cotton/Viscose/Elastane Single Jersey (SJ), requires precise control of chemical dosages, temperature, and timing to achieve consistent color quality and fabric performance. This article outlines a professional dyeing procedure for a 5 kg sample batch of Cotton/Viscose/Elastane SJ fabric with a GSM of 150, dyed in an orange shade, adhering to the Oekotex CI standards. The process was conducted on April 18, 2016, using Machine No. 1 with a liquor ratio of 1:20 and a volume of 100 liters.
Process Overview
The dyeing process involves multiple stages: demineralization, bleaching, neutralization, enzyme treatment, dyeing, rinsing, soaping, fixing, and finishing. Each step is carefully designed to ensure optimal fabric preparation, color application, and finishing while maintaining environmental and quality standards.
Detailed Dyeing Procedure
1. Demineralization (95°C, 20 Minutes)
Demineralization removes impurities and prepares the fabric for subsequent treatments. The process is conducted at 95°C for 20 minutes with the following chemicals:
Hasulyn NOF: 0.5 g/l (50 g)
Kleerix NAC Green Acid: 0.5 g/l (50 g)
This step ensures the fabric is free from metallic ions and other contaminants that could interfere with bleaching and dyeing.
2. Viscobleach (80°C, 30 Minutes)
Bleaching enhances the fabric's whiteness and prepares it for uniform dye uptake. The process runs at 80°C for 30 minutes using:
Viscobleach: 3.0 g/l (300 g)
This treatment targets the cotton and viscose components, ensuring a clean and even base for dyeing.
3. Neutralization (40°C, 15 Minutes)
Neutralization removes residual alkali from bleaching to prevent dye instability. The process is conducted at 40°C for 15 minutes with:
Kleerix NAC Green Acid: 1.0 g/l (100 g)
This step stabilizes the fabric's pH for subsequent enzyme treatment and dyeing.
4. Enzyme Treatment (55°C, 60 Minutes)
Enzyme treatment improves fabric softness and removes surface fuzz. The process runs at 55°C for 60 minutes using:
Mega PK2: 0.10% (5 g)
This step enhances the fabric's hand feel, particularly important for the elastane component, ensuring a smooth surface for dyeing.
5. Dyeing (65°C, 60 Minutes)
The dyeing process applies the orange color using reactive dyes suitable for cotton and viscose. The process is conducted at 65°C for 60 minutes with the following chemicals:
Dekol SNS: 0.5 g/l (50 g)
Ron Lube Plus C: 0.5 g/l (50 g)
Kappacom EIS: 0.5 g/l (50 g)
Sunfix Orange S2RN: 1.00% (50 g)
Glauber's Salt: 50 g/l (5000 g)
Soda Ash: 12 g/l (1200 g)
Glauber's salt promotes dye exhaustion, while soda ash fixes the dye to the fiber, ensuring vibrant and durable coloration.
6. Rinsing (Cold Rinse: 40°C, 10 Minutes; Hot Rinse: 70°C, 10 Minutes)
Rinsing removes unfixed dye and chemicals. A cold rinse at 40°C for 10 minutes is followed by a hot rinse at 70°C for 10 minutes to ensure thorough cleaning.
7. Neutralization (40°C, 20 Minutes)
A second neutralization step stabilizes the fabric's pH post-dyeing, using:
Kleerix NAC Green Acid: 1.0 g/l (100 g)
This ensures the fabric is free from residual alkali, preparing it for soaping.
8. Soaping (95°C, 20 Minutes)
Soaping removes any remaining unfixed dye, enhancing color fastness. The process runs at 95°C for 20 minutes with:
Setawash SB: 1.0 g/l (100 g)
This step ensures the orange shade meets fastness requirements for Oekotex CI standards.
9. Fixing (40°C, 10 Minutes)
Fixing improves the dye's adhesion to the fabric, enhancing wash fastness. The process is conducted at 40°C for 10 minutes using:
Kappafix GG: 3.0 g/l (300 g)
This step is critical for ensuring the durability of the orange color during use.
10. Finishing by Padding
The final finishing step enhances the fabric's softness and handle. The padding process uses:
Kleerix NAC Green Acid: 0.5 g/l (50 g)
Softlene Conc.: 20 g/l (2000 g)
This treatment imparts a soft, comfortable feel to the Cotton/Viscose/Elastane SJ fabric, making it suitable for end-use applications.
Conclusion
The dyeing process for Cotton/Viscose/Elastane Single Jersey fabric, as outlined, ensures a high-quality orange shade with excellent color fastness and fabric handle. By adhering to precise chemical dosages, temperature controls, and processing times, the procedure meets Oekotex CI standards while delivering a consistent and vibrant result. This method can be scaled for larger production runs, maintaining quality and environmental compliance.
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