The document describes a new dyeing process called Swift Synergy that produces greater results with less resources. It allows producers to dye 4 lots per day using the same machinery, with decreased water, energy, and chemical usage compared to 2.5 lots previously. This is achieved through profiling dyes and dyeing within their optimal exhaustion ranges. Producers have seen increased production from 450MT to 900MT monthly while saving over 3.73/kg in costs. The process provides shorter dyeing times, less water consumption, and high quality results without rejects.

2. What is it ?
Swift |swift| adjective happening quickly or
promptly • moving or capable of moving at high
speed
Synergy |ˈsinərjē| The interaction or cooperation
of two or more organizations, substances, or other
agents to produce a combined effect greater than
the sum of their separate effects.
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3. Which Means !
• When everyone did what others did.
• We asked Why ?
• Why not ?
• The result :
• SWIFT SYNEGY® A path breaking exhaust dyeing process
• Due acknowledgements to Mr. Shreyeskar Choudhary MD Pratibha Syntex Ltd. Indore for igniting the long
dormant mind to get back to the dye house .
• With fond memories of late David Parkes and his teachings .
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4.  In a big vertical dye house in Maharashtra, it was first
experimented in the knits division using Softflow Dyeing
machines and knit fabrics .
 From 2.5 Lots per day they could produce 4 lots per day
with no increase in machinery , and decrease in water,
energy, chemical content …. And time.
 From 450 MT per month their current months target to
produce is 900 MT.
 Is this path breaking ?
What is path breaking ?

5. • Load to Unload Time is 6
Hours approximately.
• Water consumption is 50 / kg
of fabric.
• Bulk to Bulk 100% not a
single lot reprocessed.
• Dyeing process is
irrespective of L, C, H values
or structure of fabric.
A Little more
• Remarkably Shorter
Time.
• Less Water
Consumption.
• Quality is very good
no rejection or over
dyeing

6. How ?
• Achieved by profiling dyes and dyeing within their
primary and secondary exhaustion profiles
• Calculating the total entropy and enthalpy of the reaction
between reactive dyes and cellulose.
• Choice dyes are selected in the lab by the profiling
process.

7. Bleaching

8. Dyeing

9. Wash Off

10. • Total batches dyed: Over 2000 Lots
• Materials Dyed :
• Single jersey
• 1 X 1 Rib
• Interlock
• Cotton-Elasthane , low to high power
Achieved till date

11. • Shade Wise:
• Darks – 1077 MT
• Mediums – 560 MT
• Turquoises and Royal Blue - 366 MT

12. 110
100
80
60
30 60 90 120
Conventional
Swift Synergy
Process
Temp.
Time
Preparation

13. migration
Conventional
isothermal
Dyeing
SS Process

14. Wash Off
SS Process

15. S.S. Process
DYEING COST: 33.720
STEAM COST : 14.37
POWER COST: 2.97
WATER COST: 0.12
TOTAL COST : 51.18
Conventional Process
DYEING COST: 30.48
STEAM COST : 18.47
POWER COST: 5.72
WATER COST: 0.24
TOTAL COST : 54.91
**Less water used

16. • Conventional proc 54.91/Kg
• SS Proc 51.18 / Kg
• SAVING 3.73 / Kg
• The saving will increase if water quality is
better.
• Profits from additional production obtained 60
to 100% increase.

17. > In Production Possible
•For 1500 Kg Machine per day performance
•Conventional 2.5 Lots per day = 3750 Kgs
•Conventional 3 Lots per day = 4500 Kgs
•SS Process 4 Lots per day = 6000 Kgs 60% - 30 >
•SS Process 5 Lots per day = 7500 Kgs 100% - 75 >
•5 Lots possible with good water quality.

18. • Chemical Call too Often, so man power needs to be on
their toes.
• Good Process control automation needed.
• Brine Or Glauber salt solution availability is advised.
• Quality control of raw materials is very important.
Down Side

19. • In the same example mill
• 80% of all of Knits processed moved to this process
• 10% continues in old process , but will be moved to
SS process soon.
• 10 % is Viscose - Process being developed.
• Same process also introduced into yarn dyeing and
woven fabric piece dyeing.
Real life experience

20. How we implement
• Phase 1
• Profile all raw materials
• Train Lab technicians in
• Water , Dyes and Raw
materials testing
• Create 32 set dye data base
• Correct method of data
feeding
Phase 2
• Predict recipes
• Run confirmations in 250 Kgs
• Correct recipes
• Run bulk lots.
• Train Select personnel
• Supervise process for a period
• Hand over mill .

21. Time Lines
• Phase 1
• 60 days
• Phase 2
• 30 days

22. Other Innovations
• Cold Pad Batch dyeing for knits
• Vat Dyeing of knits in conventional Jet
Dyeing Machines
• In the pipe line Continuous Dyeing of
Knits

23. Synergy Dyeing Process
Synergy Team at a leading knits producer
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25. Thank you
The role of Dr. Jayakumar Gopalakrishnan in this project is in his
personal capacity and not as a representative of AATCC or ASTM
International.
Examples cited in this presentation are specific to a company.
The values cited may not be consistent in all locations it may
increase or decrease.
All parts of this presentations are copy right protected and will not
be shared.
Swift Synergy is a registered Brand name .
All rights reserved.
Disclaimers