The document discusses dyeing methods and processes at Keya Knit Composite Ltd. It outlines the organizational structure, with the general manager at the top and operators and helpers at the bottom. It then explains the basic concepts of dyeing, including what dyestuffs are, criteria for suitable dyestuffs, and how dyeing works through adsorption, penetration, and fixation. It also lists the types of chemicals used in the dyeing section and provides an overview of the dyeing machines and their processes at the company.

1. Department of Textile Engineering
Topic: Dyeing method &mechanism
Prepared by: Anikdeb
Batch: 17th

2. Organogram of knit Dyeing Section
General Manager (GM)
Asst.General Manager (AGM)
Manager (Dyeing)
Senior Production Officer (SPO)
Production Officer (PO)
Dyeing Master
Shift in Charge
Floor in charge
Supervisor
Operator
Helper

3. What is Dyeing
Dyeing is the process of adding color to textile products like fibers, yarns, and fabrics. Dyeing is
normally done in a special solution containing dyes and particular chemical material. After
dyeing, dye molecules have uncut chemical bond with fiber molecules. The temperature and time
controlling are two key factors in dyeing. There are mainly two classes of dye, natural and made.
The primary source of dye, historically, has generally been nature, with the dyes being extracted
from animals or plants. Since the mid-18th century, however, humans have produced artificial
dyes to achieve a broader range of colors and to render the dyes more stable to resist washing
and general use. Different classes of dyes are used for different types of fiber and at different
stages of the textile production process.
What is dyestuff
Dyestuff is organic or inorganic substances which can absorb light and reflect some lights to
show color. Actually, the dyestuff is water soluble substances.
Criteria for a Suitable Dyestuff
 Cheap
 Non-toxic
 Compatible to other dyes and chemicals
 High color strength
 Better brightness
 Better fastness
 Good levelness on the materials
Classificationofdyestuff
Dyestuffs can be classified according to three ways:-
1. According to common parent structure
2. According to application
3. According to the nuclear structure
According to the nuclear structure there are two types of dyestuff
1. Cationic Dyes
2. Anionic Dyes

4. General classification of dyestuff

5. Classification according to common parent structure or Chemical classification of dyes:
The chemical constitution of dyes are varied that it is difficult to classify them into distinct
groups. The color index classifies dyes as shown.
1. Nitro dyes.
2. Nitro so dyes.
3. Azo (Monazo) dyes.
4. Azoic dyes.
5. Stilbene dyes
6. Tgri0aryl methane dyes.
7. Xanthenei dyes.
8. Quinoline dyes.
9. Methine dyes.
10. Acridine dyes.
11. Nitro dyes.
12. Sulphur dyes.
13. Thiazole dyes.
14. Thizine dyes.
15. Indamine dyes.
16. Oxazine dyes.
17. Azine dyes.
18. Lectone dyes.
19. Anthra quinine dyes.
20. Indigoid dyes.
21. Phthalocyanin dyes.
Classification according to Application of dyes:
1. Basic dyes
2. Acid dyes
3. Direct dyes
4. Reactive dyes
5. Sulfur dyes
6. Premetallized dyes
7. Azoic (Napthol) dyes
8. Disperse dyes
9. Vat dyes

6. Application of dyes according to fiber:
Group Application
Direct Cotton, Cellulosic and Blends
Vat dyes Cotton, Cellulosic and Blends
Sulphur Cotton, Cellulosic fibers
Organic
pigments
Cotton, Cellulosic, Blended Fabrics, paper
Reactive cellulosic fibers and fabric
Dispersed dyes Synthetic fibers(polyester,nylon,acrylic)
Acid Dyes Wool, Silk, Synthetic fibers, leather
Azoic Printing inks and pigments
Basic silk, wool, cotton
Oxidation dyes Hair
DevelopedDyes Cellulosic fibers and Fabric
Modernt Dyes Cellulosic fibers and Fabric, Silk, Wool
Fluorescent
Brighteners
synthetic fibers, leather, cotton, sports goods
Mechanism of Dyeing:
The process of dyeing may be divided into three phases,
1. Adsorption of dyestuff at the fibre surface
2. Diffusion of the dyestuff through the internal structure of the fire, and
3. Fixation or anchoring of the dye molecule at a suitable location or dye site.
Adsorption:
In the first phase or step the dye molecules in the dye bath move towards the fibre and those that
are nearest to the fibre get adsorbed on to the fibre surface. They form a very thin layer of

7. molecules on the fibre surface. Other dye molecules still in the dye bath can be adsorbs only if
this adsorbed layer moves further into the fibre.
Penetration:
In the second step, the adsorbed dye molecules enter the fibre structure and gradually penetrate
or diffuse into the pores or canals in the structure. The rate of penetration and the depth to which
they get will depend upon the molecular characteristics of the dye, the molecular arrangement in
the fibre and the dyeing conditions. Diffusion or penetration of dye in the fibre accounts for
almost the whole of dyeing time. The greater the penetration of dye into the fibre the brighter and
better is the dyeing. Good penetration is thus the key to quality dyeing. Poor penetration results
in dull, surfacial dyeing with unsatisfactory colour fastness properties.
Fixation
Fixation of dye means the reaction of reactive group of dye with the terminal -OH group of fiber
& thus forming strong covalent bond with fiber. Controlled by maintaining pH by adding alkali
properly. Dye and fiber bonding create by four way
1. Van der waals’ bonds
2. Hydrogen bonds.
3. Salt linkage.
4. Covalent bonds, etc.
Textile Chemicals Categoriesand Subcategories :
From pretreatment of textile to its finishing, there are various categories and subcategories of
textile chemicals:
1.Pretereatment Chemicals:
scouring agents, low foam scouring agents, wetting agents, low foam wetting agents,
sequestering agents, mercerizing agents, peroxide stabilizers, peroxide killers, neutralizers
2.Textile Dyeing Chemicals:
Solubilizers & dispersents, levelling agents, soaping agents, dyeing agents.
3.Dyeing & Printing Chemicals:
vat levelling agents, thickeners, binders, stain removers, anti back staining agents
4.Finishing Chemicals:
cationic softeners flakes/ paste, nonionic softeners flakes/ paste, anionic softeners flakes/ paste,

8. reactive softeners, cold water soluble softener flakes
5.Antistatic Agents:
spin finishes, spinning aids
Some Basic function of chemicalused in dyeing section:
Chemicals &
Auxiliaries
Commonly Used
Chemical With its
Trade Name
Function
Solublizing
Agent
Urea Increase the solubility of dyes
Controls the sublimation at high
temperature
Reduction
Inhibitor
Lyoprint RG or Resist
Salt
Mild oxidizing agent controls the
reduction of dyes at high temperature
or during steaming.
Alkali Caustic Controls the rate of reaction between
dyes and cellulose or in other words
it is used for fixation of Reactive
Dyes.
Soda Ash Controls the rate of reaction between
dyes and cellulose or in other words
it is used for fixation of Reactive
Dyes.
Increases the fastness properties if
used in washing
Sodium-bi-Carbonate Controls the rate of reaction between
dyes and cellulose or in other words
it is used for fixation of Reactive
Dyes.

9. Chemicals &
Auxiliaries
Commonly Used
Chemical With its
Trade Name
Function
Binding Agent Helizarin Binder ETS
Imperon Binder MTP
Use as an adhesive to fix the pigment
dyes on cotton fiber at high
temperature.
Wetting Agent Cibaflow Pad
Kieralon A
Sandozin EH
To increase the wet ability of fabric
and penetration of dyes in the fiber.
Dispersing
Agent
Setamol BL
Setamol WA
Dispersogen P
Used for dispersing of disperse and
vat dyes.
Antifoaming
Agent
Antimusol SF
Leonil KS-U
Used to prevent formation of foam
during stirring or during dyeing in
one bath.
Anti-migrating
Agent
Irgapadol MP
Size CA
Alginate
Emigen AS-U
Increases the viscosity of dyeing
liquor to protect migration of dyes
under high temperature.
Electrolyte Glauber Salt Decreases solubility of dyes in
liquor, Increases affinity between
dyes and fiber under moist condition

10. List of chemicals used in keya knit composite Ltd:
Multi function agent IMEROL BLUE LIQ
Basic Chemicals: Acetic Acid, Hydrochloric Acid, Sulphuric Acid
Caustic soda, Formic acid, Bleaching powder.
Detergent & Scouring agent LUBRISCOUR BD, CAUSTIC SODA
Leveling Agent OXINOLL ALL, LEVAGAL DLP.
Salt Glauber Salt, Common Salt
Fixing Agent MATFIX VNFA LIQUID, ALBAFIX ECO
Per-oxide Killer BACTA SOLAP
Anticreasing Agent EURO LUBE CONE, TEXPORT D-600
Enzyme RETRO CELLPLX, BIO-C35
Bleaching Agent ( 50% )H2O2
PH Controller Acetic Acid
Softener SOULBIO FD, GRAMAZIN-E2R

11. Terms and definition of dyeing:
1. Shade:
Depth of color %
Light shade- 0.5%
Medium shade- 1.5%
Deep shade-1.5 and above
2. Substantive:
Substantive dye is a dye used in a process in which dye molecules are attracted by physical
forces at the molecular level to the textile. The amount of this attraction is known as
"substantively": the higher the substantively the greater the attraction of the dye for the fiber.
Substantive dyes work best on textiles with high contents of fibrous cellulose and are set in a
slightly basic or neutral environment at high temperatures close to boiling point. Substantive
dyes are set by hydrogen bonding.
3. Affinity:
Affinity means the attraction of dyes to the textile materials is called affinity. It’s related to heat
or temperature.
4. Absorption:
When dye molecules come to the surface of the fiber, it is called adsorption.
5. Sorption:
When dye molecules enter into the fiber it’s called sorption.
6. Desorption:
The process by which the dye molecules come out form the inner side of the textile materials in
particular conditions it’s called desorption.

12. Dyeing Machine of Keya Knit Composite Ltd:
Working ProcessofWinch Dyeing Machines:
Machine Type Machine
Capacity/Batch
in Kgs
Quantity
(Sets)
Total
Capacity/Batch
in Kgs
Brand/Country of
Origin
Vertical Winch
(Computerized)
200 3 600 Fongs (China)
400 3 1,200 Fongs(China)
400 1 400 Fongs (China)

13. Dyeing Method On Winch Dyeing Machine:
The basic principle of all winch dyeing machines is to have a number of loops or ropes of the
fabric in the dye bath, these ropes are of equal length, which are mostly immersed in the liquor in
the bath. The upper part of each rope runs over two reels which are mounted over dye bath. At
the front of the machine, above the top of the dye liquor, is a smaller reel, which is called jockey
or fly roller. The fly roller remains freewheeling along with fabric rope. At the back of winch
tank is the winch wheel, which pulls the fabric rope from the dye bath over the jockey reel for
dropping in the dye bath for immersion. From the dropped location, the fabric rope travels back.
To be lifted and fed to winch wheel. The dyeing process on winch dyeing machines is based on
higher M: L as compared with other dyeing machines. The process is conducted with very little
tension. The total dyeing time is lengthier as compared to other machines.
PH Level different stage ofcotton during dyeing period:
STAGE PH VALUE
1 Initial Bath Ph 6.5~7.0.
2. Before Enzyme, bath pH 4.5~4.7
3 After Enzyme pH 5.5~6.0
4 Before Scouring & Bleaching, pH 5.5~5.8.
5 Scouring & Bleaching, bath PH 10.0~10.5.
6 After Scouring & Bleaching, pH 8.5~9.0
7 Before Leveling Chemicals, pH 6.5~7.0.
8 After Leveling Chemicals, pH 6.5~7.0.
9 After Adding Dyes, pH 6.2~6.35.
10 After Addition of Salt, pH 7.5~8.0.
11 After Addition of Soda, pH 10.5~11.0.
12 Before Hot Wash, bath pH 6.8~7.2.
13 Hot Wash, bath pH 8.5~8.7.
14 Before Softener Addition, bath pH 7.2~7.8.
15 After Softener Addition, bath pH 6.5~6.8.

14. Pretreatment process
Pretreatment is the preparation period of fabric fro dyeing. For getting proper fastness of fabric
and proper dyeing pretreatment is a mandatory process. Pretreatment process is occurred by
three stages
1. Demineralization
2. Scouring
3. Bleaching
Demineralization: It is a process of removing mineral materials from the water. It is done in
water treatment plant. Water from natural sources contains many mineral materials which may
hamper the dyeing process. If the mineral materials are present in water then it may lead to
uneven shade in dyeing. Besides it may also damage the fabric and the machine.
Scouring: The process to remove fats, oil, waxy substances and added the impurities by
certain percentage of alkali treatment and which increase the absorbing power of the textile units,
is called scouring.
Bleaching: The process by which the natural color of a fiber can be removed and make the
textile this pure white and bright is called Bleaching.
Keya knit composite dyeing sectionflow chart
Grey fabric receive from knitting section
Batching
Select m/c no
Fabric loading
Select production program
Pre treatment
Select recipe for dyeing
Recipe confirm by D.M/ S.P.O
Dyeing
After treatment
Unload

15. Water consumption system of Keya knit composite Ltd
M: L = 1:7
Fabric weight =500 Kg
Liquor amount = 3500 - 3700 lit
(1) Scouring:
a. Amount of water : 3500
b. Hot wash : 3500
c. Acid wash : 3500
d. Enzyme wash: 3500
(2) Dyeing:
a. Amount of water : 3400
(3) After treatment:
a. Acid wash : 3600
b. Normal wash : 3700
Total = 24,700
For 1 kg dyed fabric =24700/ 500 = 49.4(near 50) lit water required.
Dyes use in Keya knit composite Ltd
1. Remazol
2. Novacron
3. Anafix
4. Reactobond
5. Synozol
6. Sumifix
7. Dychofix
8. Argazol

16. Role of chemical bond in dyeing
Chemicals Bonds:
A chemical bond is an attraction between atoms that allows the formation of chemical substances
that contain two or more atoms. The bond is caused by the electromagnetic force attraction
between opposite charges, either between electrons and nuclei, or as the result of a dipole
attraction. The reaction between dyes and fibers must take into account the various types of
forces exerted by one molecule upon another.
Covalent Bond:
Bonds resulting in very strong chemical forces that are not easy to break expect under serve
conditions are called covalent bonds. The classic example is that of the combination of cellulose
fibers with reactive dyestuffs, where the hydroxyl group in the cellulose is covalently bonded to
a suitable atom in the reactive dye.
Vander Waal’s Forces:
These forces are so named because they were first recognized by Van der Waals in 1873. Very
weak forces of attraction are always present between the electrons of one atom and the nucleus
of another in close enough proximity. Individually these are very weak forces, but collectively
they are considered to be of sufficient strength to be the most important attractive forces between
dye and fibre. These forces of attraction are known as Van der Waals’ forces. Disperse dyes are
held in a polyester fibre by means of Van der Waals’ forces.
Hydrogen Bonds:
These forces of attraction are weak forces set up between certain atoms in the dyestuff molecule
when they are close enough to other atoms in the fiber. One of these atoms is the hydrogen atom,
hence the term “hydrogen bond”. Some direct and vat dyes are “hydrogen bonded” in cellulose
fibers.
Hydrophobic Bonding:
The hydrophobic groups, especially alkyl chains, tend to associate together and escape from
aqueous environment. The effect due to two simultaneous causes-the Van der Waals’ forces
between the hydrogen groups and the hydrogen bonds between water molecules. Each set of
forces causes respective assembly of molecules or groups to associate together and to exclude the
other. Hydrophobic bonds occur when both the fiber and dye contain a considerable portion of
purely hydrocarbon, aliphatic or aromatic, as with some dyes applied on wool or most dyes
applied on polyester. It is strictly not a new type of bond or intermolecular force.

17. Comparisonof the Relative Strength of Dye-Fiber Bonds:
Bonds type Relative strength
Van der Waals’ force 1.0
Hydrogen bond 3.0
Ionic bond 7.0
Covalent bond 30.0
Table of Fibers, Dyes and Dye-Fiber Bonds:
Fibre Dye class having
affinity
Types of dye-fibre bonds
Cellulosic: cotton,
jute, rayon, etc.
Direct, vat, solublised
vat and sulphur dye
Van der Waals’ forces and
hydrogen bonding
Reactive dye Covalent bonds
Protein/polyamide:
wool, silk, nylons
Direct, acid, metal
complex and basic dye
Ionic bond or electrostatic
bonds
Reactive dye Covalent bonds
Polyester Disperse dye Van der Waals’ forces and
hydrogen bonding
Acrylic Cationic Ionic bond or electrostatic
bonds
Disperse dye Van der Waals’ forces and
Hydrogen Bonding.

18. Keya knit composite Knit Dyeing process with Reactive Dyes
Recipe:
1. Anti creasing agent = 0.3g/L
2. Sequestering agent = 0.5 g/L
3. Leveling agent = 0.8g/L
4. Glauber salt or NaCl =80 g/L
5. Dye (reactive) = x%
6. Soda ash =5g/L
7. Or caustic soda =1 g/L
8. Acetic acid = 0.75 g/L
9. Soap = 0.25 g/L
10. M: L = 1:7
11. Time =`120 min
12. Temperature = 90-95C
Function of these Ingredients:
 Anti creasing agent is used to remove crease mark from fabric.
 Sequestering agent is used to convert hard water into soft water.
 Gluber salt is used for exhaustion of dye in the fiber.
 Soda ash and caustic soda are used for fixation of dye in the fiber.
 Acetic acid is used for neutralizing the dyed fabric.
 Soap is used for washing the dyed fiber.
Dyeing Curve:
Dyeing Curve

19. Dyeing Procedure:
At first fabric, required water and required anti creasing agent is added in the dye bath. Then
sequestering agent and gluber salt of required amount is added in the dye bath. Then the bath is
kept rest for 5 minutes. After that reactive dye of required amount is added in the dye bath. After
adding dye in the dye bath, the bath is kept for 30 minutes. During this period exhaustion of dye
occurs in the fabric. Then required amount of alkali is added for fixation of dye into the fabric.
After adding alkali we will wait for 50 minutes and then we will check the shade. If shade is all
right then fabric will be taken for after treatment.
After Treatment of Reactive Dye:
1) At first dyed fabric will be treated with hot water at 130C for 10 minutes.
2) Then the fabric will be treated with stock solution of acetic acid for 10 minutes at 120Cfor
neutralizing the fabric.
3) Then the fabric is washing with soap solution for 15 minutes at 95C.
Dyeing Process Flow Chartfor 100% CottonKnit Fabric (Turquoise Color)
Turquoise Color:
Turquoise is the color of the gem turquoise. It is a slightly greenish shade of cyan. Turquoise is
sometimes described as a mixture of pale blue and green. The name comes from the French for
Turkish.

20. Types of Turquoise Color: There are six type of Turquoise Color. They are given below:
1. Pale Turquoise (web color) (Hex: #AFEEEE) (RGB: 175, 238, 238)
2. Turquoise Blue (Hex: #00FFEF) (RGB: 0, 255, 239)
3. Bright Turquoise (Hex: #08E8DE) (RGB: 8, 232, 222)
4. TURQUOISE (web color) (Hex: #40E0D0) (RGB: 64, 224, 208)
5. Medium Turquoise (web color) (Hex: #48D1CC) (RGB: 72, 209, 204)
6. Deep Turquoise (web color Dark Turquoise) (Hex: #00CED1) (RGB: 0, 206, 209)
Process Flow Chart for 100% Cotton Knit Fabric (Turquoise Color):
Turquoise is very sensitive color. Its wash fastness is not good. Dyeing process of turquoise
color is slightly difference from other color process.
Process Sequence of Turquoise Color:
Fabric loaded
↓
Treating with anti-creasing agent (Room temperature)
↓
Adding detergent
↓
Adding Antifoaming agent
↓
Caustic dosing (dosing 6min)
↓
Turquoise Color

21. Peroxide dosing (60˚c; 5min)
↓
Run time 1 hour 95˚c
↓
Sample check
↓
If ok
↓
Drain out
↓
Normal hot (70˚c, 10min)
↓
Drain
↓
Adding Peroxide Killer
↓
Run time 55˚c, 10min
↓
Adding Acetic Acid
↓
Run time 10min 55˚c (ph-4.5)
↓
Adding enzyme
↓
Run time 1hour, 55˚c
↓
Enzyme hot- 70˚c, 10min

22. ↓
Drain
↓
Filling in the tank (run time 5min)
↓
Rinsing -4min
↓
Drain
↓
Filling in the tank
↓
Adding Leveling, Antifoaming & Anti-creasing agent (R.T.)
↓
10min run time (R.T.)
↓
10min run time (60˚c)
↓
Color dosing-30min
↓
10min run
↓
½ Salt dosing-5min
↓
½ Salt dosing -5min
↓
Runtime -25min (60˚c)
↓

23. Sample check
↓
Soda dosing (2 g/l; 20min)
↓
Remaining Soda dosing (30min)
↓
20 min run
↓
Temp rise 80˚c
↓
Run time-1 hour
↓
Rinsing-5min
↓
Drain
↓
Filling in the tank
↓
Run time (RT)
↓
Drain
↓
Filling in the tank
↓
Normal hot (60˚c, 10min)
↓
Sample check

24. ↓
Drain
↓
Adding Acetic Acid (room temp, run time-30min)
↓
Sample check
↓
Drain
↓
Filling in the tank
↓
Adding soaping agent (90˚c, run-10 min)
↓
Drain
↓
Sample check
↓
Filling in the tank
↓
Rinsing (5min room tem)
↓
Drain
↓
Filling in the tank
↓
Run time (5min, room tem)
↓

25. Drain
↓
Filling in the tank
↓
Dosing-fixing agent (15min)
↓
Run time (20min, room tem)
↓
Sample check
↓
Drain
↓
Filling in the tank
↓
Dosing softener (5min)
↓
Run time (20min, room tem)
↓
Sample check
↓
Unload
Colour Measurement
The color of textile dyes is measured using the spectrophotometer. There are different
spectrophotometers for different types of light e.g. Infrared spectrometer, ultraviolet- visible
spectrophotometer etc. but the working principle is almost the same.

26. Fig : color measurement system of spectrophotometer.
Keya knit composite Ltd yarn dyeing
Yarn Dyeing: Yarn dyeing is slightly difference from woven or knit dyeing. Dyed yarns are
used for making stripe knit or woven fabrics or solid dyed yarn fabric or in sweater
manufacturing. Yarns are dyed in package form or hank form by yarn dyeing process. Dyeing
process can be vary depending on the individual procedure of a textile engineer or a dyeing
master. Now I will give typical flow chart of yarn dyeing.

27. Process flow chart for 100% Cotton Yarn (Dark/Medium/Light shade):
Pretreatment
Batch loaded
↓
Demineralization (50˚C, 20 min; PH=4.5)
↓
Scouring & bleaching (100˚C×40 min.)
↓
Drain
↓
Rinse
↓
Drain
↓
Neutralization with acid (50°C ×20 min)
↓
Hot Wash with peroxide killer (60˚C,20 min.)
↓
Drain
Dyeing
↓
Leveling agent & Salt (60° × 20 min; PH=6)
↓
Color dosing (60°C×20 min.)
↓
Run time = 10 min. (60°C)
↓
Color migration (80°C × 20 min.)
↓
Cooling (60°C)
↓
Level Check
↓
Soda dosing (60°C×30 min.)
↓

28. Dyeing run (Dark-60°C×60 min;Medium-60°C×40 min;Light-60°C×
30 min)
↓
Dyeing sample check
↓
(If Ok)
↓
Drain
After-treatment
↓
Rinse (with cold Water)
↓
Neutralization after dyeing (50°C×20 min.)
↓
Drain
↓
Soaping (Hot wash)
↓
Drain
↓
Rinse
↓
Add finishing chemical(60°C×20 min)
↓
Drain
↓
Unload
Soft winding:
The precision winders are used to transfer the yarn from paper cones to specially designed shells
(bobbins). The process of transferring yarn from paper cones to shells is called soft winding. The
soft winding by the precision winders can heavily affect the final result of dyed yarn; therefore,
imported precision winders are preferable instead of locally manufactured machinery. Package
quality always influences the processes that come prior to or after the dying process. The proper
density and homogeneity of the package allows the color to penetrate between the various layers
of yarn, producing a uniform flow inside the batch.