DyStar® Processes
bluesign® blueXpert evaluations
bluesign Conference St. Gallen
July 2015
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
Reactive Dyeing
Conventional Exhaust Dyeing Process vs Sera® Eco Wash Process
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
Shade Selection for Reactive Process
Dark Brown Shade for ladies
apparel wear
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
Conventional process – Pre-treatment – Dyeing – Wash Off
6 hours
1. Auxiliaries 4. Auxiliaries 7. Acetic acid 10 baths
NaOH 60 g/l Glauber Salt
H2O2 (50%)
8. Conventional soaping agent
5. 3.1 % Reactive Yellow 176
2. Acetic acid 1.3 % Reactive Red 239
1.8 % Reactive Black 5
3. ‘Peroxide Killer’
6. Alkali
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
Marketing Coloration Fanny Vermandel
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July 2015
Sera® ECO WASH process
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
Recommended dyes for Sera® ECO Wash Process
Levafix® Brilliant Yellow CA Remazol® Yellow RR
Levafix Yellow CA Remazol Red RR
Levafix Amber CA Remazol Blue RR
Levafix Orange CA Remazol Golden Yellow RGB
Levafix Scarlet CA Remazol Ultra Yellow RGBN
Levafix Brilliant Red CA Remazol Ultra Orange RGBN
Levafix Fast Red CA Remazol Navy RGB 150%
Levafix Red CA Remazol Ultra Carmine RGB
Levafix Rubine CA Remazol Ultra Red RGB
Levafix Olive CA100 Remazol Yellow GR 133%
Levafix Blue CA Remazol Brilliant orange 3R spec
Levafix Dark Blue CA Remazol Orange BN
Levafix Navy CA Remazol Brilliant Red BB 150%
Levafix Golden Yellow E-G 150% Remazol Brilliant Red F3B
Levafix Yellow E-3RL Remazol Red RB 133%
Levafix Brilliant Red E-6BA Remazol Brilliant Violet 5R
Levafix Brilliant Blue E-FFN 150% Remazol Brilliant Blue BB 133%
Levafix Brilliant Blue E-B Remazol Yellow SAM
Levafix Brilliant Blue E-BRA Remazol Red SAM
Levafix Navy Blue E-BNA Remazol Blue SAM
Levafix Brown E-2R Remazol Grey SAM
Remazol Gold SAM
Remazol Terra Cotta SAM
Remazol Maroon SAM
Remazol Pacific SAM
Remazol Space SAM
Process can be conveniently implemented with selected high performance Levafix/Remazol Dyes
No issues with e.g. metamerism
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
Marketing Coloration Fanny Vermandel
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July 2015
Sera® ECO WASH process
T [°C]
20'
5' 15' 30' ' 10' 13'
10' 13'
10'
5' 10' 5'
6'
pH 6.5
pH 7.5
4 h 20 min, 5 baths
t [min]
1. 0.5 g/l Sera® Lube NEO 4. 0.5 g/l Sera Lube NEO 7. 1.0 g/l Sera Fast C-RD
2.0 g/l Sera Fil SBS 1.5 g/l Sera Gal CFTR-H
2.0 g/l NaOH (100%) 45.0 g/l Glauber Salt
6.0 ml/l H2O2 (50%) 8. 0.2 ml/l acetic acid (98%)
5. 0.02% Remazol® Gold SAM
2. 0.8 ml/l acetic acid (98%) 1.56% Remazol Terra Cotta SAM
1.94% Remazol Space SAM
3. 0.2 g/l Sera Zyme C-SX
6. 15 g/l Soda ash
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
Marketing Coloration Fanny Vermandel
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July 2015
Detailed bluesign® Blue Way calculations
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
Results shown as in bluesign® Blue Way Tool
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
Marketing Coloration Fanny Vermandel
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July 2015
bluesign® blueXpert – “Sera® Eco Wash process”
- 50 % - 49 % - 51 % - 28 % - 31% - 38 %
water energy CO2 emissions time chemicals costs
Huge Savings for all measured parameters
Chemicals Savings: dyes & auxiliary costs in both processes are
considered identical, chemicals savings represent the dyes and
Glauber Salt quantities
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
Marketing Coloration Fanny Vermandel
10
July 2015
Polyester Dyeing
Conventional Exhaust Dyeing Process vs
Scour/Dyeing Optidye PES Process with Dianix ® XF2
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
Optidye PES
Which Data Are Required for the Optidye PES calculations?
Dyes/auxiliaries Machinery data Article data
Diffusion coefficient Heating rate min./max. Type & Form
Levelling properties Temperature range V Value
Liquor turnover pH Correction
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
Optidye PES, Recipe & Process Optimization for Polyester Dyeing
Critical temperature range
TStart ... TEnd
Heating rate
Dyeing time at max. temperature
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
Optidye PES - Realization in Practice
Determination V value for PES (dyeing rate)
Calculation of process parameters
Trial Dyeings in lab and in bulk
Transfer of the data to production
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
Marketing Coloration Fanny Vermandel
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July 2015
Optidye PES, Method for Determining the V Value of Polyester
V Scale
Dyeing:
0.33% Dianix® Red CC 0.25
1 g/l Sera® Sperse M-IS, pH 4.5, LR 40:1 Exhaust:
20 min at 105 °C Remaining liquor with new sample
(heating rate: as rapid as possible) 0.5 60 min at 130 °C
Visual determination
4
V = 0.5
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
Optidye PES Examples of V Values in One Dye house
Dyeing
Exhaust
V = 0.5 V = 3.0 V = 4.0 V = 8.0
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
Optidye PES - Temperature Programs for Different PES Fibres
140 6 min
20 min
130
90 min
120
Temperature [°C]
110
100
90 V = 0.25 (sewing yarn)
V = 1.00
80 V = 3.00 (micro fibre)
0.30% Dianix® Yellow S-4G
70
0.15% Dianix Red S-G
0.30% Dianix Blue S-2R
60
0 30 60 90 120 150 180
Time (min)
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
Sustainable processes in disperse dyeing
Comparison for Polyester Black Shade for high end Active Wear
Conventional processing for Optimized processing with scour/dyeing, Optidye® PES
medium to dark shades calculation and reductive clearing in dyeing bath
process time 415 min, 6 baths process time 225 min, 3 baths
1. 1.0 g/l washing detergent 2. 2.0 g/l dispersing agent 1. 2.0 g/l Sera® Gal P-SDL (dispersing) 2. 0.38 % Dianix® Yellow Brown XF2
2.0 g/l soda ash 1.0 g/l lubricant 1.0 g/l Sera Lube M-CF (lubricant) 0.45 % Dianix Rubine XF2
2.0 g/l mild oxidant 2.0 g/l Sera Con P-NR (mild oxidant) 7.20 % Dianix Black XF2
3. dyestuff pH 4.5 sodium acetate/acetic acid pH 4.5 Sera Con M-TC (acid donor)
4. Alkaline reductive clear
5.0 ml/l caustic soda 50%
4. 5.0 ml/l caustic soda 50% 3. Alkaline reductive clear 4. pH 5 acetic acid
3.0 g/l Sera® Con P-RCN or or
3.0 g/l hydrosulfite 5.0 ml/l caustic soda 50%
3.0 g/l Sera Con P-RCN or Acid reductive clear
2.0 g/l Sera® Con P-ACT
5. pH 5 acetic acid Acid reductive clear
pH 3.5 - 4 V-value=1
2.0 g/l Sera Con P-ACT, pH 3.5 - 4
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
Marketing Coloration Fanny Vermandel
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July 2015
bluesign® blueXpert – “Scour/Dyeing Optidye PES process”
- 50 % - 53 % - 54 % - 46 % - 28 %
water energy CO2 emissions time costs
Huge Savings for all measured parameters
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
Notes on trademarks:
DyStar, econfidence, Sera, Levafix, Remazol, Dianix are
trademarks of DyStar Colours Distribution GmbH
Bluesign is a trademark of bluesign technologies ag
© DyStar Singapore Pte. Ltd. 1A International Business Park #10-01 Singapore 609933 www.DyStar.com
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July 2015
