Foam Dyeing

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FOAM DYEING TECHNOLOGY

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Transcript of Foam Dyeing

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Prepared By : Mazadul Hasan sheshirID: 201000040000813th Batch (session 2009-2013)Department : Wet Processing Technology Email: [email protected] : www. Textilelab.blogspot.com (visit)

Southeast University Department Of Textile Engineering

I/A 251,252 Tejgaon Dhaka Bangladesh

Prepared By :

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In case of foam dyeing, the main dyeing elements is foam. For that’s this dyeing is called foam dyeing. A fabric is padded with a foam formed from an aqueous solution of a dyestuff, a foaming agent and a carrier for the dyestuff and the padded fabric is maintained at elevated temperatures to fix the dye. The advantages of the process include improved dye prefixation, improved migration of the dye into the fiber, higher color yields in the fabric even after relatively short dyeing times and improved dimensional stability of the dyed fabrics.

Foam is a dispersion of a gas in a liquid. Here the liquid is generally water and the gas is generally air but it may also be an inert gas. This is familiar as fort on beer shaving foam etc.

Foam Dyeing

FOAM DYEING

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Broadly there are two types of foam namely

• Dispersion foam

• Condensation foam

TYPES OF FOAM:

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1. White fabric - cotton, rayon, silk or other natural fiber to dye on

2. Dharma Fiber Reactive MX dyes

3. Soda Ash Fixer

4. Synthrapol

5. Squeeze bottles to hold your dyes

6. Foam shaving cream, preferably containing aloe

7. Flat, shallow, plastic or metal pan

8. Plastic mixing bowls

9. Wire whisk

10.Tape

MATERIALS NEED FOR FOAM DYEING:

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1. It should generate foam readily.

2. It should offer a good wetting capability.

3. It should exert fast an uniform wetting action.

4. It should show little or no effect on color fastness.

5. It should be compatible with other products of the finishing mix.

6. It should be least effect ed by water hardness.

7. It should not cause yellowing of white materials.

8. It should be easily stabilized. 9. It should be capable of producing various bubble sizes to meet specific

requirements.

REQUIREMENTS OF FOAMING AGENTS:

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1. Pre-wash the fabric in Synthrapol. This removes any oils or dirt that might be on the fabric and gives you better dye results. 2. Dissolve one cup soda ash in one gallon of hot water. Soak the fabric in the soda ash solution for 5-10 minutes, wring lightly and hang dry.

3. Dissolve your dye powders (2 tsps. for colors without an *, 4 tsps. for colors with one *, 8 tsps. for colors with two *) in a small amount of warm water, stirring into a smooth paste. Stir in 1/2 cup lukewarm water. For reds and colors containing red, filter the dye solution through a coffee filter or piece of silk to remove difficult to dissolve particles. Add 1/2 cup shaving cream to the filtered dye solution, and then pour this mixture into the squeeze bottle.

4. Dilute about half a can of shaving cream with a cup of water in a large mixing bowl. Whisk the mixture until well blended and thick and creamy. Pour mixture into the tray until about an inch deep.

FOAM DYEING PROCEDURE:

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5. Squirt the dye/shaving cream mixture over the shaving cream/water mixture in the tray in any pattern you wish. Use a comb, chopsticks, or any tool to swirl and spread the dye into any pattern desired.

6. Place a piece of the prepared fabric on the surface of the shaving cream and dye pattern. Remove any air bubbles by pushing down gently with a tool or a gloved hand.

7. Allow the fabric to sit on the surface of the dye/shaving cream for 5 minutes, and then remove fabric by lifting carefully. Place on a flat surface shaving cream side up and allow to sit for 2 to 24 hours to develop the dye. The piece needs to remain moist for the activation to take place.

8. Rinse fabric in cool running water to remove the soda ash, and then increase temperature to hot. Continue to rinse until water is almost clear, then wash in hot water and Synthrapol to remove any excess dye. Dry, press and voila!

FOAM DYEING PROCEDURE:

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(a) horizontal padder;

(b) doctor coating, roller coatingand flow coating;

(c) pressure or vacuum application;

(d) transfer (double-sided)

Kiss-coating system Morrison reverse roller Knife-over-roller coating system MonfortsVacu-foam system

The Stork RSF (Rotary Screen Foam)system is illustrated in figure. The foamfrom thefoam generator is supplied to achamber (A), which is formed by twostainless steel blades. Theupper blade (B)has a tip of synthetic material and is pressed against the rotary screen (C) by air bellows (D). The lower blade (E) is pressed against the rotary screen by acombination ofmechanical pressure andhydrostatic foam pressure

Methods of foam application:

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Foam vs. Emulsion:

Foam Emulsion

1) It is the dispersion of a gas in a liquid2) Unstable3) Foaming agent used.

1) It is a mixture of two immixable liquid2) Comparatively more stable than foam.3) Emulsifier used.

#Emulsifier is a special chemical used to mix oil & water.#Optical Brightening agent is used for white dyeing.

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Sancowad Foamer NT (Clariant), Nekanil LN (BASF).

1. Generate foam readily

2. Wide range of wetting technology

3. Fast & uniform wetting action

4. Little or no effect on color fastness

5. Compatible with other products

6. Least affected by water hardness

7. Least affected by temperature

8. Do not cause yellowing of white

9. Tend itself to be easily stabilized

10. Capable to comply with specific requirement.

Foam is a medium only like water in regular wet processing technology. Foam only replace water, other processing materials will be there for processing.

FOAMING AGENT:

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1. Low material, water for low m:l ratio

2. Low Waste

3. Eco-friendly

4. Energy Saving

ADVANTAGE:

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It can be classified in following categories:

Dispersion foam: It is produced by the introduction & mixing of gas from an

external source into a liquid phase. E.g. Dispersion Tank in textile [fig].

It is used in textile processing.

Condensation foam: It is formed from the generation of a gas within the

liquid, either by chemical reaction or by physical change. E.g. [fig]

CLASSIFICATION:

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• Inter lamellar liquid drains out of spherical foam cells.

• The lamellae grow thinner, exchange of gas or breakage of lamellae, small bubbles aggregates to foam bugger bubbles until finally the foam collapse.

#Salt brings dye on surface of fabric

#Soda fixes dye.

#Linear Process/Application: Main chemicals like NaOH, NaCl, Dye

#Progressive Process/Application: Auxiliary chemicals

COLLAPSE OF FOAM:

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Continuous foam application technique flow chart is as follows:

FOAM GENERATION:

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FOAM EVALUATION CRITERIA:

• Blow-Ratio: The blow ration expresses the volumetric ration of liquid to foam.

• Range of application: 1 : 8 – 1 : 15• Bubble Size: Range: 0.1 – 0.3 mm dia• Homogeneity: Constant sizes.

• Ionic Nature: 1 ) Anionic Surfactants which has more foaming power, not very sensitive to temp change, used for cotton & polyester.2 ) Non-ionic: Foaming power less than anionic. Foaming power reduced by temperature and addition of electrolytes.3) Cationic: Unused.

• Drop Escape Time: This is the time that elapses before the first drop of liquid emerges from the foam. Range: 45 – 90 cc. Uneven application, possibility of less……………

• Half Life period: It is the time taken for one half of the liquid in a definite volume to drain. Range: 4 -60 min

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FOAM APPLICATION SYSTEM:

There are several types of foam application system. Such as-

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HORIZONTAL PADDING MANGLE:

Advantage Disadvantage1) Better wetting power2) Better Foam Decay3) Lower Investment cost

1) Only suitable for woven fabric2) Tailing or ending effect occurs.

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Here, foam collapse with squeeze roller. This process is called “VALCHEM” process.

Advantage Disadvantage1) Better wetting power2) Better foam decay

1) One sided foam application2) More investment cost

APPLICATION WITH A COATING BLADE:

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In this case, foam is applied using coating blade while they are collapsed using a suction nozzle action on the back of substrate. This is developed by United Ranchants & Ram Factures

Advantage Disadvantage

1) Better wetting power2) Better foam decay3) More even application.

1) Requires suction pressure2) More energy consuming and costlier3) Suitable only for woven and knit fabric

Application with Coating Blade and collapse with suction nozzle:

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This process is developed by Gaston county & union carbide. It is called FFT process.

Advantage Disadvantage1) Use of foaming agent is low2) Popular for application with fluorescent bright agent.3) Lighter foam density4) Low cost

1) More energy required due to low density

Foam application by pressure Nozzle:

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This process is developed by “MITTER”. They are suitable for carpets.

Advantage Disadvantage1) Better collapse2) Better design is possible

1) Require more energy.2) More costlier

Application with rotary screen printing:

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In this case, two sided foam application is done by using transfer roller and dosage shots.

This is developed by “KUESTER”. It is called Janus minifoam applicator.

Advantages Disadvantages

1) Doctor blade can control foam2) Two sided application of foam.

1) More costlier2) Foam collapse is not good.3) Suitable for delicate fabric.

Two Sided foam application with transfer roller:

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Here, foam application is done by indirectdoctor blade dosage and foam collapse is controlled by vacuum cylinder suction. It is developed by “MONFORTS”.

Advantage Disadvantage1) Better collapse2) Better foam control3) Wet on Wet: It helps multiple dosing of chemical;

however more cost and fabric damage is possible due to pressure.

1) One sided foam application2) More power consumption3) More costly.

Foam Application with indirect doctor blade:

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Advantage & Disadvantage of foam finish/technology:

Advantages Disadvantages

1) Save water

2) Save chemicals (0 – 20% minimum)

3) Save cost

4) Reduce water pollution

5) Save energy

6) Faster production

7) Printing do not need thickener

8) Wet on wet

9) Two sided application is possible.

1) Investment cost is more.

2) Skilled man power is required

3) Application limited, only for cotton and

polyester

4) More attention required.

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1. Yarn Manufacturing TechnologyLink : http://www.facebook.com/pages/Yarn-Manufacturing-Technology/485014954866808

2. Fabric Manufacturing TechnologyLink : http://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605

3. Garments Manufacturing TechnologyLink : http://www.facebook.com/pages/Garments-Manufacturing-Technology/472364799463126

3. Wet processing TechnologyLink : http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-/468645219825404

4. Fashion-Design-and-TechnologyLink : http://www.facebook.com/pages/Fashion-Design-and-Technology/587655294583875?ref=ts&fref=ts

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