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Breakthrough in Pakistan, India and

Türkiye - patented spray dyeing for yarn

and fabric is setting new standards

INDIGO full dyeing/ring dyeing
REACTIVE SULFUR RotaSpray Space dyeing Patented RotoDyer spray application
The newly developed PS Pad-Spray-Steam Process A pre-reduced liquid Sulfur dye range with minimal For functionalization minimum application (MA) on fabric,
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for yarn and fabric enables a salt-free continuous sulfide content from ARCHROMA in combination with approximately 12% - 35% pick-up is very often applied on
dyeing of Reactive dyes without limitation of colour advanced spray dyeing is successfully used for face side only. For warp yarn dyeing/finishing a pick-up of
depth. The diffusion behaviour of the dyes is warp yarn with significant advantages in water 80 – 120% ore even more can be easily realized.
comparable with Cold Pad Batch dyed material. saving. This modified Sulfur process fulfils all the
Intermediate drying as normally used in classical ecological issues that effected Sulfur dyes and their To summarize the total cost of ownership and life cycle
pad-dry-chemical pad-steam process is eliminated. application in the past. costing as meaningful cost management tools, we
This will lead to significant energy savings and much conclude the following key arguments.
lower investment costs as well. Artistic Fabric Garment
Industries and ORTAANDOLU has implemented the Spray dyeing is a disruptive technology and will replace
reactive dye process on warp yarn already. long-established systems such as large slasher/rope
dyeing machines with liquor volumes of 10,000 to 50,000
RotaSpray Revolution in VAT and REACTIVE dyeing on woven liters. Due to low liquor volume (52 l) and reduced yarn
fabric content (6 m) in the RotoDyer this new spray dyeing
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PS Pad-Spray-Steam Process has started conception results in the highest possible flexibility with
With adapted formulations, process and plant layout modifications INDIGO, VAT, successfully in February 2019 in Lahore/Pakistan at small lot sizes and low liquor residues and yarn losses
during recipe changes. A complex tank storage
REACTIVE, SULFUR, DIRECT and PIGMENT dyes will be applied and fixed continuously NISHAT MILLS with outstanding results. management with recycling tanks for INDIGO dyeing
on Cellulosic / Lyocell warp yarn and fabric by use of the patented RotoDyer spray PIGMENT becomes superfluous. The non-contact spray application
prevents dirt, fluff, grease, waxes, residual surfactants or
dyeing (forced application). The non-contact spray application also allows the defined In addition a new one-bath Pigment dyeing method alkali from being dragged into the spray solution.
using pigment preparations, combined with a
application of high affinity optical brighteners, fixing agents, functional chemicals, auxiliaries package, is developed for DENIM with Differences in the substantivity of dyes in a spray
formulation are not critical since it is applied by spraying in
special neutralization agents and oxidation chemicals. great feedback in the DENIM industry as well as at forced application. The yarn is not subject to mechanical
the retailers by promoting a sustainable “water-free stress from crushing and thus no change in the capillary
By optimizing the spraying parameters in the actions nowadays. This disruptive spray dyeing dyeing” method for warp yarn. Wash down effects as structure will take place. The RotoDyer spray technology
RotoDyer and RotoCoater spraying technology, technology has been implemented in important well as Raw DENIM can be created according to supports "zero-discharge" concepts (e.g., INDIGO filtration /
significant water, chemical and energy savings were DENIM producing countries such as Turkiye, India customers’ requests. recycling), is economical and sustainable (BAT candidate).
achieved in the finishing of textile fabrics as well as and Pakistan with great R&D support from DyStar The space requirement and the investment cost for warp
dyeing equipment is drastically reduced.
the warp yarn dyeing. The inevitable existing INDIGO team and an enthusiastic engagement of
limitations in sheet/slasher and rope dyeing ARTISTIC FABRIC GARMENT INDUSTRIES, ARVIND All common classes of dyes for Cellulose / Lyocell fibers
technologies for warp yarn, smaller lot size, the and ORTAANADOLU R&D team. can be applied without contact and there are completely
tremendous cost pressure and increased global new combination possibilities, e.g. of INDIGO, VAT and
exigencies on sustainability and resource The standard INDIGO warp yarn spray process uses SULFUR dyes in one spray solution. Salt-free continuous
conservation have been motivating drivers of a a stable Hydrosulfite E type or an improved REACTIVE dyeing is already state-of-the-art in slasher /
technology leap forward for the DENIM industry. formate-based Hydrosulfite with the trade name sheet dyeing systems and is used with great success
HydroBlue 90 as the reducing agent. Selected (pad-spray-steam process).
®
INDIGO special auxiliaries avoid the formation of vat skin,
There is a high demand in upgrading the DENIM protect the reducing agent and the INDIGO dye from
warp yarn dyeing technology for ecological and RotaSpray in Pakistan is represented by Abdur Rahman
economic reasons. The marketing story of the oxygen in the air, thus avoiding the oxidation of Sulfur Black Enterprises (irfan.hashmi@arenterprises.pk /
sustainability is getting pushed to get reality with the INDIGO dye that interferes with the application. +92 300 8274439)

RotoDyerTWIN
February/March 2019 February/March 2019