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The purpose of this study is to check the effectivity of plasma in the natural dyeing of polyester fabric using four natural dyes – Turkey red, Lac, Turmeric and Catechu using plasma and alum mordant. The surface modification on the polyester fabric by plasma along with the use of benign mordant alum is studied. The enhancement of dyeability in polyester fabric with natural dyes is the main focus. Due to surface modification, the wettability increases, which leads to better dye uptake. Better dye uptake and better dye adherence are the main objectives.

Plasma-mediated natural dyeing is the main design of this research work. The effect of plasma treatment on surface modification of synthetic fabric polyester and its subsequent effects on their dyeing with different natural dyes, namely, Turkey red, Lac, Turmeric and Catechu are studied. The dyeability was further enhanced by the use of alum as mordant. The main focus is on the betterment of natural dyeing of polyester fabric using sustainable natural dyes resources for dyeing and to reduce wastewater contamination from the usage of toxic additive chemicals for cleaner production.

Plasma-mediated and alum-mordanted dyeing method facilitated very good dyeability of all the four natural dyes, namely, Turkey red, Lac, Turmeric and Catechu. Color strength (K/S) values and fastness properties of plasma-treated samples were far better than untreated samples. The synergistic effect of plasma and alum mordanting has made natural dyeing of polyester very easy with very good fastness results. Natural dyeing of polyester after 2 min of plasma treatment showed excellent and desirable results. The process is also easy to be adapted by industries.

As polyester is hydrophobic, natural dyeing of polyester fabric is not very easy, but with plasma-mediated natural dyeing, it becomes a very facile dyeing method; thus, there are no limitations. Use of plasma has reduced the need for any chemical additives which are usually added during the dyeing process.

This process of natural dyeing of polyester fabric can be scaled up to industrial dyeing with natural dyes. Plasma pretreatment of the fabric followed by premordanting with alum has facilitated the natural dyeing well.

Use of plasma in place of chemical modifiers can be a green and environmentally friendly approach for sustainable coloration of polyester fabric, providing a clean wet processing for textiles dyeing.

The synergistic effect of plasma-mediated and alum-mordanted natural dyeing of polyester has not been attempted by any researcher. To the best of the authors’ knowledge, this is for the first time that pretreatment with atmospheric plasma followed by alum mordanting of polyester fabric has shown very good dye uptake and fastness properties as the dye molecules could penetrate well after 2 min of the plasma treatment.