PROJECT REPORT ON

REACTION MECHANISM OF REACTIVE DYES IN

BENGAL HURRICANE GROUP ON CELLULOSE
FIBER.
BASIS OF

BENGAL HURRICANE GROUP

Prepared By :

Prepared By : Mazadul Hasan sheshir

ID: 2010000400008
13th Batch (session 2009-2013)
Department : Wet Processing Technology
Email: mazadulhasan@yahoo.com
Blog : www. Textilelab.blogspot.com (visit)

Southeast University
Department Of Textile Engineering
I/A 251,252 Tejgaon Dhaka Bangladesh

right

CONTENTS

Introduction
Raw Materials
Importance of The Survey
Reason of using Reactive dyes in major
textile industry in Bangladesh
Methods of Dyeing & Printing Cotton
Goods with Reactive Dyes
Technical Deficiency of Reactive Dyes,
Causes and Remedies of Technical
Deficiency
Conclusion

Chapter 1
Acknowledgement
Project Work is an academic function of the Pabna Textile Engineering College. Our teacher Md. Abdul
Mannan, Principal, Pabna Textile Engineering College, gave us an opportunity to choose preferable
mills for Project Work. I chose Bengal Hurricane Dyeing & printing (pvt.) Ltd. joyfully with the
supervision of Mithun Biswas, Asst. Manager(production).
During the Project with Bengal Hurricane Dyeing & printing (pvt.) Ltd. I worked in all the
departments related with Dyes and Chemicals. Beside these, I learned about Dye Quality Control and
Storage System,printing, Garments, Store & Inventory , finishing & specially dyeing.
Our deepest appreciation goes to Mithun Biswas, Asst. Manager(production)Dyeing, Bengal Hurricane
Dyeing & printing (pvt.) Ltd. to give us the opportunity to have project work at BENGAL
HURRICAN GROUP.

I would like to thank Engr. Md. Iqbal Mahamud (Head of the Factory), GM, Dyeing, Bengal Hurricane
Dyeing & printing (pvt.) Ltd. for helping to know about the all aspects of BENGAL HURRICAN
GROUP.

I would also like to thank Tareq Ahmed(Deputy Manager),Md.Anwarul

Islam(Deputy Manager), Md. Arif Rabbani Talukdar(Deputy Manager),Dyeing, Bengal Hurricane Dyeing
& printing (pvt.) Ltd. for helping to know about the all aspects of BENGAL HURRICAN GROUP.

Our gratitude also goes to all the employees of BENGAL HURRICAN GROUP for their sincere cooperation, support and valuable advice which they have provided us during the two months of
training.

Lastly I express my gratitude to our supervising teacher, the name that should be mentioned first, Shib
Shankar Chakraborty, Head of the Dept. Wet Processing Technology for his valuable direction &
supervision.

However, I have prepared my Industrial Attachment overcoming all the difficulties & also the shortage of
time. Here I would like to present the report.

Chapter:2
Application of reactive dyes in
major textile industries in
Bangladesh

Application of Reactive dyes in

major textile industries in
Bangladesh

Chapter:3
Project Abstract

The use of reactive for Dyed products has dramatically increased over the last 50
years. Reactive dyes are now used to produce multiple products. Reactive
coloring components are inert into materials which are adhered to the base
substrate by the application of soda ash which act as fixing agent.
The main goal of our project is to provide information about the reason of using
reactive dyestuff in major textile industry in Bangladesh, different methods
using in our industry for cotton dyeing with reactive dyes, technical deficiency
of reactive dyes during dyeing & causes and remedies of deficiency of reactive
dyes.

During reactive dyeing there is a rule of using different amount of soda ash with
fixed amount of salt & auxiliaries. In case of dyeing of cotton with reactive dyes
alkali pH should be correctly maintained as during dyeing more electrolytes
required for exhaustion and alkali for fixation.

However the rubbing fastness and hand feel properties of dyed fabric depends on
the amount of soda ash. When we use fewer amounts of soda ash then hand
feel is good but rubbing fastness is not good. And when we use more amounts
of soda ash then rubbing fastness is good but hand feel is not good.

Chapter 4
INTRODUCTION

With the evaluation of the wet processing industries the use of the reactive dyes
in the most of the industries increases day by day. As a result to complete the
project it is has become a part to discus about the evaluation or growth of the
wet processing industries in Bangladesh. Now the number of the wet processing
industries and finishing industries in Bangladesh is 193 which are totally export
oriented according to the survey of the BTMA which has been provided into
their we address.
But the interesting matter is that with the growth of the textile wet processing
mills the number of the employee is not increasing. This is because of to reduce
the cost and increase the quality the modernization of the machine is also
increasing which reduce the number of worker in wet processing industries. But
what is the actual number of the worker in wet processing industries has not
been found due to the lack of proper survey in this sector.
Our project work was estimated as:
APPLICATION OF REACTIVE DYES IN MAJOR TEXTILE IN BANGLADESH &
DEFICIENCY OF REACTIVE DYE:
The project work is interesting as well as lengthy but we must admit that we had
to really work hard and it helps us a great deal to know about whole procedure
of reactive dyeing on dyed fabric. Though reactive dyeing products exhibit
intrinsic characteristics which make them suitable for multiple products
application but reactive dye has it main problem with hydrolysis while dyeing as
a result wastage of the reactive dye increase and it become difficult to match
the proper

The objects of project are:

Knowing the source of textile raw materials of wet
processing and cost.
To mention the reasons of using reactive dyes in major
textile industry.
To study on the application of reactive dyes
To learn about the technical deficiency of reactive dyeing.
To study the causes and remedy of deficiency of reactive
dyeing.

Chapter 5
RAW MATERIALS
Raw material is a
unique substance in
any production oriented
textile industry. It not
only plays a vital role
in case of continuous
production & for high
quality fabric but also it
is related to the profit
of the industry.

Types of raw material

The basic raw
materials used in wet
processing industries
are:
Fabric
Dyestuffs
Chemicals &
auxiliaries.

Names & source

Fabric:
Different types of fabric treated in Bengal Hurricane Group pvt
Ltd. dyeing section are namely

dyeing section

dyeing section

Single Jersey
Single jersey with Lycra
attachment
Single Jersey with slub
Double Jersey
Polo pique

Back pique
Rib Fabric
Flat back Rib
Interlock

Interlock with Lycra

Pique
Lacost
Lacost Lycra
Fleece
Tery Fleece
Waffle
Melange

Fibres dyed:

By reactive dyes the

following fibres can be
dyed successfully:
1) Cotton, rayon, flax and
other cellulosic fibres.
2) Polyamide and wool
fibres.
3)Silk and acetate fibres

It covers a wide range of

color spectrum and
includes shades varying
from bright to heavy
dark like,
a. Violet
b. Blue
c. Green
d. Red
e. Black
f. Yellow

g.Etc.

Trade names
Some trade names of this dye are mentioned:
Trade name

Manufacturer

Country

Procion

I.C.I

U.K

Ciba cron

Ciba

Switzerland

Remazol

Hoechst

Germany

Levafix

Bayer

Germany

Reactone

Geigy

Switzerland

Primazin

BASF

Germany

Drimarine

Sandoz

Switzerland

Popularity of reactive dye:

Reactive are mostly used for dyeing cellulosic fibres. At past cellulosic fibres
were dyed with direct and vat dyes, but after the introduction of reactive
dyes there utility has become limited. Reactive dyes are superior to direct
dye in the following aspects:
i) Ability to procedure bright shades of wide range.
ii) High leveling quality.
iii) Good washing fastness.
iv) Good light fastness.
And it is superior to vat dyes in the following aspects:
i) Simple dyeing method therefore one stage dyeing.
ii) Low temperature dyeing (below 1000C)
iii) Lower cost, i.e. cheaper.
Again its dyeing process is fast and gives brighter shades than metallized azo
dyes. For the above reasons reactive dyes are more popular.

The general structure of reactive dye is: D-B-G-X.

NH (bridging part)
C
N
C

Cl

Hetreocyclic ring

C - NH
N

-N

N-

Chemical structure of reactive dyes

Here,
D= dye part or chromogen (color producing part)
Dyes may be direct, acid, disperse, premetallised dye etc.
B = bridging part.
Bridging part may be NH- group or NR- group.
G = reactive group bearing part.
X= reactive group.

Classification of reactive dyes:

Reactive dyes may be classified in various ways as below:
1) On the basis of reactive group:

a) Halogen (commonly chlorine) derivatives of nitrogen containing

heterocycle, like 3 types-

Triazine group
Pyridimine group
Quinoxaline dyes
Example:
Triazine derivatives: procion, cibacron.
Pyridimine derivatives: reactone
Quinoxaline derivatives: levafix.
b)Activated vinyl compound:
Vinyl sulphone
Vinyl acrylamide
Vinyl sulphonamide.

Example:
Vinyl sulphone: remazol
Vinyl acrylamide: primazine
Vinyl sulphonamide: levafix.

Classification of reactive dyes:

2) On the basis of reactivity:
a) Lower reactive dye:
Here ph is maintained 12-12.5 by using NaOH in bath.
b) Medium reactive dye: here pH is maintained 11-12 by using Na 2CO3 in dye
bath.
c) Higher reactive dye: here pH is maintained 10-11 by using NaHCO 3 in dye
bath.
3) On the basis of dyeing temperature:
a) Cold brand:
These types of dyes contain reactive group of high reactivity. So dyeing can be
done in lower temperature i.e. 320-600C.
For example: PROCION M, LIVAFIX E.
b) Medium brand:
This type of dyes contains reactive groups of moderate reactivity. So dyeing is
done in higher temperature than that of cold brand dyes i.e. in between 60 0-710C
temperatures.
For example, Remazol, Livafix are medium brand dyes.
c) Hot brand:
This type of dye contains reactive groups of least reactivity. So high temperature
is required for dyeing i.e. 720-930 C temperature is required for dyeing.
For example PRICION H, CIBACRON are hot brand dyes.

The reactive rate of some compounds are

mentioned below:
COMPOUND
Water
Iso-propanol
Ethanol
Methanol
Glucose

STRUCTURE
H-OH
CH3-CHOH-CH3
CH3-CH2-OH
H-CH2-OH
C6H12O6

REACTIVE RATE
1.0
0.7
7.4
12.3
5.5

So from the above table it is obvious that secondary hydroxyl group is the beast reactive while
primary one is the most reactive.

Dyeing mechanism of reactive dye:

The dyeing mechanism of material with reactive dye takes place in 3 stages:1.Exhaustion of dye in presence of electrolyte or dye absorption.
2.Fixation under the influence of alkali.
3.wash-off the unfixed dye from material surface.

Now they are mentioned below:

1.Dye absorption:

When fibre is immersed in dye liquor, an electrolyte is added to assist the exhaustion
of dye. Here NaCl is used as the electrolyte. This electrolyte neutralize the negative
charge formed in the fibre surface and puts extra energy to increase dye absorption. So
when the textile material is introduces to dye liquor the dye is exhausted on to the
fibre.

Dyeing mechanism of reactive dye:

2. Fixation:
Fixation of dye means the reaction of reactive group of
dye with terminal OH or-NH2 group of fibre and thus
forming strong covalent bond with the fibre and thus
forming strong covalent bond with the fibre. This is an
important phase, which is controlled by maintaining
proper pH by adding alkali. The alkali used for this
purpose depends on brand of dye and dyeing
temperature. Here generally caustic soda, soda ash or
NaHCO3 is used as alkali depending upon reactivity of
dye. They create proper pH in dye bath and do as the
dye-fixing agent. The reaction takes place in this stage is
shown below:

3.

Alkali

1. D-SO2-CH2-CH2-OSO3Na + OH-Cell

pH10-12.5

D-SO 2-CH2-CH2-O-Cell + NaHSO3

alkali
2. D-SO2-CH2-CH2-OSO3Na + OH-Wool

3.

D-SO 2-CH2-CH2-O-Wool + NaHSO3

alkali

pH1012.5

3. Wash-off:
As the dyeing is completed, a good wash must be applied to the material to remove extra
and unfixed dyes from material surface. This is necessary for level dyeing and good

Application method of reactive dyes varies significantly with type of dyes, shade
required, and available equipments in the mill. These are 3 application procedures
available:

1. Discontinuous method-Conventional method

-Exhaust or constant temperature method
-High temperature method
-Hot critical method.
2. Cotinuous method-Pad-steam method
-Pad dry method
- Pad thermofix method
3. Semi continuous method- Pad roll method
- Pad jig method
- Pad batch method.

Stripping of reactive dye:

1.Partial stripping:
Partial stripping is obtained by treating the dyed fabric with dilute acetic
acid or formic acid. Here temperature is raised to 70-100C and treatment
is continued until shade is removed by desired amount. After that a
through washing is necessary to remove the product of hydrolysis. The
amount of acid used is as below: Glacial acetic acid
: 5-10 parts
With water
:1000 parts
Or
Formic acid
:2.5 to 10 parts
With water
:1000 parts
Temperature
: 70 - 100C
Time
: until desired shade is obtained.

2. The
Full
stripping:
recipe
is as below: Na-hypochlorite : 1% at room
temperature
For complete stripping the goods are first treated with
Na-hydrosulpite: at boil.
(hydrose) at boil then washed off
Time sodium: hydrosulphite
30 min
D-R-Cl
+
H-OH
D-R-OH
and bleached with 1% sodium hypochlorite (NaOCl) at
+ H-Cl
room temperature. This is carried out for 30 min.
Hydrolysis of activated vinyl compound containing dye,
D-F-CH2-CH2-OSO3H + H-OH
D-F- CH2-CH2-OH + H2SO4

For preventing hydrolysis the following precautions are taken

1.As hydrolysis increases with increasing temperature during dissolving and
application temperature should not be more than 40C.
1.Dye and alkali solution are prepared separately and mixed just before using.
2.Dye and alkali should not be kept for long time after mixing.

Important factors for dyeing cellulosic fibre with

cold brand reactive dye in batching process:

The important factors are as follows:

1) pH of the dye bath:
The optimum pH for fixing cold brand reactive dyes on cotton and viscose rayon
depends on individual dyes, the temperature and time of dyeing. pH decreases with
increasing temperature and time of dyeing. For most of the dyes the optimum pH is
10.8 to 11 at 20o to 25oC. Soda ash has been the best alkali for dyeing at 30 oC for
cotton, mercerized cotton and linen. Increased fixation (due to higher temperature)
and increased dye bath stability and better reproducibility are the advantages of
soda ash as the fixing agent.
For viscose rayon the optimum pH is 10.3 at 20 o to 25oC.

2) Amount of alkali:
The amount of alkali used for fixing depends on the depth of shade dyed and the
liquor ratio employed.Some quantities of alkali required for fixing the reactive dyes
are given table 28.

3) Dyeing temperature:
Since increase in temperature affects the rate of physical and chemical processes
involved in dyeing, it is important in dyeing reactive dyes also. The affinity of the
dye for the fibre decreases with increases in temperature and at the same time the
rate of hydrolysis of the dye increases and adversely affects the fixation of color
yield. However the rate of diffusion of the dye in the fibre increases with increased
temperature. At temperatures lower than 20oc, the rate of fixation is very low.
Hence for most of the dyes a temperature of 20 o to 25oC is the recommended
temperature while for some other dyeing at 50 o to 60oC with sodium bicarbonate as
the alkali gives maximum color value.

Important factors for dyeing cellulosic fibre with

cold brand reactive dye in batching process:
4) Electrolyte concentration:
Since reactive dyes have low affinity for cellulose exhausting the dye bath by
adding common salt or Glaubers salt prior to fixation can increase the
fixation. The amount of salt required producing adequate exhaustion
decreases with decreasing liquor ratio. Thus for pale shade on cotton and
viscose rayon 15 and 10 g/l of common salt used. The quantities may be
increased to 30 and 20 to 30 g/l for medium and deep shades on these
fibres.

5) Time of dyeing:
Generally the dye may be added in two portions. The salt may also be added
in two lots. The exhaustion takes place in 20 to 30 min. There is generally no
advantage in extending the period beyond 30 min. The alkali is then added
and the dyeing continued for 30 to 90 min. The depth of shade and reactivity
of the dye decide the time of dyeing. For deeper shades larger times are
required.

6) Liquor ratio:
With decreased liquor ratio, both exhaustion and fixation take place to
increased exert. However the rate of fixation of most of the dyes is not
significantly affected. As the liquor ratio is decreased, the effectiveness of
increasing salt addition also decreases. Hence lower amount of salt are
sufficient to get optimum exhaustion.

Why low affinity reactive dyes are preferred for dyeing?

If the reactivity of the dye is increased considerably, the rate of reaction with the fibre
increases. There fore, the dyeing can be carried out in a short time. However in this case the
rate of dye also increases, leading to deactivation of a part of the dye. This results in
wastage of the dye. If on the other hand the reactivity of the dye is decreased, the extent of
hydrolysis can be reduced considerably. However this results in the slower rate of reaction
with the fibre also. The ultimate object of dyeing is to react as much of the dye ass possible
with the fibre and minimize the hydrolysis of the dye. This is achieved in practice in two
stages. The dyeing is first started from the aqueous medium under neutral conditions when
the dye does not react either with the fibre or with water. Then gluber salt or common salt is
added to exhaust the dye onto the fibre as much as possible. In this respect, this stage of
dyeing (exhaustion) resembles the dyeing of direct dyes on cotton. Then the second step (that
of fixation or reaction with the fibre) is carried out by adding the alkali (usually used soda
ash). Since the exhausted dye is already on the fibre, it is more likely that the exhausted dye
reacts with the fibre in preference to water. However the dye present in the dye bath (which
contains a substantial amount of the reactive dye) can now react with water since it is under
alkaline condition. It is already stated that the hydrolyzed dye cannot further react with the
fibre but dye to the affinity forces; it is absorbed by the fibre and is retained in it. During the
subsequent washing or soaping the substantivity held hydrolyzed dye gets stripped into the
treatment of the dyeing with boiling soap or detergent solution removes almost all hydrolyzed
dye. However if the affinity is very low, exhaustion of the dye bath prior to fixation cannot be
achieved substantially. This results in a larger amount of the reactive dye remaining in the
dye bath and getting hydrolyzed when alkali is added subsequently. If the dye has high
affinity for cellulose like a direct dye, it becomes difficult to remove the hydrolyzed dye from
the dyeing since it is also absorbed by and retained in the fibre by fairly strong affinity
forces, through not as strong ass the covalent bond formed between the dye and the fibre.
Hence in actual practice low affinity dyes are selected for converting in to reactive dyes.

Dyestuffs:
Dye
REACTIVE
DYE

Brand name
Bezactive

Origin/source
Bezema , Switzerland

Ciba

Ciba , Switzerland

Dychufix

Hubei Hwalle dyestuff Ind.co.

Kemafix

Jaychem,India

Levafix

Dystar , Germany

Procion

Dystar, Germany

Jackazol

India

Kemazol

Jaychem,India

Remazol

Dyestar , Germany

Solazol

Solarfine , Taiwan

Solacion

Solarfine , Taiwan

Chemicals:
Brand name
Novolube Jet
Bluton BVB1
Cibacel DBC
Cibafix ECO
Cibafluid C
SandocleanPCLF
Permacol FA
Novostone CR
Cotton white T
Cyclanon E
Cyclanon ECO
Jinlev RLF349
Eulysin S
Felosan NOF
Uvitex EBF
Jinlev CL-225
Oxalic caid
Palegal FA-8
Respumit BU
Permacol SQ
Na thiosulphate
Uniperol O
Uvitex EVF
Uvitex 2B
Mollan129
Acetic acid
Reduction HCS
Mollan130
Bluton 2B

Type
Anti creasing agent
Violet tone brightener
Sequestering agent
Fixing agent
Anticreasing agent
Detergent
Stabilizer
Enzyme
Redder tone brightener
Fixing agent
Reduction cleaning agent
Dispersing agent
pH buffer in PET dyeing
Detergent
Whitening agent
Levelling agent for reactive dye
Iron remover
Levelling agent for disperse dye
Antifoaming agent
Sequestering agent
Peroxide killer
Washing agent for PET dyeing
PET brightener
Yellow tone brightener
Soapinging agent
pH controller
Reduction cleaning agent
Sequestering agent
Whitening agent

Source
Techna,Italy
CHT,Germany
Ciba,India.
Ciba ,Switz.
Ciba ,Switz.
Clarient,Germany
Techna,Italy
Techna,Italy
CHT,Germany
BASF,Germany
BASF,Germany
Geigy,Taiwan
BASF,Germany
CHT,Germany
Ciba ,Switz.
Geigy,Taiwan
BASF,Germany
BASF,Germany
Techna,Italy
BASF,Germany
Ciba, Switz.
Ciba ,Switz.
Rota,dystar
Geigy,Taiwan
Rota,dystar
Ciba,India

 Remark
The list is for the time of our industrial
attachment. It varies according to the
availability of the material & their price.
The price has not been supplied to us due to
their secrecy act.
The annual requirement was not available &
is a record of the procurement department.

Chapter 6

IMPORTANCE OF THE SURVEY

The main goal of our project is to provide information about the reason
of using reactive dyestuff in major textile industry in Bangladesh,
different methods using in our industry for cotton dyeing with
reactive dyes, technical deficiency of reactive dyes during dyeing &
causes and remedies of deficiency of reactive dyes.

As these topics are very sensitive for dyeing industries, it is very much
important to make a survey. It will be very helpful not only for our
studying period but also for our future career.

This survey also has these importances:

1. To mention the reason of using reactive dyes in major textile industry.

2. To study on the application of reactive dyes.
3. To learn about the technical deficiency of reactive dyeing.
4. To study the causes and remedy of deficiency of reactive dyeing.

Chapter 7
Reason of using Reactive Dyes in Major Textile Industries in Bangladesh
Maximum textile industries in Bangladesh are based on cotton knit fabric and reactive dyes are easily applicable
to cellulose fibres.

Other associated reason as follows:

1. Reactive dyes are soluble in water.

2. They have very good light fastness with rating about 6.

3. The dyes have very stable electron arrangement and can protect the degrading effect of ultra-violet ray.

4. Textile materials dyed with reactive dyes have very good wash fastness with rating about 4-5 due to strong
covalent bonds formed between fibre polymer and reactive group of dye.

5. Reactive dyes give brighter shades and have moderate rubbing fastness.

6. Dyeing method of reactive dye is easy. It requires less time and low temperature for dyeing.

7. Reactive dyes are comparatively cheap.

8. Fixation occurs in alkaline condition.

9. Reactive dyes have good perspiration fastness with rating 4-5.

10. It has a wide range of shade

Chapter 8

Methods of Dyeing Cotton Goods with Reactive Dyes

REACTIVE DYE :
Reactive dye react with the fibres mainly react with cellulose fibres e.g. cotton, jute, bast fibres,
viscose, flax. It can be applied to protein fibres e.g. wool & silk. Reactive dye contains reactive
group and this reactive group makes covalent bonds with the fibres and becomes the part of the
fibre.
The general formula of reactive dye as follows:
D-X-Y
Here D->Chromophore of dye post
X->Bridge
Y->Functional group
Influencing factors:
D-X-Y + Fibre ->D-X-Y-Fibre Covalent bond
Reactive dyes water soluble
1. PH
D-F + Cell-OH ->Dye-F-O-cell
D-F + H-OH ->Dye-F-OH
2. Temperature.
Hydrolysis
Properties:
1.

Anionic in nature.

2.

Soluble in water.

3.

Form strong covalent bond

4.

Better wet & light fastness.

5.

Have better substantivity.

6.

Dyeing is carried out at alkaline condition.

3. Conc. of electrolyte.
4. Time.
5. Liquor ratio.

REACTIVE DYEING FOR SENSITIVE SHADE AT 60oC

Dyeing:

Anticreasing Agent (.5 g/l)

Leveling Agent (1 g/l)
A. Acid ( .2 g/l)
Dyes (According to Shade %)
G. Salt (According to Shade %)
Soda Ash (According to Shade %)
60min at 60OC,
Neutralization (Dyeing):
A. Acid (1 g/l)
10min at 40-50OC,
Soaping:
Soaping Agent (.5 g/l)
Dyeing curve:
Sequestering Agent Color Dosing
Leveling Agent
Linear (30min)

60 0C
50 0C 10min

50min

Bath drain
35 C
PH +Hardness Check
0

20min 30min
10min
10min
Salt (15min) 1 g/l Soda Rest Soda
(30min)
(60min)

35 0C Cold
wash

Process steps:
Dyeing:

HOT BRAND REACTIVE DYEING:

Anticreasing Agent (.5 g/l)
DYEING AT 92oC:
Leveling Agent (1 g/l)
A. Acid ( .2 g/l)
Dyes (According to Shade %)
G. Salt (According to Shade %)

Soda Ash (According to Shade %)

60min at 80OC, PH = Above8

(Always)
Neutralization (Dyeing):
A. Acid (1 g/l)

10min at 4050OC,

A. Acid (.5 g/l)

Softener (1.5 g/l)

Soaping:
Soaping Agent (.5 g/l)

20min at 7080OC,
Fixing & Softening:
Fixing Agent (.5 g/l)

15min at
40OC,
20min at
40OC,
Bath
Drain

800C 40min
Sequestering Agent Color Dosing
Leveling Agent
Linear (30min)

60 0C
50 0C 10min

50min

Dyeing curve:
Bath Drain

350C
20min 30min
10min
10min
PH +Hardness Check Salt (15min) 1 g/l Soda Rest Soda
(30min)
(60min)

35 0C Cold wash

N.B: The temperature increase at the grade 10C/min because

its an important matter to avoid the shade variation in dyeing

Dyeing:

DARK COLOR DYEING WITH

Anticreasing Agent (1.5 g/l)0
REACTIVE DYE
AT
60 C
Leveling Agent
(1 g/l)
A. Acid (.2 g/l)
Dyes (According to Shade %)
G. Salt (According to Shade %)
Soda Ash (According to Shade %)
60min at 60OC,

60min at 60OC,

Neutralization (Dyeing):
A. Acid (1 g/l)
10min at 40-50OC,
10min at 40

50OC,

Soaping:
Soaping Agent (.5 g/l)
20min at 70-80OC,

20min at 7080OC,

Fixing & Softening:

Fixing Agent (.5 g/l)
15min at 40OC,
15min at
15min at 40OC,
O

40 C,

A. Acid (.5 g/l)

Softener (1.5 g/l)
20min at 40OC,

20min at
40OC,

Bath Drain

Dyeing procedure for dark shade

Felosan NOF/Wetting agent = 0.5g/l
Kappazon H53NEU/Stabilizer (H 2O2) = 0.5
g/l
Anticreasing agent = 1.0 g/l [Only for S/J]
60oC x 5'
Caustic 2 g/l
60oC x 15'
Hydrogen peroxide 2.5 g/l [Dosing 10']
(60oC - 80oc)
Temperature rise up to 105oC

30'
Acetic acid 1.0 g/l
H2O2 killer 0.5 g/l
60oC x 10'
Acetic acid 0.8 g/l (To control pH = 4.55.5)
Enzyme 1.5 g/l
55oC x 45' - 60'
Kappaquest FE / Sequestering Agent
0.35 g/l

90oC x 5'
Sarabid LDR 0.5 g/l (leveling agent)
60oC x 5'
Gluber Salt (Runtime 10')

60oC x 10'

Dye stuff
60oC x 35' Runtime 20'
Soda ash
60oC x 40' Runtime 60'
Bath drop after shade matching

Hot rinse
60oC x 10'
Soaping
80o - 95oC x 10'
Cold rinse
45oC x 10'
Neutralize (Acetic acid = 0.5 g/l)
45oC x 10'
Fixing
40oC x 15'
Softening

Unload

Dyeing Procedure for White

Felosan NOF/wetting agent 0.5 g/l

Kappazon H53NEU /Stabilizer 0.5

g/l

Anticreasing agent 1.0 g/l [Only

for S/J]

Caustic 3 g/l
60oC x 15'
Hydrogen peroxide 10.0 g/l
60oC x 10'
Syno white 4BK/Optical brightener
(60o 80oC)
105o x 60'
Acetic acid 1.0 g/l
NT x 10'
Acetic acid 0.8 g/l [To Control PH4.5 - 5.5]
Enzyme 1.5 g/l
55oC x 45' - 60'

Sequestering agent
0.5 g/l

90oC x 5'

Acetic acid 0.35 g/l

Softener 1.5 g/l

N. Hot

Unload

40oC x 10'

Dyeing procedure for Light/Medium Shade

Felosan NOF/Wetting agent 0.5 g/l

Kappazon H53NEU /Stabilizer (H2O2) 0.5
g/l
Anticreasing 1.0 g/l [Only for S/J]

60oC x 5'
Caustic 2 g/l

60oC x 15'
Hydrogen peroxide 2.5 g/l

(60o - 80oC)
Temperature rise up to 105oC

30'
Acetic acid 1 g/l
H2O2 Killer 0.5 g/l

60oC x 10'
Acetic acid 0.8 g/l [To Control P H- 4.5 - 5.5]
Enzyme 1.5 g/l

55oC x 45'
Sequestering agent / Kappaquest FE 0.35
g/l

90oC x 5'
Sarabid LDR 0.5 g/l (leveling agent)

Anticreasing agent 0.5 g/l [ For S/J]

60o x 5'
Dye stuff

60oC x 35' Runtime 20'

Glauber Salt

60o x 10' Runtime 20'

Soda ash

60o x 40' Runtime 60'

Bath drop after shade matching

Hot rinse

60o x 10'
Soaping

80o - 90oC x 10'

Cold rinse

45o x 10'
Neutralize

45o x 10'
Softening

Unload

NOTE: - During Bleaching we maintain gradian to rise

temperature from 80o - 105oC as 1.5o/min and cooling

Dyeing procedure for S/J Light / Medium Color

Felosan NOF/ Wetting agent = 0.5 g/l
Kappazon H53NEU /H2O2 Stabilizer = 0.5
g/l
Anticreasing agent = 1.0 g/l

60o x 5'
Caustic = 2 g/l
60oC x 15' [Dossing]
Hydrogen peroxide (H2O2) = 2.5 g/l
(60o - 80oC)
Temp rise up to 105oC & Run - 30'

Acetic acid = 1.0 g/l

H2O2 killer / Kappaquest FE = 0.5 g/l
60oC x 10'
Acetic acid = 0.8 g/l [To control PH - 4.5 5.5')
Enzyme = 1.5 g/l
55oC x 45' - 60'
Sequestering agent = 0.35 g/l
90oC x 5'
Sarabid LDR /Levelling agent = 0.5 g/l
Anticreasing - 0.5 g/l

60o x 5'
Dye stuff

60o x 35' - Run time - 20'

Glauber Salt

Dosing - 60o x 10' - run time - 20'

Soda ash

60 x 40'
Bath drop after shade matching

Hot rinse - 10' x 60oC

Soaping

80o - 90oC x 10'

Neutralization / Acetic acid

45oC x 10
Cold rinse - 45o x 10'

Softening

Unload

Migration Dyeing procedure for dark, medium & light shade

Felosan NOF/wetting agent 0.5 g/l

Kappazon H53NEU /stabilizer (H2O2) 0.5

Glauber Salt [Run time 10']
g/l

60o x10'
Anticreasing 1.0 g/l [Only for S/J]
Temperature rise up to 80oC [ Run time 20']

60oC x 5'

80oC x 20'
Caustic 2 g/l
cooling to 60oC
60oC x 15'

Hydrogen peroxide 2.5 g/l

(60oC - 80oC)
soda ash
Temperature rise up to 105oC

60oC x 40' Run time 60'

o
105 C x 30'
Bath drop after shade matching
Acetic acid 1.0 g/l

Kappaquest FE /H2O2 killer 0.5 g/l

Hot rinse
60oC x 10'
60o x 10'
Acetic acid 0.8 g/l [To control P H = 4.5 -
Soaping
5.5']

80oC - 95oC x 10'

Enzyme 1.5 g/l
Cold rinse
55oC x 45' - 60'

40o x 10'
Sequestering agent 0.35
Neutralize
90oC x 5'

45 o x 10'
Sarabid LDR 0.5 g/l
Fixing [ For medium & dark shade]
Anticreasing agent 0.5 g/l [for S/J]

40 o x 10'

Dye stuff
60oC x 35' Run time - 20'

Softening

Unload

COLOR

BLACK

RECIPE
Sample
(Dyeing)
SATAZOL YELLOW 3RS=1.649%
SATAZOL RED 3BS =O.912%
SATAZOL BLACK NNT=8.47%

RED

KIRA.YELLOW HB=1.4%
KIRA. RED HB =2.0%
KIRA. RED SP2B=6.64%

MERUN

KIRA.YELLOW HB=0.47%
KIRA. RED HB =3.8%
KIRA. BLUE HB =0.86%

DK-BLUE

KIRA.YELLOW RR=0.188%
KIRA. RED RR =0.29%
KIRA. BLUE RR =1.26%

PINK

DK- TURGISH

SETA. RED 3BS =0.078%

SOLA.RED SP2B=0.02%

SATAZOL YELLOW 3RS=0.385%

SATAZOL RED 3BS =O.049%
SATAZOL BLUE BB=1.64%

SAMPLE

Sample (Dyeing)
COLOR

RECIPE

CLASSIC BLUE

SATAZOL YELLOW 3RS=0.013%

SATAZOL RED 3BS =O.066%
SATAZOL BLUE SETR =0.62%

GOLD RUST

SATAZOL YELLOW 3RS=3.14%

SATAZOL BLUE BB =O.004%
SATAZOL BLUE BB =0.40%

VIO-LET

SATAZOL RED 3RS

SATAZOL RED 3BS
BZ. BLUE VW

TURGISH

E/B BLUE RSPL =2.1%

R/M T. BLUE G =0.6%

LIGHT YELLOW

=0.65%
=O.48%
=1.40%

SETA. YELLOW 3BS=0.048%

RM. YELLOW 3GL =0.076%

NATURAL

BEZ.YELLOW SLF=0.154%
BEZ.RED SLF
=0.05%
BEZ.BLUE SLF
=0.132%

DEEP LILAC

E/B. YELLOW-4GL=0.008%
RED 3BSN
=1.1%
BE. BLUE VRN =1.14%

SAMPLE

Printing of cotton fabric with reactive dyes (block and screen

printing method), combination shade.
Introduction

By the term textile printing we mean the localized application of dyes or

pigment and chemical by any method, which can produce particular
effect of color on the fabric according to the design. In this practical
we print cotton fabric with cold brand reactive dyes in block and
screen-printing methods in combination method.
A dye, which is capable of reacting chemically with a substrate to
form a covalent dye substrate linkage, is known as reactive dye. The
dye contains a reactive group and this reactive group makes covalent
bond with the fibre polymer and act as an integral part of fibre.
Reactive dyes forms covalent bond with fibre polymer and thus attach
itself with fibre. It is now a day mostly used for dyeing and printing of
cotton yarn and fabric. It is a cationic dye. Cold brand reactive dyes
have higher reactivity.
Block printing method is the oldest printing method. It is used
mostly in sarees, handkerchiefs etc. in this printing method
we use blocks of different designs.
In screen printing a very little screen made by glass fibre is used.
There are many types of screen-printing, but we have done in our
experiment was hand screen-printing. Hand screen-printing is mostly
used for sarees to 14-16 colors in on pattern can be produced at a
time.

Style of printing:

Direct style.

Method of printing:
Block and screen-printing method.

Sample:
One piece of square size bleached, scoured cotton fabric (small) and One
piece of square size bleached, scoured cotton fabric(bigger)

Combination color:
Total Dyes = 1.8gm
Blue = 0.6gm
Red = 0.6gm
Yellow = 0.6gm

Recipe:
Dye:
Total Dyes = 1.8gm
CIBA CRON RED = 0.6gm
CIBA CRON BLUE = 0.6gm
CIBA CRON YELLOW = 0.6gm
Urea = 8gm
Thickener = 70gm
Alkali = 8gm
Additional water = as required.

Preparation of thickener:
1)16 gm of starch and 200cc water are taken in
bowl.
2)Heat is applied and solution is stirred
continuously until a thick viscose solution is
obtained.
3)By continuous stirring and boiling a specific
viscosity is obtained.
4)The heat application is stopped otherwise
viscosity falls down. So temperature is
maintained strictly.

Preparation of printing paste:

1) At first we take required amount of dyestuffs in a bath.
2) Then little amount of water is added into the bath for
mixing these dyes. And start stirring for mixing the
three types of dye.
3) Then required amount of urea is added into the dye
bath.
4) After then required amount of thickener is added
5) Then continuous stirring is done for few minutes for
mixing all the ingredients of print paste.
6) After mixing finally required amount of alkali is added
to the dye bath and mix them with the help of stirring.

Printing process:

Block printing method:

1)The fabric, which will be printed, is placed on the

printing table.
2)The printing paste is put on the tray box.
3)The block is selected and it is touched with print
paste.
4)Then block is pressed upon the sample fabric.
5)After pressing the block on the sample fabric the
block is put off from the fabric.
6)Finally we get the printed fabric of required dyes.

Screen-printing method:
1) The fabric is placed on the printing table of flat screenprinting machine. The table is made of soft by laying
on it.
2) Then the screen is placed on the sample fabric.
3) The printing paste is taken on the screen perforation.
4) Thus we can find the printed fabric with a smooth
wooden strike the paste is spread over the screen with
slight pressure.
5) So that the dye particles can penetrate through the
screen perforation.
6) Thus we get printed fabric.

After treatment:
The printed fabric is steamed for 5-10 minutes
in a cottages steamer at 1050-1100C and
washed with cold water for removing unfixed
dye and exhausted thickener and then dried.

Conclusion

Printing of cotton fabric with reactive dyes has

excellent build up property and maximum
fixation. Shade is also bright. By this
experiment we have acquire knowledge about
process of printing cotton fibres with cold
brand reactive dyes in combination shade. The
shade of printed fabric is moderately good, as
we required. Special thanks to our teacher and
his assistants for grate cooperation.

Chapter 9
Technical Deficiency of Reactive Dyes, CAUSES AND THEIR
REMEDIES

Hydrolysis is the main problem in dyeing with

Reactive dyes. Only 60 to 70 percent dyes are
absorbed in Reactive dyeing. There are also
many causes of technical deficiency of
reactive dye. Those are described below:

Hydrolysis of reactive dyes:

Under alkaline condition, reactive dyes react with the terminal hydroxyl group of
cellulose. But if the solution of the dye is kept for long time, its concentration drops.
Then the dye react with the hydroxyl group of water .The reaction of dye with water is
called Hydrolysis of reactive dyes.

Factors which affect the hydrolysis of the reactive dye:

1.

Salt concentration:
When the cellulosic textile material is sink into water it convert into negetive charge or anionic
charge. But the reactive dye is also convert into anionic charge. So the surface of the cellulosic material repel
the dye molecules. To overcome the problem we use electrolite material like salt. It hepls to netralize the
negetive ion over the textile material and helps the reactive dye ion to fix on the surface of the materail. As a
result If we increase the concentration of the salt hydrolysis of the reactive dye will decrease.

2.pH:
if the pH of the medium increase hydrolysis of the reactive dye also increase. This is for, reactive dye
ionised more in alkaline medium and as a result it react with hydroxyl group of the water.
3.Temperature:
With the increase of temperature hydrolysis of the reactive dye increases.
4.Substantivity:
With the increase of the substantivity hydrolysis of the reactive dye increase.
5.Reactive group of the reactive dye:
Hydrolysis of the reactive dye depends on which group does it bears. Vinyl sulphone dye hydrolyize
more than the Triazinyl group.

Factors which affect the hydrolysis of the reactive dye:

Hydrolysis of water:
Hydrolysis of the water is also a cause
of the technical deficiency of the reactive dye.

Remidies of the hydrolysis of the reactive dyes:

The highest absorption of the reactive
dye is about 70%. To minnimize the more lose of the
reactive dye we should maintain proper liquor ratio,
proper time and temperature. Even the pH of the
emdium is also an important factor to avoid the
more wastage of the reactive dye

Faults and their remedies for the technical deficiency of reactive dyes:

There creates many problems and defects in dyed fabrics when dyeing with Reactive
dyes due to technical deficiency. Some defects may be remedied by some process.
Those are described below:

Defect: Colors are not fast to washing, Abrasion; Staining in the fabric when
transporting from place to the other, water marks on the fabric
Remedy : Wash the fabric with soap and soda ash at right temperature. Adding
sequestering agent will yield good results. Treating with Ammonia will also give good
results.
Defects in the fabric due to Printing- Need to take out full color
Remedy: Treat the dyed fabric with Sodium Hydrosulphite with 5-10 gm Sodium
Hydrosulphite at 75 deg C for 30-45 minutes. Add 5-7 gms Caustic Soda for even
removal of colors. The color becomes light yellow or brown after removal. Wash it
thoroughly with soap.
The color can also be removed by solution of Sodium Hypochlorite. Treat the fabric
with a sodium hypochlorite solution ( 3-5 gms Chlorine) for 20-30 minutes. Keep the
pH between 9-10. The fabric is treated with Acetic acid after removal of color to
remove chlorine and to neutralize the fabric.
The fabric can be re-dyed after removal of color

Faults and their remedies for the technical

deficiency of reactive dyes:

Defect: Bleeding in colors during washing, abrasion

Remedy: Boil the fabric with caustic, Treat the fabric with Hydrogen Peroxide ( 5-10 gpl, 60-70 deg C) to make the color fast.
Defect: The fabric has been dyed in darker shade, uneven dyeing
Remedy: To take out color from the fabric treat it with caustic for 45-60 min at 70 deg C. Thereafter treat the fabric with 1020 gpl Acetic Acid for 40-60 min at 80-85 deg C.
Defect: Uneven dyeing, marks of water, marks of colors
Remedy: Wash the fabric in soap and re-dye in a darker shade
Defect : The fabric has become stiff and rough after dyeing
Remedy: Finish after adding right softener
Defect: Color staining of fabric, uneven dyeing
Remedy: Re-dye the fabric in darker shade.
Defect: Color staining in fabrics of darker shade, uneven dyeing.

Remedy: Dye the fabric in Sulphur black.

Caution: Please treat a small length fabric to check the effectiveness and any harmful effects before
commencing a full treatment.

Defect: Color staining of fabric, uneven dyeing

Remedy: Re-dye the fabric in darker shade.
Defect: Color staining in fabrics of darker shade, uneven dyeing.
Remedy: Dye the fabric in Sulphur black.

Chapter 10

Conclusion

Obviously the project work we have discussed has many other arguments
but as far as we believe the presented view to a large extent is one
that has a predominant role in our textile sector especially in
REACTIVE DYEING & thus has the ability to influence our thoughts.

REACTIVE DYEING is truly an important dyeing phenomenon for

cellulose materials & ranks as the major contribution to the
progression of any textile dyeing industry. Dyeing parameters have a
great influence on reactive dyeing which have described in my report.
It was really an important subject & also innovative one. I have tried
my best to express the topics properly.

The project work has given us a special interest & has been arranged as a
presentation of the application reactive dyes in cotton dyeing. I think
anyone can research in future about this topic which will enrich our
textile knowledge.

Any absolute conclusion is impossible but waiting the pros & cons Im
certain that my position is a tenable one.

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