Controlled Coloration with DyStar: high-performance dyes and technologies improve competitiveness

Citation

(2004), "Controlled Coloration with DyStar: high-performance dyes and technologies improve competitiveness", Pigment & Resin Technology, Vol. 33 No. 2. https://doi.org/10.1108/prt.2004.12933bab.004

Controlled Coloration with DyStar: high-performance dyes and technologies improve competitiveness

Controlled Coloration with DyStar: high-performance dyes and technologies improve competitiveness

Keywords: Dyes, Textiles, Colour, Technology

Rising quality specifications accompanied by increasing cost pressure makes a very challenging situation for textile finishers and the textile industry as a whole. Reliable, cost- effective products and technologies are essential for survival in this market. As a leading textile dyes supplier, DyStar markets high-quality products, efficient application procedures and expert service to help reduce customers' costs and give them an edge on quality. DyStar's Color Confidence and Controlled Coloration programmes translate these features into real customer benefits. The Color Confidence programme supports quality performance and ecological integrity in coloured fabrics, adding value through the entire textile processing chain, and minimising end-user complaints. The Controlled Coloration programme is aimed at application benefits for the dyer and printer, combining reliable dye selection, application processes and know-how to optimise Right-First-Time dyeing and printing, and minimise production costs.

Global retailers and converters are putting, increasing pressure on textile finishers to produce quality goods at lower cost. That means textile mills have to ensure rapid and reliable coloration. A single shading operation can raise the cost of dyeing by 20 percent; if the dyeing is still off-shade or unlevel even after several shading additions, production costs can double. Reliable and reproducible processes that ensure a high proportion of Right-First- Time dyeings and prints are therefore the key to success.

All textile finishers are aware that dyeing and printing are highly complex processes. One of the main problems is batch-to-batch reproducibility. Dyeings can be sensitive to changes in dyebath volume and the resulting changes in liquor ratio. The fibre blends that are currently fashionable make it particularly difficult to obtain the same shade and fastness properties on all fibres. Dr Michael Woydt, Head of Coloration Technology at DyStar, explains: “There are over a hundred potential errors that can affect the outcome. The most important factors for good reproducibility are the liquor ratio, using accurate amounts of dyes and chemicals and a detailed knowledge of textile substrates and dyeing and printing mechanisms. That means textile finishers need reliable partners and products.”

Technical service and quality dyes are the basis for Controlled Coloration

DyStar's Controlled Coloration programme makes it the ideal partner for meeting these requirements, as Dr Michael Woydt explains: “We have subsidiaries with trained staff and modern service labs in all major markets to make sure we can give our customers expert assistance before and during production. We pride ourselves on marketing reliable colorants for all fibres and processes. That is why our products undergo thorough testing and are standardised within very narrow tolerances.”

Remazol^® RR reactive dyes for cellulosics are a good example of the principles of Controlled Coloration. The Remazol RR trichromatic combination was developed specifically for exhaust dyeing of difficult shades. Insensitivity to dyeing parameters such as salt, alkali, temperature, liquor ratio and process times ensures reliable application. Remazol RR dyes are carefully balanced, with good build-up and homogeneous fixation properties to ensure level, reproducible and economical dyeings.

Another example of Controlled Coloration is the Dianix^® CC range of disperse dyes for polyester. Dianix CC comprises 13 dyes that offer customers genuine benefits. The dyes are standardised within very narrow tolerances and the maximum deviation in colour strength is 2 percent.

All Dianix CC dyes have been designed to be compatible in their application behaviour based on uniform rates of dye uptake and diffusion. Dianix CC dyes are also insensitive to fluctuations in dyeing times and temperatures, making them the right choice for reliable and reproducible Right-First-Time dyeings.

Automated Controlled Coloration with Optidye

Selecting the optimum dyeing method is extremely important for synthetic fibres such as polyester. A systematic examination of the dyeing process on the basis of physical chemical parameters therefore makes sense. That is why DyStar is focusing on computer-optimised dyeing: it has brought together its knowledge of dyeing mechanisms, dyes, substrates and machines in the Optidye^® range of computer programs to analyse processes and calculate the optimum time/temperature profile for specific substrates and dyeing processes, the amount of auxiliaries required and the correct pH. Moreover, the Optidye programs can be integrated into established process control software. Optidye saves time and money by cutting process times and enhancing reliability. For example, Optidye P can considerably reduce dyeing times with Dianix CC compared with a standard process and also reduces auxiliary requirements by up to 25 percent.

Abacus software calculates profits

The savings made with Optidye have a clear impact on the bottom line. To quantify the benefits, DyStar has developed the Abacus computer program to calculate process costs and profits on the basis of key variables. Abacus helps dyers to find the most economical process and can also be used as a guide in investment decisions such as purchasing new machinery. Naturally, it is also an excellent way of quantifying the benefits of DyStar's Controlled Coloration concept.

The benefits of Controlled Coloration are clear. Ken Huang, Senior Vice-President of Formosa Taffeta Co. Ltd (FTC), Taiwan, the world's leading polyamide dyer, confirms that the concept pays off: “We used to work on the principle of trial and error. Optidye has made dyeing a calculable and automated process. Thanks to Optidye we have increased the reproducibility of dyeings to around 98 percent and cut operating costs by up to 10 percent. That gives us a clear competitive advantage.”