Exhaust Dyeing

Regional Technical Service Europe Exhaust dyeing DyStar.doc/DH

Indanthren dyes in exhaust dyeing

Indanthren® dyesin

exhaust dyeing



ContentRecommendations for dyeing yarn with vat dyes for the first time................................................................................................................................................ 3Good levelness can be achieved in vat dyeings through.............................................................................................................................................................. 4Advantages of cylindrical and conical packages .......................................................................................................................................................................... 5Tube systems .............................................................................................................................................................................................................................. 6Advantages and disadvantages of winding types......................................................................................................................................................................... 7Winding density as a function of yarn thickness and type ............................................................................................................................................................ 8Properties of pressed packages................................................................................................................................................................................................... 9Effect of temperature on liquor flow rate .................................................................................................................................................................................... 10Dye liquor flow rate for cellulosic yarns ...................................................................................................................................................................................... 11Loss in weight of cotton ............................................................................................................................................................................................................. 12Water requirements ................................................................................................................................................................................................................... 13Water quality.............................................................................................................................................................................................................................. 14Complexing capacity for CaCO3................................................................................................................................................................................................. 16Rub fastness.............................................................................................................................................................................................................................. 17Colour measurement units ......................................................................................................................................................................................................... 18Reasons for a pretreatment ....................................................................................................................................................................................................... 20Pretreatment of cotton yarn ....................................................................................................................................................................................................... 21Prepigmentation process ........................................................................................................................................................................................................... 23Leuco process ........................................................................................................................................................................................................................... 24High temperature process.......................................................................................................................................................................................................... 25Dye selection for the high temperature process ......................................................................................................................................................................... 26Indanthren

® Brilliant Red LGG.................................................................................................................................................................................................... 27

Hank yarn dyeing with Indanthren dyes ..................................................................................................................................................................................... 28Dyeing of PES/CEL with disperse / Indanthren dyes.................................................................................................................................................................. 29Finishing of Indanthren dyeings ................................................................................................................................................................................................. 30Obtaining a deeper shade in a fresh dyebath............................................................................................................................................................................. 33Dye selection for cross-wound packages................................................................................................................................................................................... 34Auxiliaries recommendation for exhaust processes ................................................................................................................................................................... 36RoDos process .......................................................................................................................................................................................................................... 42Dyeing on the piece dyeing beam .............................................................................................................................................................................................. 49Indanthren combination recommendations ................................................................................................................................................................................ 55RAISA - computer program for the application of Indanthren dyes ............................................................................................................................................ 59Note ........................................................................................................................................................................................................................................... 60



Recommendations for dyeing yarn with vat dyes for the first time

• Use dyes with good levelling properties(Group A in our recommended list; see further below)

• Avoid dyeings > 6% (with brilliant green > 4 %).

• Avoid winding densities above 400 g/l and packages over180 mm diameter.

• Pump output of the equipment should be 20-30 l/kg/min.

• Material to be dyed should be completely submerged in theliquor (no short liquor).

• It should be possible to reverse the liquor flow.



Good levelness can be achieved in vat dyeings through

• Regular package structure.

• Pump performance that guarantees a liquor throughput of 20-30 l/kg/min.

• Intensive pretreatment: boiling-off or bleaching.

• Pigmentation and dyeing at high temperatures (80 - 90 °C).

• RoDos® process

• The addition of levelling auxiliaries (Peregal® P, Albigen® A).

• Optimum finishing of the dyeing.

• Use of dyes with good levelling-out properties.



Advantages of cylindrical and conical packages

Comparison: conical - cylindrical ð Preference for cylindrical package form

Reason:

Winding Exacter with constant radius.

Rounding off Not necessary as winding is exacter.edges

Spacer No spacers needed for insertion systems; better sealing; up to 30 %higher loading possible.

Loading the Simpler; no spacers;dyeing machine Supply from winding dept. in blocks of 6.

Pressing Better utilization of available space and better seal betweenpackages.

Flow Smaller edge to middle difference;better seal between packages.

Unwinding Easier unwinding, particularly with long packages.



Tubes Fibres Advantages Disadvantages

Tube systems

Biko Press PAC + WO Weight up to 3 kg; Winding not preciseyarn compression

AVA CO up to Nm 40/1 Weight up to 1.5 kg; Unwinding problems;yarn compression no compression

Di CO up to Nm 100/1 Weight up to 1.5 kg; No compressionPES/CO no spacers

Multiflex CO + PES/CO Weight up to 1 kg; One-way tubesTube compression Spacers necessary

AC tubes CO up to Nm 50/1 Weight up to 1.5 kg; One-way tubestube compression;no spacers

Metal Universal very durable; Expensive;CO + PES/CO no staining PES/CO: inner layers may

become shiny



Advantages and disadvantages of winding types

Winding machine cost: low high

Package winding: stable unstable

Density: uniform not uniform

Unwinding performance: not so good good

Characteristic image zones: yes no

Normal winding(constant angle)

Precision winding(changing angle)



Substrate Yarn thickness Winding density

Winding density as a function of yarn thickness and type

Cotton up to Nm 40/1 ≈ 400 g/l



PES/Cotton Nm 50/1 ≈ 350 g/l

Linen ≈ 250 - 350 g/l

Viscose ≈ 350 g/l

Calculation of winding density: RAISA exhaust process



Properties of pressed packages

Winding thickness = Tube diameter

Winding density uncompressed = 330 g/l20 % compressed ≈ 400 g/l

Package diameter max. 200 mm

Package weight 5“ tube ≈ 1400 g (tube 130 g)6“ tube ≈ 1600 g (tube 150 g)



Effect of temperature on liquor flow rate

Example: Cotton, Nm 70/1, compressed packages, 1,450 g each220 mm package diameter420 g/l winding density1.5 bar pressure drop

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Dye liquor flow rate for cellulosic yarns

The above values take into account the usual leaks in the package column.

The true flow rate is therefore normally 10-30 % less, but nevertheless adequate.

Liquor throughput l / min / kg fabric

too low < 20sufficient 20 - 25good to very good 25 - 30too high > 30



Loss in weight of cotton

The loss in weight depends on the quality of the fibre.

Boiling-off / Bleaching

4 - 6 %

Bleaching + Mercerizing

6 - 10 %

Dyeing of grey yarn

4 - 6 %

Dyeing of pretreatedfabric

Possible gain afterdyeing



Vat dyeing

light dark

Reactive dyeing

light dark

80 l 120 l 100 l 120 l

Water requirements

The following amounts of water are required for 1 kg* of cellulosic yarn:

Pretreatment: 3x 10 l 3x 10 l 3x 10 l 3x 10 l

Dyeing: 1x 10 l 1x 10 l 1x 10 l 1x 10 l

Finishing: 4x 10 l 8x 10 l 6x 10 l 8x 10 l

Total:

* Liquor ratio 10:1



Water qualityThe process water for textile mills must meet the following minimum standard:

• Colourless / clear

• Free from vegetable and mineral impurities

• Free from iron and manganese compounds

• Soft

pH: 6 - 8Hardness: max. 6 °ClarkSuspended matter: < 1 mg/lOrganic load: < 20 mg/lResidue on ignition: < 50 mg/lIron: < 0.1 mg/lManganese: < 0.05 mg/lCopper: < 0.01 mg/lNitrate: < 50 mg/lNitrite: < 5 mg/lFree CO2: 0 if possible (risk of corrosion)



Possible problems with hardness• Lower colour yield.

• Poor reproducibility of the dyeings.

• Dusting of the yarn, particularly when rewinding onto another bobbin.

• Poor fastness properties.

• Hard handle.

• Poor wettability.

• Deposits on the machines.

• Poor levelling-out properties, particularly with wound packages.

• Formation of spots.

These problems can be avoided by

. . . good pretreatment of the fabric.

. . . the use of Dekol® SAD, SN, Trilon® TA or TB in the dyeing process.

Of iron is present, Trilon® FE should be used too.



Complexing capacity for CaCO3

1 g . . . complexes . . . mg CaCO3* . . . °dH** . . . °Clark . . . °fH p.p.m. (USA)

Dekol® SAD 108 6.0 7.5 10.8 108

Dekol® SN 125 7.0 8.7 12.5 125

Lufibrol® DK 162 9.1 11.3 16.2 162

Trilon® TA Powder 353 19.8 24.7 35.3 353

Trilon® TA Liquid 176 9.9 12.3 17.6 176

Trilon® TB Powder 235 13.2 16.4 23.5 235

Trilon® TB Liquid 118 6.6 8.2 11.8 118

* at pH 11** 1 °dH = 10 mg CaO / l water = 17.9 mg CaCO3 / l water



Rub fastness

• As the rub fastness depends very much on the substrate, the pattern card gives no data.

• If the dry rub fastness is good, it is normally not possible to improve the wet rub fastness.

• Staining through fibre abrasion and foreign bodies are not taken into account.

• Dark reactive dyeings often have better wet rub fastness than vat dyeings(½ - 1 point).

Factors that affect the rub fastness:û Material.û Dye concentration.û Water hardness.û Improper finishing of the dyeing.û Inadequate liquor flow rate.



Colour measurement units

Total colour difference: DE DE

Difference in lightness: DL DL

Difference in saturation: DS DC(Brilliance, clarity)

Difference in shade: DT DH

Daylight: D 65

Incandescent light: A

Department store light: TL 84

Fluorescent tube light: F

NBS Cielab



Pretreatment



Reasons for a pretreatment

• Good rewetting of the fabric (e.g.: terry fabric).

• Brilliant shades.

• Heavy contamination in short liquors.

• High amounts of spin-finishing oils.

• Migration of impurities during drying in rapid dryers.

• Reproducibility of the dyeings.



Boiling-off Bleaching

Pretreatment of cotton yarn

2.0 g/l NaOH 100 % 4.0 ml/l hydrogen peroxide 50 %1.0 g/l Lufibrol® DK 1.5 g/l NaOH 100 %1.0 g/l Kieralon® CD or MFB 1.0 g/l Prestogen® D

1.0 g/l Kieralon® CD or MFB

Liquor ratio 10 : 1 Liquor ratio 10 : 1Treatment time 30 min Treatment time 30 minTemperature 95 °C Temperature 95 °C

rinse. Extraction, if required:

When the bleaching time is up, add to the liquor: 1,0 g/l Lufibrol® DK and maintain at 95 °C for a further 10 min

rinse.



Dyeingof

cross-woundpackages



Prepigmentation process (< 3 % Indanthren® dye)

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� � 2 g/l Dekol® SN ... ml/l caustic soda 38 °Bé ... % Indanthren dye ... g/l Hydrosulfite Conc. BASF

1 - 2 g/l Peregal® P (if necessary)... g/l sodium nitrite or glucose (necessary for dyes

that are sensitive to overreduction)



Leuco process (> 3 % Indanthren® dye)

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� 2 g/l Dekol® SN ... % Indanthren dye ... ml/l caustic soda 38 °Bé ... g/l Hydrosulfite Conc. BASF1-2 g/l Peregal® P (if necessary)... g/l sodium nitrite or glucose (necessary for dyes that are sensitive to overreduction)



High temperature process (< 2 % Indanthren® dye*)

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� 2 g/l Dekol® SN � 3 ml/l caustic soda 38 °Bé 1 g/l Trilon® TA Powder 3 g/l Hydrosulfite Conc. BASF

< 2 % Indanthren dye *... ml/l caustic soda 38 °Bé 4 g/l Rongal® 5242 or > 5 g/l Rongal HT

1-2 g/l Peregal® P (if necessary) 3 g/l Glucose (necessary for dyes that are sensitive to overreduction;

not necessary in case of Rongal 5242)* See „Dye selection for the high temperature process“



Dye selection for the high temperature process

Indanthren® Shade Indanthren® Shade

Yellow 5GF unchanged Blue BC** unchangedGolden Orange G* weaker Blue CLF weakerOrange 3G duller, weaker Brilliant Green FFB weakerOrange RRTS duller, weaker Olive Green B unchangedRed FBB weaker Olive MW brownerBrilliant Violet RR much bluer Olive T brownerBrilliant Violet 3B bluer, weaker Brown BR yellowerDark Blue BOA unchanged Brown RN yellower, weakerNavy Blue BF greener Brown LBG yellowerDark Blue DB** weaker Grey 5607 bluer, weakerDark Blue 5508** weaker Direct Black RBS unchangedNavy Blue G redder Direct Black RB unchangedBrilliant Blue RCL** unchanged Direct Black R unchangedBlue RS** unchanged Direct Black 5589 unchanged

* At < 1% take account of fastness to light** Sensitive to overreduction



Indanthren® Brilliant Red LGG

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� 2 g/l Dekol® SN � 10 min suck off (vacuum), 1 g/l Trilon® TA Powder Oxidation: 5.0 ml/l hydrogen peroxide 50 %... % Indanthren Brilliant Red LGG ®Colloisol * 0.5 g/l Setamol® WS... g/l soda ash 5 min cold, 15 min at 60 °C,... g/l Hydrosulfite Conc. BASF drop the bath,

cold rinse with overflow until clear,� 25 g/l glaubers salt Soaping: see „Finishing of vat dyeings“

* Combination dyes see Combination recommendations „Brilliant Red“.



Hank yarn dyeing with Indanthren® dyes

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Dyeing Rinsing RinsingOxidation Soaping Rinsing

� 2 g/l Dekol® SN � Cold rinse with overflow until pH 10. 1 g/l Trilon® TA Liquid ... % Indanthren dye � Cold rinse without overflow ... ml/l caustic soda 38 °Bé ... g/l Hydrosulfite Conc. BASF � 4 ml/l hydrogen peroxide 50 %1-3 g/l Peregal® P (if necessary) 1 g/l Setamol® WS 3 g/l glucose (necessary for dyes

that are sensitive to overreduction) � 1 g/l Kieralon® B high conc.



Dyeing of PES/CEL with disperse / Indanthren® dyes

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� 1-2 g/l Dekol® SN � ... ml/l caustic soda 38 °Bé0.5 g/l Trilon® TA Powder ... g/l Hydrosulfite Conc. BASF1.0 g/l Setamol® WS 1-2 g/l Peregal® P (if necessary)... % disperse / Indanthren dye ... g/l sodium nitrite or glucose (necessary for... ml/l acetic acid pH 4 - 5 dyes that are sensitive to overreduction)



Finishing of Indanthren® dyeings (light shades, < 1 %)

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Oxidation Soaping Rinsing Softening

� � 2 g/l Ludigol® or hydrogen peroxide 50 % 2.0 g/l Basosoft® EUK

0.5 ml/l acetic acid 30 %� 1 g/l Kieralon® B high conc.



Finishing of Indanthren® dyeings (medium shades, 1 - 3 %)

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Oxidation Soapinng Rinsing SofteningReductiveclearing

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� 2 ml/l caustic soda 38 °Bé � 1.0 g/l Kieralon® B high conc.2 g/l Hydrosulfite Conc. BASF1 g/l Setamol® WS � 2.0 g/l Basosoft® EUK

0.5 ml/l acetic acid 30 %� 2 g/l Ludigol® or hydrogen peroxide 50 %

0.5 g/l Setamol® WS



Finishing of Indanthren® dyeings (dark shades, > 3 %)

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Oxidation 2nd soaping Rinsing SofteningReductiveclearing

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1st soaping

� 2 ml/l caustic soda 38 °Bé � 0.3 g/l Uniperol® O microperl2 g/l Hydrosulfite Conc. BASF1 g/l Setamol® WS � 1.0 g/l Kieralon® B high conc.

� 2 g/l Ludigol® or hydrogen peroxide 50 % � 2.0 g/l Basosoft® EUK0.5 g/l Setamol® WS 0.5 ml/l acetic acid 30 %



Obtaining a deeper shade in a fresh dyebathExample:

In vat dyeing, 2.0 % dyeing

approx. 90 %* of the dye is fixed in the yarn = 1.8 % dye *approx. 10 %* remains in the dye liquor, which is drained = 0.2 % dye *

To deepen a shade by 20% in a fresh dyebath requires:

10 %* to reestablish the original dye concentration = 0.2 % dye *20 % to deepen the shade = 0.4 % dyeQuantity of dye required = 0.6 % dye

Basic premises for calculating the chemicals:dye fixed in the yarn = 1.8 % dye *dye remaining in the liquor = 0.2 % dye *20 % to deepen the shade = 0.4 % dyeDye quantity to be used in the calculation = 2.4 % dye

* Exact value depends on dye, depth of shade, dyeing temperature, liquor ratio and levelling auxiliary.



Dye selection for cross-wound packages(Not high temperature process)Group A Group B Group CPastel shades Light / medium shades Dark shades

(up to approx. 2 % Colloisol)

Indanthren® Indanthren® Indanthren®

Yellow 5GF / F3GC Golden Orange G* Brilliant Red LGGOrange 3G Orange RRTS Navy Blue BF / TRRBrilliant Orange GR Brilliant Violet RR / 3B Dark Blue BOAScarlet GG Navy Blue G Dark Blue DB** / 5508**Red FBB Blue RS** / BC** / GC** Brown LBGRubine R Brilliant Blue RCL** Olive MW / TBlue CLF Olive Green B Direct Black R / RB / 5589Brilliant Green FFB Brown BR Black BBOlive R Direct Black RBSBrown RN / 5170Grey 5607 + all dyes listed in + all dyes listed in

Group A Groups A + B

* At < 1 % take account of fastness to light ** Sensitive to overreduction



Dye selection for cross-wound packages(Not high temperature process)

Group DShockoxidation(remove liquor by suction)is necessarily needed

Indanthren®

Brilliant Pink RBrilliant Orange RKBrilliant Red LGG ***Red FGL ***Red Violet RRN

Mainly used onmercericed cotton yarnorviscose (embroidery yarn

*** Soda or soda/caustic soda method



Indanthren dyes in the exhaust processGeneral informationYellow 5GFBrilliant, pure shade. Higher standard to light fastness than vat yellow 2. Suitable for HT process. Little shade change during soaping. Fast to colouredbleaching. Reduce pH to appr. 9 before oxidation, otherwise shade somewhat brownish. Combinations of green and a large amount of yellow are prone to“green eating”. Phototropic. Not fast to mercerizing.

Yellow F3GCNeutral yellow shade. Little shade change during soaping. Very good light fastness. Fast to coloured bleaching. Average chlorine fastness. Combinations ofgreen and a large amount of yellow are prone to “green eating”. The only yellow that is fast to mercerizing.

Yellow 3RVery high light- and wet fastnesses. In deep shades also fast to weathering. Good combination dye for beige and brown shades. At exposure to light quiterapid shade shift to brown (first break); resulting shade is very consistent.

Golden Yellow RKHigh tinctorial strength, economic, Strong staining on PES (lemon yellow). Fast soaping. Less “green eating”. Use Brilliant Pink R or Red Violett RRN asshading components.

Golden Orange GGood levelling properties. Combination dye for khaki and olive shades. Suitable for HT process. Pronounced shade change during soaping. Fast to colouredbleaching. Light fastness in pale shades may be a problem- use > 1%.

Orange 3GGood levelling properties. Standard and shading dye. Little shade change during soaping. High standard of fastness. Fast to coloured bleaching.

Brillant Orange GRHigh tinctorial strength and outstanding brilliant shade especially for warn clothes. Little change during soaping (redder). Very good compatibility withIndanthren Scarlet GG Colloisol.

Orange RRTSHigh colour strength. Economic. Not recommended for light shades, because of average levelling-out properties and moderate light fastness. Shading dyefor deep brown shades. Suitable for HT process. Little shade change during soaping. Protect vat from light. Fast to coloured bleaching. Good standard of wetfastness. Shade change towards yellow during drying and ironing (reversible).

Scarlet GGHigh all-over fastness. Standard and combination dye with high colour strength. Fast soaping.



Indanthren dyes in the exhaust processGeneral informationBrilliant Red LGGOnly suitable for yarn dyeing, not for rope dyeing, due to its low affinity.Most brilliant vat red for deep red shades. Good levelling properties. Colour yield increased with soda or soda/caustic soda. Use Yellow 5GF, Red FBB andBlue CLF as shading components. Not recommended as a shading component for pale shades, because of limited light fastness. Crosswound packagesmust be preoxidized by suction extraction after dyeing. The dye must be oxidized with a large amount of peroxide at pH 7 – 9. Not recommended forapplication in rope-dying machines. Low substantivity. Fast to coloured bleaching.

Red FGLOnly suitable for yarn dyeing, not for rope dyeing, due to its low affinity.Colour yield increased with soda or soda/caustic soda. No overflow rinse or reductive clearing. Must be oxidized with a large amount of peroxide at pH 7 – 9.Use Yellow 5GF, Red FBB and Blue CLF as shading components. The only weatherfast red of vat dyes. Some lack in wet fastness compared to other vatred brands. Higher light fastness in pale shades than other vat reds.

Red FBBStandard and combination dye. Good levelling properties. Suitable for HT process. Light shades should not be applied by the pigmentation process (pigmentaffinity too high). Little shade change during soaping. High standard of fastness. Fast to coloured bleaching.

Brilliant Pink ROnly suitable for yarn dyeing, not for rope dyeing, due to its low affinity.Sensitive against most auxiliaries, use only Setamol WS, Avolan IS or sulphonated castor oil (Monopolbrillantöl). No levelling agent! Dye at highertemperatures (80 – 90°C). No overflow rinse or reductive clearing. Oxidation only with peroxide, appr. 10 ml/l 35% 38°Bé. Light tenderer. Use Golden YellowRK or Red Violett RRN as shading components.

Rubine RVery high tinctorial strength. Pronounced shade change during soaping, therefore exact soaping conditions necessary. Best alternative for heavy red andrubine shades.

Red Violet RRNOnly suitable for yarn dyeing, not for rope dyeing, due to its low affinity.Sensitive against most auxiliaries, use only Setamol WS, Avolan IS or sulphonated castor oil (Monopolbrillantöl). No levelling agent! Dye at highertemperatures (80 – 90°C). No overflow rinse or reductive clearing. Oxidation only with peroxide, appr. 10 ml/l 35% 38°Bé. Use Golden Yellow RK or BrilliantPink R as shading components.



Indanthren dyes in the exhaust processGeneral informationBrilliant Violet RRMost brilliant violet dye. High colour strength. Average levelling-out properties in light shades. Apply with Peregal P. Becomes bluer as dyeing temperatureincreases. Suitable for HT process (much bluer). Shade may change during soaping and drying. Fast to coloured bleaching. Use as a single dye for solidshades only if there are no particular requirements with regard to fastness to water drops and ironing. Faster to mercerizing than Brilliant Violet 3B.

Brilliant Violet 3BHigh colour strength. Can improve the chlorine fastness of Indanthren Blue BC when applied in combinations. Suitable for HT process (somewhat bluer).Fast to coloured bleaching. Other properties similar to those of RR.

Navy Blue TRRHigh colour strength. The only navy blue dye with good fastness to water drops and ironing. Retarded by dye-affinitive levelling and dispersing agents.Becomes redder as dyeing temperature increases. Dry cleaning causes the dyeings to bleed out red.

Navy Blue BFHigh colour strength. Economic. Apply with Peregal P. The only navy blue dye that covers dead cotton. Suitable for HT process (greener). Pronounced shadechange towards red during soaping. Fast to coloured bleaching. Limited fastness to water drops, ironing and mercerizing. Note shade change caused byfinishing (becomes redder).

Navy Blue GGreenish navy blue. Good levelling properties. Mainly for medium shades. Suitable for HT process (redder). Shade change towards red during soaping andon overdrying. Fast to coloured bleaching. High standard of fastness. Limited fastness to water drops and ironing.

Dark Blue BOAHigh colour strength. Economic. Standard dye for dark blue shades. Apply with Peregal P. Suitable for HT process. Pronounced shade change towards redduring soaping. High standard of fastness. Limited fastness to water drops and ironing.

Dark Blue DBHigh colour strength. Economic. Suitable for HT process but glucose necessary. Pronounced shade change towards red during soaping, but less than withDark Blue 5508. High standard of fastness.

Dark Blue 5508High colour strength. Economic. Poorer levelling properties than Dark Blue DB. Suitable for HT process but glucose necessary. Pronounced shade changetowards red during soaping. Fast to coloured bleaching. High standard of fastness. Better cost-benefit ratio than Dark Blue DB.



Indanthren dyes in the exhaust processGeneral informationBrilliant Blue RCLClear, brilliant blue shade. Apply with plenty of caustic soda and not too much hydrosulfite. Use Blue CLF for pale shades, because of better levelling-out.Sensitive to overreduction and overoxidation. Suitable for HT process but glucose necessary. Fast to coloured bleaching. Good fastness to chlorine. Highstandard of fastness. Ideal for workwear.

Blue RSHigh colour strength. Economic. Apply with plenty of caustic soda and not too much hydrosulfite. Good levelling properties. Suitable for HT process butglucose necessary. High standard of fastness. Not fast to chlorine. Sensitive to overreduction and overoxidation.

Blue BCStandard dye. High colour strength. Economic. Suitable for HT process but glucose necessary. Fast to coloured bleaching with peroxide. Limited fastness tochlorine. Good general standard of fastness. Sensitive to overreduction and overoxidation.

Blue CLFTop-quality product with a high standard of fastness. No overreduction or overoxidation. Outstanding levelling properties. As a combination dye, mainly forpale to medium shades. Higher colour yield when soda is used as the alkali. Vat skinning. Low substantivity. Suitable for HT process. Little shade changeduring soaping. Fast to coloured bleaching. Maximum chlorine fastness, but chlorine treatment at pH values below 9 partially destroys the dye.

Brilliant Green FFBStandard dye for all green shades. Good levelling properties. Suitable for HT process. High standard of fastness. Fast to coloured bleaching. Limitedfastness to ironing (shade change towards blue on overdrying). Limited rub and wash fastness in deep shades (Olive Green B performs better). Limited lightfastness in combinations with a large amount of yellow.

Olive Green BStandard dye for maximum fastness requirements. Stable in the HT process. Pronounced shade change during soaping. In green, olive and khaki shades,improves the light fastness of the other dyes. Fast to weathering. Fast to coloured bleaching.

Olive MWStandard dye for olive shades. Moderate levelling properties. Little shade change during soaping. Good coverage of dead cotton. Suitable for HT process(browner). High standard of fastness. Fast to coloured bleaching.

Olive TStandard dye for military and civilian uniforms. Moderate levelling properties (add Peregal P). Suitable for HT process (browner). Little shade change duringsoaping. Fast to coloured bleaching. Outstanding fastness to light, water drops and ironing.



Indanthren dyes in the exhaust processGeneral informationOlive RGood levelling properties. Mainly for pale to medium shades. Pronounced shade change during soaping. On military fabrics, IR reflectance is similar tochlorophyll curve. Fast to coloured bleaching. Good light fastness. Limited fastness to water drops, ironing and mercerizing.

Brown BRStandard dye. Moderate levelling-out properties in pastel shades. Suitable for HT process. Becomes yellower as temperature increases. Little shade changeduring soaping. Fast to coloured bleaching. Fast to light and weathering.

Brown RNGood levelling properties. Very good in combinations with other IW dyes. High standard of fastness. Fast to coloured bleaching.

Brown 5170Ideal combination dye for beige, brown and olive shades. Good levelling properties. For pale to medium shades. Little shade change during soaping. Fast tocoloured bleaching. High light fastness. Fast to weathering. Average coverage of dead cotton.

Brown LBGHigh colour strength. Economic. Use Peregal P for pale and medium shades. Little shade change during soaping. Outstanding fastness to light andweathering. Good coverage of dead cotton. Fast to coloured bleaching with peroxide. Limited chlorine fastness.

Grey 5607Ideal standard dye for pale to medium grey shades. Good levelling properties. Little shade change during soaping. Suitable for HT process (bluer). Fast tocoloured bleaching. Fast to chlorine.

Grey NCFor military textiles (IR values). Fast soaping. Excellent fastness property profile.

Direct Black RBS/RBHomogeneous grey and black dyes. Economic medium and deep grey shades. Use Peregal P. Suitable for HT process. Fast to coloured bleaching withperoxide. May stain accompanying material red during chlorine bleaching. Cover dead cotton. Limited fastness to light and water drops in pale shades.

Direct Black 5589/RHigh colour strength. Economic. For black and deep grey shades. Suitable for HT process. Fast to coloured bleaching. Fast to washing, light and weathering.

Black BBEconomic deep black. Must be oxidized with strong oxidizing agent (hypochlorite or persulfate). Not suitable for coloured bleach goods and washables.Stains accompanying material red.



Auxiliaries recommendation for exhaust processes Pretreatment Dyeing Finishing

Dekol® SN Dispersant (protective colloid) and chelating agent for all stages in dyeing textiles produced from cotton and ist blends.

Peregal® P Improves the levelling-out properties of vat dyes, generally without affecting the color yield.

Trilon® TA Form water-soluble complexes with the ions of alkaline earths and heavy metals.

Hydrosulfit konz. BASF Universal reducing agent.

Rongal® HT Special reducing agent for high temperature processes.

Setamol® WS / BL Dye-dispersing agent.

Rongal® 5242 Liquid reducing agent. Insensitive to the atmospheric oxygen. It is necessary to use small amounts of Hydrosulfite Conc. BASF to achieve complete vatting.

Albigen® A Stripping and levelling agent.

Lufibrol® DK Extracting agent with dispersing and complexing effect.

Kieralon® CD / MFB Low-foaming wetting agent and detergent with emulsifying and extracive action and complexing effect.

Ludigol® Oxidizing agent for high alkaline liquors too. Without fibre damage.

Uniperol® O microperle Aftertreatment agent for a better rub fastness. Removes depositions of dye pigments.

Prestogen® D Peroxide stabilizer with dispersing effect.

Kieralon® B high conc. Soaping-off agent with good wetting and dispersing effect.

Primasol® NF Deaerating wetting agent. Rapid wetting at low temperatures. More foam formation in fully softened water.

Leophen® M Wetting agent with deaerating and foam-suppressing action. Not applicable in dyebaths with vat dyes.

Basosoft® EUK Liquid softener for all types of fibres.



RoDos® process

... for optimum levelling of vat dyeings



Bath exhaustion rate

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Dyeing time

Bat

h e

xhau

stio

n, %

too fast

optimum rate

too slow



Bath exhaustion in vat dyeing (prepigmentation process)

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Dyeing time, min

Bat

h e

xhau

stio

n, %

Pigmentation Single addition of hydrosulfite Metered hydrosulfite*

* Metering of hydrosulfite is not recommended.



Redox potential, mV

40 °C 60 °C 80 °C- 200

- 300

- 400

- 500

- 600

- 700

- 800

- 900

- 1000

40 °C 60 °C 80 °C

HydrosulfiteRongal® 5242

2 % Indanthren® Olive T ®Colloisol



Bath exhaustion and redox potential in Indanthren dyeingRoDos® process

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0 10 20 30 40 50 60 70Time, min

Bat

h e

xhau

stio

n, %

-1000

-800

-600

-400

-200

080 °C 80 °C 60 °C

Red

ox p

oten

tial, mVPigmentation

Start of NaOH/Rongal® 5242 metering

End of metering

+ hydrosulfite



RoDos® process

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0 10 20 30 40 50 60 70Time, min

Tem

per

atu

re, °

C

� � �

� �2 g/l Dekol® SN 18 ml/l NaOH 38 °Bé1 g/l Trilon® TA Powder 2 g/l Rongal® 5242 (depending on depth of shade)... % Indanthren® dye add at a constant rate over 20 min2 ml/l NaOH 38 °Bé2 g/l Peregal® P �

... ml/l NaOH 38 °Bé (final quantity, calculated with RAISA)2-4 g/l Hydrosulfite Conc. BASF (depending on depth of shade)

Complete reduction and maintenanceof the redox potential by addition of

hydrosulfite

Slow reduction by metered additionof NaOH/Rongal® 5242

Pigmentation



Advantages of the RoDos® process

• Better levelness.

• Modern measurement and control technology can be used to monitor thestate of the vat (redox potential).

• Reduced wastewater burden as a result of lower hydrosulfite concentration.

• Rongal® 5242 protects against overreduction by hydrosulfite as long as thequantity of hydrosulfite does not far exceed the quantity of Rongal 5242.

• Easy to meter Rongal 5242 as it is liquid, stable to the oxygen in air andwater and it is active only with enough quantity of caustic soda.



Dyeing on the piece dyeing beam



Winding the goods onto the beam

When winding goods onto a beam, the following points must be noted:

⇒ Tension of the goods

⇒ Thickness of the goods on the beam

⇒ Covering the perforations



Thickness of goods on the beam

The structure and density of the goods, and the diameter of the beam determine howmuch can be wound onto the beam.

The following data can be taken as a guide

• Tightly woven fabrics:

Beam diameter in mm = batch size in m

• Open fabrics:

Beam diameter in mm x 2 = batch size in m

• Terry fabric and knitgoods:

Batch size depends on the diameter of the beam and the sizeof the dyeing machine.



Coverage of the perforationsOpen fabric: overlap = winding thicknessTight-woven Ware: overlap = approx. 4 - 6 cm

Overlap too small:

Correct overlap:

O O O O O O O O O O O O O O O O O O O O O O O O O O O O O OO O O O O O O O O O O O O O O

O O O O O O O O O O O O O O O O O O O O O O O O O O O O O OO O O O O O O O O O O O O O O

Material

Material

Beam

Beam

Overlap

Overlap



Dye selection for piece dyeing

Group A Group B Group CPastel shades Light / medium shades Dark shades

(up to approx. 2 % Colloisol)

Indanthren® Indanthren® Indanthren®

Yellow 5GF / F3GC Golden Orange G* Navy Blue BF / TRROrange 3G Orange RRTS Dark Blue BOABrilliant Orange GR Brilliant Violet RR / 3B Dark Blue DB** / 5508**Scarlet GG Navy Blue G Brown LBGRed FBB Brilliant Blue RCL** Olive MW / TRubine R Blue RS** / BC** Direct Black R / RB / 5589Blue CLF Olive Green B Black BBBrilliant Green FFB Brown BROlive R Direct Black RBSBrown RN / 5170Grey 5607

+ all dyes listed in + all dyes listed in Group A Groups A + B

* At < 1 % take account of fastness to light ** Sensitive to overreduction



Indanthren® dyes

+ =

Combination recommendationsfor exhaust dyeing



Indanthren® combination recommendationsExhaust dyeingMain dyeShading dye

Yellow 5GF / F3GC Golden Orange G* Brilliant Red LGG (not for piece dyeing)Orange 3G Orange 3G / RRTS* Yellow 5GFScarlet GG Brilliant Orange GR Red FGL (not for piece dyeing)Red FBB Yellow 5GF / F3GC Red FBBBrilliant Green FFB Red FBB Blue CLFBrown RN Brown RN / 5170Olive R Olive R

Red FBB / Rubin R Brilliant Violet RR Blue CLFYellow 5GF / F3GC Brilliant Violet 3B Red FBBOrange 3G / RRTS* Red FBB Brilliant Green FFBScarlet GG Rubin R Olive RBrilliant Orange GR Blue RS* Brown RNBlue CLF / RS* / BC* Blue BC* Grey 5607Brown RN / 5170 / BR* Blue CLF

Yellow

Violet

Orange

Light blue

Brilliant Red***

Red

* ≥ 1% dye** ≥ 2 % dye*** Soda or soda/caustic soda




Brilliant Blue RCL Grey 5607 Blue BC* / RS* / CLFBlue RS* Red FBB Navy Blue G*Blue BC* Navy Blue G* Red FBBRed FBB Brilliant Violet 3B Brilliant Violet 3BBrilliant Violet 3B Blue CLF / RS* / BC* Brilliant Green FFBBrilliant Green FFB Brown RN / 5170 Olive Green B

Dark Blue DB* / 5508* Brilliant Green FFB Brown RN / 5170Navy Blue G* / BF* / TRR* Olive Green B* Yellow 5GF / F3GCScarlet GG Yellow 5GF / F3GC Orange 3GRed FBB Orange 3G Scarlet GGRubin R Blue CLF / RS* / BC* Red FBBBrilliant Green FFB Brown RN / 5170 Brilliant Green FFBOlive Green B Olive R Olive RBrown BR* Grey 5607Direct Black RB

Kingfisher, pigeonRoyal blue

GreenNavy blue, Dark blue Beige

Grey blue





Olive R / MW* / T** Brown RN / 5170 Grey 5607Yellow 5GF / F3GC Brown BR* / LBG** Yellow 5GF / F3GCOrange 3G Yellow 5GF / F3GC Orange 3GGolden Orange G* Orange 3G / RRTS* Scarlet GGScarlet GG Golden Orange G* Red FBBRed FBB Scarlet GG Navy Blue G*Navy Blue G* Red FBB Blue CLFDark Blue DB* Blue RS* / BC* Brilliant Green FFBBlue CLF / RS* / BC* Brilliant Green FFB Olive RBrilliant Green FFB Olive Green B Brown RN / 5170Olive Green B Olive R / MW*Brown RN / 5170 Direct Black RB*Brown BR* / LBG**

Olive Grey, Light greyBrown





Direct Black RB Direct Black 5589 Black BBDirect Black RBS Direct Black R / RBOrange 3G Navy Blue G*Orange RRTS* Navy Blue BF*Red FBB Dark Blue DB*Dark Blue DB* / 5508* Dark Blue 5508*Blue RS* / BC* Olive Green BBlue CLF Olive TOlive Green B Brown BR* / LBG*Olive R / MW* / T**Brown 5170 / BR*

BlackDark grey Black




RAISA - computer program for the application of Indanthren® dyesRAISA contents the following segments:

General informationsProduct information• Dyes• Auxiliaries• EcologyProcess information• Continuous processes• exhaust processesCalculations• Dye calculation (g/l, %, g/kg)• NaOH concentration• Amounts of Trilon to use• Temperature conversion (°C, °F)Fibre separationTitration procedures• Caustic soda, soda ash• Hydrosulfite• Rongal 5242• Ludigol• Hydrogene peroxide• Sodium hypochlorite

RAISA has been developed for our customers in order to provide information about our dyes, auxiliaries and the different processes.

There is also the possibility for different calculations.

Exhaust processesGeneral• GeneralCombination recommendations• Combination recommendationsDye selection• Dye selection on fastness grounds

or technical criteria in processingCalculations• Chemical calculation for

- cross wound packages, hank yarn and beam- Overflow, jet, winch and drum dyeig machines- Jig with / without metering of chemicals

• Package density• Yarn count systems

(dtex, den, Nm, Ne ...)Fault tracing• Fault tracing

Continuous processes

R ecipe calculation andA pplication technology for I ndanthren dyesS ytematicallyA djusted



Note

The information submitted in this publication is based on our current knowledge and experience. In view of the many factors that may affect processing and application, these data do not relieve processors from

the responsibility of carrying out their own tests and experiments; neither do they imply any legally binding assurance of certain properties or of suitability for a specific purpose. It is the

responsibility of those to whom we supply our products to ensure that any proprietary rights and existing laws and

legislation are observed.

The following brand names are registered Trade Marks of DyStar :Indanthren, Colloisol

The following brand names are registered Trade Marks of :Albigen, Basosoft, Dekol, Kieralon, Ludigol, Lufibrol, Peregal, Prestogen, Primasol,Rongal, Setamol, Trilon, Uniperol und Vitexol.

Exhaust Dyeing

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