project on Application of Disperse & Reactive Dyes In a P-C Blended Fabric of 65-35 In Using Two Bath System

PROJECT REPORT ON Application of Disperse & Reactive Dyes In a P/C Blended Fabric of 65/35 In Using Two Bath System BASIS OF BSCIC SHILPA NAGARY, FATULLAH, NARAYANGANJ... PROJECT TITLE

PROJECT REPORT ON

Application of Disperse & Reactive Dyes In a P/C Blended Fabric of 65/35 In Using Two Bath System BASIS OF

BSCIC SHILPA NAGARY, FATULLAH, NARAYANGANJ

ACKNOWLEDGEMENT

Praise be to Allah the creator and sustainer who has given us strength and opportunity to complete our two months long industrial attachment at “Fakir Apparels Ltd.”

Pabna Textile Engineering College has given me the opportunity to perform the industrial project report with “Fakir Apparels Ltd.” I am grateful to Md Abdul Mannan, the principal of the college for giving me the opportunity to accomplish the attachment.

Special thanks go to my supervising teacher Shib Shankar Chakraborty Sir, without whose help it would not have possible to complete the training successfully.

May I also take the opportunity to express my sincerest gratitude to “Fakir Apparels Ltd.” management, and administration & personnel for their kind co-operation

My deepest appreciation goes to ED-Sir and to DGM –Sir , who provided us all the necessary information we needed

Above all, I would like to acknowledge my deep debt to all teachers of our college and especially of “WET PROCESSING TECHONOLOGY Department ” for their kind inspiration and help, which remain as the backdrop of all my efforts.

Finally, I would like to acknowledge that I remain responsible for the inadequacies and errors, which doubtless remain.

PROJECT TITLE

Application of Disperse & Reactive Dyes In a P/C Blended Fabric of 65/35 In Using Two Bath System.

The dyeing of the polyester and cotton blend fabric (P/C fabric or PCF) has becomes a challenge to the modern textile industries due to its variation in color value, shed depth, tensile strength and surface residual weight loss All of this drawback can be control by the proper selection of the dye-fiber combination which ultimately governs the XRD, SEM, FTIR analysis of the dyed blend fabric The water fastness or wash fastness and light fastness can be also improved by the proper analysis of the thermodynamic equilibrium of dye fiber bond and its stoichiometry.

The present work deals with the ways of testing the compatibility of disperse & reactive dyes with P/C blended fabrics dyeing in different textile industries in Bangladesh This report includes three laboratory trials that were carried out for three different reactive dyes to check the compatibility for use in a dye recipe on cotton knitted goods In this study, Spectrophotometric analysis was conducted and the fixation

of each dye was determined by using computer colour matching system The results found from different industries were analysed and discussed This testing can be used as a tool for selecting good quality dyes

as well as to reduce dyeing cost and hazard Finally few recommendations are highlighted to overcome the problem of selecting better quality dyes for cotton goods in textile industries in Bangladesh.

Fiber reactive dyes for cotton were shown to vary widely in their substantivity for the fiber Substantivity also depended on dye bath temperature and salt concentration, as expected The relative substantivities

of the hydrolyzed forms of the reactive dyes were assessed in the laboratory by means of a sample, quick and inexpensive paper chromatography test Correlation of the substantivity of the dye with the amount removed from the cotton under various washing conditions indicated that it should be possible to select higher or lower washing temperatures based on the substantivity of the dye to be removed In addition, the paper chromatography test was useful for quick selection of dyes of about the same substantivity Mixtures of such dyes dyed cotton with little change in hue during the dyeing process; dyes of different substantivity gave pronounced color changes.

If the theoretical knowledge is a glass of water, then the practical knowledge would be drinking of the water So, for any technical education the practical experience is the most important along with the theoretical knowledge.With the evaluation of the wet processing industries the use of the reactive & disperse 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 206 which are totally export oriented according

to the survey of the BTMA which has been provided into their web address.

The application & fixing of a dye to a substrate, normally with the intention of obtaining an even distribution throughout the substrate Dyeing is the Wet Processing Technology by which physical and chemical changes happen in textile material.

Reactive dye stuffs directly combinds with cellulose by chemical bonding i.e covalent bonds are produced They have excellent wash fastness Mainly used on cotton dyeing Can also be applied on wool, silk and nylon dyeing Dyeing is carried out in an alkaline bath.

By achieving Practical knowledge it is possible to apply the theoretical knowledge in the technical field For any technical education, practical experience is almost equally necessary in association with the theoretical knowledge The Industrial attachment is most effective process of achieving the practical experience It provides

us sufficient practical knowledge about production, management, productivity, evaluation, work study, efficiency, Industrial management, production planning & control, Production cost analysis, inventory control, purchasing, utilities and Maintenance of machinery and their operation technique etc.

Industrial project report is an essential part of four years B.Sc in Textile Engineering course of Pabna Textile Engineering College under the University of Rajshahi We had the opportunity to perform the industrial attachment at “FAKIR APPARELS LTD.” During two month long attachment, I am studied the man, machine, material aspects of the knitting section, Dyeing section, quality control section, planning section, grey fabric inspection, finished fabric inspection, finishing section and merchandising section of the factory, also studied about the reactive dyes According to my studies there we have prepared the following report and would like to present

Dyeing:

Dyeing is the process by which a textile material is to be changed physically

or chemically, so that it looks mono uniform colored Or we can say that , Dyeing is the process of imparting colors to a textile material in loose fiber,yarn , cloth or garment form by treatment with a dye

Blending:

Blending is the combining of different fibres together intimately to achieve a desired product characteristic Blends can influence colouring, strength,

spinning, cost, etc

Advantages of Blending:

two different fibres are synergised For instance, in the blend of cotton and polyester, cotton provides the absorbency and polyester provides the strength.

combining the aesthetic comfort properties of the natural fibres with the

desirable characteristics.Improving spinning, weaving and finishing efficiency and the uniformity of product.

Methods of Blending:

Blending can be done at the opening stage, drawing etc.

spread one on top of the other and fed into the blending feeder.

the yarn numbering system used for filament yarns) blended tog.

Polyester is a term often defined as “long-chain polymers chemically composed of at least 85% by weight of an ester and a dihydric alcohol and a terephthalic acid” In other words, it means the linking of several esters within the fibers Reaction of alcohol with carboxylic acid results in the formation of esters.

Polyester is a manmade polymer material It is made from coal, air, water and petroleum products Polyester is a strong fiber that keeps its shape and therefore resists wrinkling The fiber does not withstand medium to high temperatures and melts and burns at the same time, therefore ironing polyester must be done at a cool temperature, if at all Threads of polyester last for a long time and wear well, so are used for many garments and sewing projects Polyester does not shrink like its natural counterpart and holds dye extremely well,

a good thing for textile artists, but bad for stain-removal from polyester items Polyester was extremely popular in the 1950s but since then is used more as a blend than the main fiber used for garments or fabric.

The chemical name for the polyester used in fiber production is polyethylene terephthalate

or PET This compound is also used to make plastic soft drink bottles, which can be melted down after use, allowing the PET fibers to be reused Companies currently producing polyester fiber include Color-Fi, Dak Fibers, Fiber Science Inc and Palmetto Synthetics.

Cotton:

Cotton is an all-natural fiber made from the pod of a cotton plant It is the principal fiber used in making the world's clothing Cotton is known for being light, cool, comfortable and absorbent Many people describe cotton as a fabric that "breathes." It is also easy to dye and to clean, though dyes do not hold as fast to natural fibers as to the synthetic fibers of polyester Cotton can withstand high temperatures, but does wrinkle easily and shrinks with washing.

Blend Benefits

A polyester cotton blend can be versatile, as it most likely retains the coolness and lightness of the cotton fiber, but also adds the strength, durability and wrinkle- resistance of polyester A polyester cotton blend should only shrink slightly in comparison to a garment or fabric that is 100 percent cotton This blend is often preferred by at-home sewers and quilters as it is extremely easy to sew.

Blend Cons

Adding polyester to cotton can cause unattractive pilling of the fabric and make the fabric not withstand high temperatures as well Many people prefer pure cotton to a polyester blend cotton in clothing that they need to breathe,

as the blend does not breathe or stay as cool as pure cotton.

Uses

Polyester cotton blend is mostly used in the garment industry to make clothing that people want to be able to wash and wear without having to iron and that will be tougher than a 100 percent cotton blend and withstand more washing Many home sewers prefer polyester cotton blends as it is more forgiving and easy to sew than pure cotton, as it wrinkles and shrinks less.

Reactive dyes are easily applicable to cellulose fibers & disperse dyes are mostly suitable for polyester that is why for p/c blended fabric both disperse and reactive dyes are used.

Other associated reason as follows:

REACTIVE:

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 fiber 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

DISPERSE:

1.Generally these dyes are insoluble in water, but they are soluble in hot water in some extent.

2.These dyes have no ionic groups.These are used for dyeing hydrophobic fibre like polyester, nylon, cellulose acetate, tri-acetate, acrylic etc.

3.It has no affinity to cellulose fibre.

4 It gives Variety shade of color

5 Its washing, rubbing, and light fastness are good.

6 It is connected with fibre by hydrogen bond and Venders walls force.

7 Dye particles of these dyes are smaller than the other dyes.

8 These are soluble in organic solvent like benzene, toluene, zyline etc.

9 These are applied in neutral or acetic medium.

10 These are applied at high temperature i.e 125-140°C.

11 Solubility of this dye bath increase with temperature.

600 It is essential for disperse dyes to be able to withstand various dyeing conditions, pH and temperature, resulting in negligible changes in shade and fastness

Disperse dyes are often substituted azo , anthraquinone or diphenylamine compounds

which are non-ionic and contain no water solubilising groups The dye particles are thus

held in dispersion by the surface-active agent and the dyes themselves are called disperse dyes They are marketed in the form of either an easily dispersible powder or a concentrated aqueous dispersion and are now the main class of dye for certain synthetic fibres

CLASSIFICATION OF DISPERSE DYES:

Anthraquinone, monoazo and disazo disperse dyes are the most important classes

of disperse dyes in terms of market share, there are a number of other important classes as follows ;

- Nitroarylamino disperse dyes

- Coumarin disperse dyes

- Methine disperse dyes

- Naphthostyryl disperse dyes

- Quinophthalone disperse dyes

- Formazan disperse dyes

- Benzodifuranone disperse dyes

Disperse Dyes used in Fakir Apparels Ltd

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.

The list is for the time of our industrial attachment It varies according to the availability of the

material & their price.

The list is for the time of our industrial attachment It varies according to the availability of the material & their price.

 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.

Imperial

Taifix Red SF 3BT Taifix Yellow SF 3RT Taifix Black SF BSDT Taifix Black SF BT Everzol Black B Everzol Black GR Everzol Red 3BS Everzol Yellow 3RS

Terasil Red W4BS Terasil Red WW-BFS Terasil Blue WRBS Terasil Blue BGE-01 Terasil Yellow 4G Terasil Yellow W4G Terasil Red R Terasil Navy WRS Terasil Black WNS Terasil Orange 5RL Terasil Yellow W5SL

Nakalon Bri Blue BGF Nakalon Yellow 4GN

Remarks:

Reactive Dye:

The dye which reacts with the fibers chemically and makes covalent bond with the fibers & become

an integral part of it is called reactive dyes Reactive dyes contain reactive group & the covalent bond

is formed between dye molecules & the terminal –OH group of cellulosic fibers respectively.

D-SO 2 -C 2 H 4 -OSO 3 Na + OH-Cell D-SO 2 -C 2 H 4 -O-Cell + NaHSO 3

D= Chromospheres of dye part

B= Bridge (It’s a part of dye molecules) e.g NH-, -NR group

Y= Reactive group bearing part (It can be a heterocyclic ring)

X= Reactive atom or group (It can be the halogen group or activated vinyl group) e.g.-CH=CH 2

Reactive Dyes used in Fakir Apparels Ltd Company name Brand name Origin Dyes name

Cibacron Red WB 150%

Cibacron Blue FNR Cibacron Black WNN HC Cibacron Orange W 3R Cibacron Navy WRS Cibacron White 4BK Cibacron Syno White BRB

Reactive Dyes used in Fakir Apparels Ltd.

Terasil: Switzerland SK: Korea

Drimaren: Germany Ciba: Switzerland

Remazol: Germany Sumifix: Japan.

Levafix: Germany Benzactive: Switzerland

Terasil & Disperse dyes are mainly used for dyeing polyester Acid dyes are use to Nylon.

Sumifix, Drimaren, Remazol, Levafix, Ciba, Sk all these dyes are use to dyeing the Cellulose or Cellulose based fabric.

Company name Brand name Origin Dyes name

Sumifix Red EXF Sumifix Blue EXF Sumifix Navy Blue BS Sumifix Black B-150%

Sumifix Brill Yellow 3GP Sumifix Scarlet 2GF

Livafix Fast Red CA Livafix Blue CA Livafix` Red CA Livafix Amber CA Livafix Yellow CA Livafix Scarlet CA

Remazol Red RGB Remazol Blue RR Remazol Red RR Remazol Navy RGB Remazol Deep Black GWF Remazol Green 6B

Steps of Reactive Dyeing:

Dyeing with reactive dye generally done in three

steps-Exhaustion of dye in presence of electrolyte or dye absorption.

Fixation of dye under the influence of alkali.

Washing off the unfixed dye, electrolyte and alkali from material.

Steps of Disperse Dyeing:

Dispersion of dye in the dye bath with the help of dispersing agent.

At high temperature (around 140 o C) crystalline structure converted to amorphous form.

Then dye molecule enters into the fiber.

 When cooling happen dye molecules entrapped into the fibers (Amorphous region becomes Crystalline)

Dyeing of polyester and its blends:

Dyeing of Hydrophobic fibres:

Dyeing of Hydrophobic fibres like polyester with disperse dyes is a completely different dye transfer system.

The process involves dye transfer from liquid (water) to a solid organic fibre and it takes as following:

1 Dispersion of the dye in the solid phase into water by breaking up into molecules(dissolution of the dye).

2.Adsorption of the dissolved dye from the solution onto the fibre surface.

3.Diffusion of the dye molecules from the fibre surface into the interior of the fibre.

How does it happen:

• The first step of dye dissolution in the dyebath depends on the dispersability and solubility of the dye with the help of dispersing agents.

• The second step is the adsorption of the dye by the fibre which is turn is affected by

solubilition of the dye and fabric affinity.

• The rate of diffusion of the dye into the fabric.