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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.
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.
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.
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
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