Dye fixation

There are many ways of dye fixation depending on the dyestuff class
and the substrate. Some of them as listed below:
Baking: This method is carried out in a gas or an electric baking
machine that utilizes dry heat.
It is used for fixing pigment prints and reactive dyes.
The dye is fixed in ventilated chambers filled with air heated at 160-180
degree Celsius.
Fabric moves continuously for 2-5 minutes on the rollers in the
machine.
The temperature and time may vary for different dyes and fabrics.
Wet development:
In this process, the printed and dried fabric is passed in open width
through a rectangular tank containing an alkaline solution and large
quantities of electrolyte to suppress dyestuff bleeding.
It has limited scope as it is a suitable method for fixing only certain
reactive and azoic dyes on cellulosic fabrics. The treatment is carried
out for 10-20 seconds at 100-110 deg. C and is immediately followed by
washing.
The composition of the wet development bath, time and temperature
vary with the type of dyestuff to be fixed.
Pad- batch method:
This process is recommended for cotton fabrics printed with reactive
dyestuff.
The printed fabric is first padded with sodium silicate on a padding
mangle and then the fabric is immediately passed on to a perforated
beam where it remains for duration between 10 minutes and 3 hours,
depending on the type of reactive dye used.
Then it is washed thoroughly in cold water.
This fixation technique should not be used for viscose as sodium silicate
reacts with the fibers and affects the handle of the fabric.
Normal Steaming:
This method is carried out in industrial steamers at or slightly above
atmospheric pressure and a temperature of about 100 deg.C.
During normal steaming the printed areas absorb moisture and form a
localized dye bath which is like a gel.
The dye gets dissolved in this mini dye bath and diffuses inside the
fibers which have also swollen in the meanwhile.
The thickening agent prevents the dyestuff from spreading outside the
printed area, i.e. it prevents ‘ bleeding’.
If the print paste contains more quantity of the hygroscopic agent or if
the steam is too moist, then the thickening agent becomes diluted and
bleeding will occur.
Also, if the steam is too dry then the moisture absorbed by the
thickening agent is not sufficient and the dyestuff will not fix suitably.
Pressure Steaming:
This method is done using steam under pressure which accelerates the
fixation of disperse dyes on polyester and acetate.
This system produces full color yields and bright prints.
It is carried out in star steamers.
The star steamer is a simple equipment with radiating arms for carrying
the cloth. During the process, dry steam is fed at the bottom and the
inside is kept completely moisture free and under pressure after
allowing all the air and condensate to go out.
High Temperature Steaming:
This rapid dye fixation method involves the usage of superheated
steam.
In this process live steam is raised to 180 degree C at atmospheric
pressure by bringing it in contact with radiators which are at
temperature of over 200 degree C and passed over dyed products.
This method can be carried out on many classes of dyes and fibers.
Dispersed dyes can be fixed in these steamers at 180 degree C in 1-2
mins.
It is a continuous process and gives full color yield and bright prints.
Use of superheated steam shows advantages of faster heating, shorter
fixation time and less color spread if the print has not been dried.
Ageing:
Ageing is similar to steaming, with the only difference being the
duration of treatment.
Ageing is carried out in steamers for shorter duration ranging from 1-14
mins in a flash ager, while steaming is a relatively a longer treatment
that takes between 45 mins and 2 hours to finish.
Ageing is generally used for Vat dyes on cellulosic fabrics.
The dye is printed on the fabric and padded with thickened solution of
sodium hydrosulfite and alkali, followed by steaming for a very short
period, generally 20-40 secs at 110-125 degree C.
Washing Off
• The final treatment given to all printed textiles is washing off. Washing off
is a physio-chemical process which removes the dirt and other substances
from the textile and improves the texture.
• It involves rinsing the fabric in water to remove the print paste chemicals
and additional unfixed dyestuffs, followed by a soaping treatment which is
suitably selected according to the type of dyestuff and fabric.
The steps involved are:-
• Preparing the washing liquor using simple detergents.
• Achieving the required temperature and wetting the textile
• Emulsifying impurities after separating them from the textile
• Removing the liquor from the textile by rinsing.
• Drying
.
Washing Off
• Industrially, rinsing and soaping treatments are given either in open-
width form or in rope form.
• In the case of delicate fibers , the open width method is preferred it
avoids creases and wrinkles and permits processing of huge lots.
• However, rope-form is more effective as it provides a stronger
mechanical action and therefore, ensures better cleaning and
relaxation of the fabric structure.
.
Recent Developments in Printing
• The industry is strongly committed to minimal seconds, strict color
control, and decreased dead time.
• Dead time is the time the equipment is not operating because of
changing equipment components like screens, or changing colors for
different patterns.
• Dead time in screen printing has decreased to less than 30 minutes
for most systems and patterns.
Recent Developments in Printing
• Computer monitoring of printing processes decreases the
environmental impact as manufacturers recognize the direct costs of
inefficient use of materials and energy and incorporate closed-loop
recycling of chemicals, solvents, water and energy.
• Dye chemists use computers to calculate formulas to match swatches
submitted by designers and monitor dyeing or printing processes so
color is consistent.
• Computers automatically register each color in a print so that edges
match.