Econtrol Dyeing Process: An Ecological and Economical Approach

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Econtrol Dyeing Process: An Ecological and Economical Approach

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DOI: 10.1007/978-3-7091-0109-4_28

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Econtrol Dyeing Process: An Ecological
and Economical Approach

Shamshad Ali, Zeeshan Khatri, and Khan Muhammad Brohi

Abstract Ecology and economy are among the most used catch words of our time,
and their significance is of the greatest possible importance for the survival of textile
industry. Econtrol dyeing process was introduced by Dystar and Monforts in ITMA
in 1995 to provide the textile dyer with a dyeing system that would produce a simple,
rapid, and economical, continuous dyeing method for cellulosic fibers with minimal
chemical usage. The most significant and unique feature of this process is that it does
not use a separate fixation step, i.e., steaming, curing, or dwell time, which is essen-
tial and associated with the conventional reactive dyeing methods in practice. It can
be used to dye all ranges of shades that can be obtained with reactive dyes through
various dyeing processes on all cellulosic fibers such as cotton, viscose, tencel, and
linen. This paper represents a review of the economical and ecological merits
offered by this process in comparison with other continuous dyeing methods. The
example of Afroze Textile Mills Limited, Karachi, Pakistan, is provided as a case
study which is running this process successfully since last 5 years.

Keywords Continuous dyeing • Conventional reactive dyeing • Economical con-


tinuous dyeing • Econtrol dyeing

1 Introduction

To understand the emergence of the Econtrol process and its success, the following
points are to be considered by the dye houses.
1. The number of shades to be dyed has risen steadily with higher fastness
specifications.
2. Environmental regulations have become more stringent.

S. Ali (*)
Department of Textile Engineering, Mehran UET, Jamshoro, Pakistan
e-mail: shamshadonline@gmail.com

M.A. Uqaili and K. Harijan (eds.), Energy, Environment and Sustainable Development, 291
DOI 10.1007/978-3-7091-0109-4_28, # Springer-Verlag/Wien 2012
292 S. Ali et al.

3. Batch sizes have declined dramatically.


4. Delivery times are reduced [1].
Traditionally, four dyeing processes have been employed to dye cotton and
viscose with reactive dyes by continuous method (Fig. 1). They are as follows:
1. Cold pad-batch.
2. Pad-dry Thermofix.
3. Pad steam.
4. Pad-dry chemical pad-steam [2].
The characteristic features of the mentioned continuous reactive dyeing pro-
cesses for cellulosic fibers are given in Table 1.
The selection of dyeing process depends upon many factors, most importantly the
cost of the process. Most of the processes use high temperature (100–160 C) and
hazardous chemicals (urea, sodium silicate, and salt) in order to achieve maximum
yield.
The limitations of these dyeing processes are listed in Table 2.

Fig. 1 Most common dyeing methods for cellulosic fibers

Table 1 Characteristic features of continuous reactive dyeing processes [3]


Processes Drying Fixation ( C) Fixation medium
Pad-batch – 20–35 Padding liquor
Pad-wet steam – 102 Steam 100%
Pad Thermofix 110–130 C 160 Air
Pad-dry chemical pad-steam 110–130 C 102 Steam 100%

Table 2 Limitations of most common dyeing processes [3]


Dyeing process Drawbacks
Pad-batch High fixation time, bath stability
Pad-dry Thermofix Low light fastness, damage of elastan, yellowing
Pad-wet steam Limited yield, tailing
Pad-dry chemical pad-steam Special machine necessary, high energy demand
Econtrol Dyeing Process: An Ecological and Economical Approach 293

2 Econtrol Dyeing Process

The Econtrol process was developed jointly by Dystar and Monforts. It is one of the
few real inventions in process development and machinery in recent years.
It comprises just three steps: Application of the dyes through padding, drying in
moist condition, and washing off [4], as shown in Fig. 2.
The dyeing range is a simple arrangement shown in Fig. 3. The range is started
with a lead fabric, which brings water into the installation through the wetting
arrangement in order to establish the chamber climate. The jet temperature is
120 C. After a short time, the bath containing the dye liquor is raised and the fabric
is impregnated with dyestuff. When the dye goods reach the wetting arrangement,
this is turned away. A measuring device controls and regulates the steam content
of the atmosphere in the hotflue. The goods dwell for 2 min in the hotflue and
the reactive dyestuff is fixed to the fiber with a high yield [2, 5]. Owing to the mild
fixation climate in the machine compared to that in other common dyeing pro-
cesses, soft fabric handle is obtained. Econtrol is the registered trade mark
of Dystar.

Fig. 2 Econtrol continuous


dyeing method for cellulosic
fibers

Fig. 3 Econtrol process steps. (1) Feeding section, (2) pad mangle, (3) wetting unit, (4) Thermex
hotflue, (5) measuring and control unit (chamber atmosphere), (6) steam injection unit, (7) outlet
section
294 S. Ali et al.

2.1 Role of Humidity

It is worth mentioning here that fixation of reactive dyes is impossible in normal


drying conditions. During drying, the temperature of the moist good is far lower
than the surrounding temperature. The fabric temperature depends on the humidity
of the air used to dry it [1].
If humidity is 25% and the air temperature is 120 C, the temperature on the
surface of the goods is around 68 C. If humidity is increased to 30%, the tempera-
ture on the goods is around 71 C (see Fig. 4). The Econtrol process uses this
physical fact to fix the reactive dye during drying. Three key variables, time,
temperature, and humidity, are used to ensure accurate control of the dyeing process
in the Thermex Hotflue. The goods should spend about 2–3 min in the chambers
[1, 2]. The presence of humidity in the fixation chamber assists in the diffusion of
dyes inside the fabrics with compact weave structure.

2.2 The Process Edge

The process is developed to achieve optimum results in the shortest possible time.
The fewer the variables affecting the dyeing process, the higher the probability of
achieving this goal. Tolksdorf reported 25 variables in pad-dry chemical pad-steam
process that can adversely affect the dyeing process. By contrast, Econtrol process
has 15 dyeing process variables (40% reduced). This is owing to the fact that the

Fixation conditions:
Surrounding temperature: 120 - 130°C, humidity: 25 - 30% 120 °C
120 60
final fixation
Humidity in the fabric [%]

50
Fabric temperature [°C]

100
Moisture content of the fabric Fabric temperature
80 Wetbulb temperature 40
68 - 69 °C
60 30

40 20

20 10

0 0
0 0,5 1,0 1,5 2,0
time [min]

Fig. 4 Econtrol – material temperature and humidity of the goods [6]


Econtrol Dyeing Process: An Ecological and Economical Approach 295

Econtrol process does not use a separate fixation step, which is, curing, steaming, or
batching [1].
Likewise, improved light fastness rating is obtained because there is no urea
present in the recipe, and the absence of salt is helpful in the washing-off process
[2]. Similarly, 35% less time will be needed for Econtrol process in lab matching
when compared against the pad-dry chemical pad-steam process [1].
Figure 5 shows the amount of various chemicals used by different dyeing
processes in the dyeing of ten million meters of fabric.
It is interesting to note here that the most environment-friendly process is often
also the most economical. Econtrol is a relevant example to quote. By eliminating
the need of curing/steaming stage, huge amount of energy can be saved [1].
Similarly, there is no need to go for harsh chemicals such as salt, urea, and
sodium silicate. It would eventually extend the life of the dyeing machine. More-
over, since they do not have to wash out, they cannot contaminate effluent or
exhaust air. Econtrol process is, therefore, both economical and eco-friendly. This
process can be used for fabrics weighing 70–500 g/m2.
Depending upon the working conditions in production plants, Table 3 presents
the summary of average depth of shade obtained from dyeing processes.

Fig. 5 Chemical 600


consumptions in continuous
dyeing
500
Chemical consumptions in Tons

400

300

200

100

0
PDCPS PDC CPB ECONTROL
Reactive Dyeing Processes

Table 3 Depth of shade Dyeing process Yield (%)


(yield) of different dyeing
processes [3] Pad moista 100 (as a standard)
Pad-batch 95
Pad-dry Thermofix 95
Pad-wet steam 85
Pad-dry chemical pad-steam 105
a
The Econtrol process offered by Clariant
296 S. Ali et al.

3 Industrial Production: A Case Study

In Pakistan, Afroze Textile Mills Limited situated in Karachi is the leading dye
house that is running the Econtrol process successfully since the last 5 years. The
data taken from their production unit are listed in Tables 4 and 5.
Medium or highly substantive reactive dyes are selected for the dyeing process.
The dyeing recipe employed there with success is in the range of 40–100 g/L.
The Drimarene CL (Clariant) and Remazol RGB (Dystar) dyestuffs are used there.
There are three chambers in the Thermex Hotflue (Monforts) at Afroze Textile
Mills Limited; each chamber has a cloth content of 32 m length.
The bulk production is achieving 25% greater depth of shade from Econtrol
process than pad-dry cure process by using the same amount of dyestuff. In com-
parison with cold pad-batch process, they are getting similar fastness ratings except
light fastness, 1–2 rating less. The Econtrol process has replaced the pad-dry cure
process and the pad-dry chemical pad-steam process done for 100% cotton fabric
with reactive dyes in Afroze Textile Mills Ltd., Karachi, Pakistan.

4 Ecological Benefits

The Econtrol process simultaneously offers the following ecological benefit:


The combined reduction in the quantities of chemicals (urea, salt, and sodium
silicate), and dyes from the recipe, also the water used for washing-off process,
greatly cuts down the effluent load discharged from the dye house to the environ-
ment [2].

Table 4 Padding recipe used Reactive dyes Quantity (g/L)


for Econtrol process in Afroze
Textile Mills Limited Soda ash 20
Caustic soda 48 Be 10
Mild oxidizing agent 6
Antimigrating agent 10

Table 5 Process conditions Parameters Range


used for Econtrol process in
Afroze Textile Mills Limited Padding temperature 25 C
Drying/fixation temperature 140 C
Drying/fixation time 2 min
Humidity 25–30% volume
Steam regulation 50%
Exhaust air damper 30%
Speed of machine 50 m/min
Econtrol Dyeing Process: An Ecological and Economical Approach 297

5 Economical Benefits

The Econtrol process offers the following significant economic advantages:


Lower chemical cost, this is owing to the elimination of the usage of various
chemicals and auxiliaries that include urea, salt, and sodium silicate, and are
considered essential for the reactive dyeing process.
Lower dyes cost, this is due to the higher fixation yield, that is, less dye would be
required to obtain the required depth of shade on the fabric.
Lower water cost, as a result of greater fiber–polymer reaction, the hydrolysis of
dyes will be lower and hence, the washing-off process would definitely utilize less
volume of water.
Lower energy cost, in consequence of the exclusion of the thermofixation step
during the continuous dyeing process on the Thermex Hotflue, reduced thermal
energy would be needed for the fiber–polymer reaction to take place.
The process also has a logistical benefit: As the fabric is in dry state at the end of
the Econtrol process, they do not have to be washed off immediately and can be
stored. Now it can be said that the new dyeing technology is more economical
despite its somewhat higher investment cost (hotflue plus accessories) [2].

6 Conclusions

The key issue that will concern the continuous dyer in the future would be the
search for the dyeing process which must be simple to use for ranges of shade, and
can provide the dyer the economy, even when dyeing small batches, and rapid color
change, as the duration of the fashion trend is on fall worldwide, plus it should be
reliable, due to excellent reproducibility, and without any harm to the environment.
The continuous dyeing on Thermosol machine would continue to deliver all these
features in the shape of economical and ecological dyeing process, that is, Econtrol.

Acknowledgments The authors are thankful to Mr. Kamran Khatri, Clariant Pakistan Limited,
Mr. Abdul Razak Khatri, Dystar Pakistan, for providing relevant data, and Mr. Shoaib Ansari,
Afroze Textile Mills Limited, Karachi, for his continuous help and support in this work.

References

1. Tolksdorf FP (2006) Econtrol - The modern art of continuous dyeing. Melliand Textilber
12:228–232
2. Wersch KV (1998) Economic and ecological aspects of the continuous dyeing of cellulosic
fibres. Melliand Textilber 79:166–167
3. Roth A (2007) Dyes for cellulosics – pad moist, Clariant Pakistan Limited, Karachi
4. http://www.ptj.com.pk/Web%202004/04-2004/dyster.html. Accessed Nov 2009
5. http://www.monforts.de. Accessed March 2009
6. General continuous processes by dye class, Dystar Pakistan Limited, Karachi, 2001

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