Textiles leave one of the largest water footprints on the planet and dyeing poses an especially big problem. Textile dyeing is the No. 2 polluter of clean water on earth, following agriculture. Dye houses in India and China are notorious for not only exhausting local water supplies, but for dumping untreated wastewater into local streams and rivers.

1. Topic : waterless dyeing
hsm - 409
presented by Zeba
Dayalbagh educational institute

2. Content
• Introduction
• Water in textile industry
• Waterless dyeing
• Major concern for textile industries
• What if you could dye fabric without water ?
• Companies working on waterless textiles
• Techniques of waterless dyeing

3. Introduction
• Dyes are colored organic compounds used to impart color onto cloth. The current
process for dyeing textiles is operative, but inefficient and harmful.
• The primary function of water in the dyeing process is to rinse excess dye off of
the fabrics that have been colored.
• the current commercial dyeing methods use a significant amount of water, and
pollute most of that water during the process. For each product manufactured, the
typical water to dye ratio is 15:1

4. Introduction
• Textiles leave one of the largest water footprints on the planet and dyeing poses
an especially big problem.
• Textile dyeing is the No. 2 polluter of clean water on earth, following agriculture.
• Dye houses in India and China are notorious for not only exhausting local water
supplies, but for dumping untreated wastewater into local streams and rivers.

5. Water in textile industry
• The textile industries is one of the biggest consumer of water.
• On average 100- 150 liters of water is needed to process 1 kg of
textile material, with some 28 billion kilos of textiles being dyed
annually.
• About 2.4 trillion gallons of water are used in synthetic dyeing.
• Water is used as solvent in many pretreatment and finishing
processes, such as washing, scouring, bleaching and dyeing.

6. Waterless dyeing
Waterless dyeing is the process by which dyeing is perform without
water. It is the process that used no water and requires less
energy than traditional methods of dyeing, while still achieving
impressive colors in solids and prints. Waterless dyeing process
required less process, time, chemicals, & auxiliaries. As a result
production cost is also less.

7. MAJOR CONCERN FOR TEXTILE INDUSTRIES
• Higher Water Consumption
• Higher Energy Consumption
• Higher CO2Emission
• Higher Effluent Generation
• Longer Dyeing Cycle
• Poor Reproducibility
• Intensive Labor

8. What if you could dye fabric without water ?
• No Water
• No Waste Water
• Low CO2Emissions
• Low Energy Consumption
• No Chemicals & Additives
• Complete Automation

9. COMPANIES WORKING ON WATERLESS TEXTILES
• Color zen
• Air dye
• Adidas (“dry dye” technology)
• Dye coo
• Nike

10. Color Zen
• Its process modifies cotton’s molecular structure and allows
dye to settle within the fibres without requiring the massive
discharge of water,
• eliminating the need to rise off fixing agents that keep a
fabric’s coloring consistent

12. Air Dye
• Instead of water, the company’s technology uses air to
disperse dye. Air Dye's process embeds dye within textile
fibres instead of merely on them,
• so color lasts longer and is more resilient to chemicals and
washings

13. Adidas (“Dry Dye” Technology)
• Instead of water, Adidas’ supplier uses compressed and
pressurized carbon dioxide as the agent to disperse dye
within polyester fabric.
• The CO2, which takes on liquid-like properties, is contained
in stainless steel chambers.
• After the dyeing cycle the CO2 becomes gasified, and dye
within the cotton fibres condenses as it separates from the
gas.

15. NIKE
• NIKE, Inc. has named this sustainable innovation “Color Dry” to
highlight the environmental benefits and unprecedented coloring
achieved with the technology
• Color Dry technology eliminates water by using heat and pressure to
convert liquid CO2 to supercritical fluid carbon dioxide, or “SCF”
CO2, which then permeates and carries the dye into the fabric

17. Techniques of waterless dyeing
Dyeing With Supercritical CO2
Digital Printing
Plasma Dyeing
Foam Dyeing

18. Cont..
DyeCoo Dyeing
Air Dyeing Technology
Transfer Printing

19. Air dyeing technology
Air dye technology manages the application of color to textile without the
use of water, it is also called as water-free dye technology. It was
developed and patented by colored , A California-based sustainable
technology company. Airflow was the key element of the technology, as
air is an ideal transport medium. The replacement of dye liquor with air
as A method of transporting piece goods in jet-dyeing machines was A
big step toward reducing water and chemicals consumption

20. Air dyeing technology

21. Air dyeing technology
The Air Dye process employs air instead of water to help the dyes
penetrate fibers. Air dye technology heats up fabric, then injects dye
directly into the fibers in the form of a gas. It is the process that used
no water and requires less energy than traditional methods of dyeing,
while still achieving impressive colors in solids and print

22. Advantages
• Unlimited flexibility with regard to all fiber except pure wool and fabric weight classes
between 30 and 800 grams per square meter, as well as all standard market dyestuffs
• The lowest liquor ratio on the market: approximately 1:2 for man-made fibers and 1:3 to
1:4 for natural fibers, depending on the article and structure
• Energy savings of up to 40 percent, thanks to a frequency
• Converter, and the use of air as a transport medium, while all other systems need water
• A reduction in the overall process time of approximately 25 percent
• And lowest water/wastewater levels.

23. Dye Coo dyeing
Dye Coo dyeing is a waterless dyeing process
in which Supercritical CO2 is used. When
carbon dioxide is heated to above 31 and
pressurized to above 74 Bar, it becomes
supercritical , a state of matter that can be
seen as an expended liquid, or a heavily
compressed gas. This supercritical is main
medium for Dye Coo dyeing system.

24. Dye Coo dyeing

25. Dyeing process
• The dyeing takes place in following
• steps :
• Dissolution of dye in CO2
• Transport to the fibers
• Adsorption of dye on fiber surface and finally
• Diffusion of dye into the fiber takes place

26. Dyeing process
The sample to be dyed is wrapped around a perforated stainless steel tube and mounted
inside the autoclave around the stirrer. Dyestuff powder is placed at the bottom of the
vessel and the apparatus is sealed, purged with gaseous CO2 and preheated. When it
reaches the working temperature, CO2 is isothermally compressed to the chosen working
pressure under constant stirring. Pressure is maintained for a dyeing period of 60 mins
and afterwards released. The CO2 and excess dyes are separated and recycled. After this
dyeing procedure, the dry sample is removed and rinsed with acetone if necessary to
remove the adhering residual dye

27. Process

28. Advantage
• Elimination of water treatment and water pollution
• No need of drying textiles
• Gives good rubbing fastness
• Dyeing occurs with high degree of levelness
• CO2 is non toxic obtained from natural resources and can be easily recycled in dyeing
process
• Dyeing houses may be started on
• Sites where there is water scarcity

29. Advantage
• No waste water (problem in textile industry)
• No require additives
• No final drying
• Recycling
• Solvent
• Colorants
• Environmental
• friendly

30. Disadvantage
• High pressure and high temperature are observed
• during the process. The system requires a lot of money.

31. Sublimation and Transfer Printing
Sublimation and transfer printing
described as Waterless coloration
technology in that heat is applied by
press, heated roll or calendar to
sublime the disperse dyes and drive
color into the interior of the fabric.

32. Cont..
• It is done by way of explanation the design is printed onto a
special sheet of release paper using sublimation ink which is
pressed onto the garments

33. Transfer Printing

34. Sublimation and Transfer Printing
• At a very high temperate and pressure the ink forms a gas
which then permanently dyes the polyester content of the
fabric.
• Sublimation technology is almost exclusively a polyester
specific solution.

35. Plasma dyeing
The physical definition of plasma is an ionized gas with an essentially equal
density of positive and negative charges.
Different reactive species in plasma chamber interact with the substrate surface
cleaning, modification or coating occurs dependent of the used parameter.
• Plasma process can be carried out in different manners,
• substrate can be treated directly in the plasma zone.
• substrate can be positioned outside the plasma remote process.

36. Plasma dyeing
• substrate can be achieved in the plasma followed by a subsequent
grafting.
• substrate can be treated with a polymer solution or gas which
will be fixed or polymerized by a subsequent plasma treatment

37. Plasma dyeing

38. Advantages
• Plasma dyeing is a very surface sensitive method.
• It is a revolutionary way to carry dye to fabric and fabric surfaces.
• It is so advanced that it not only colors the yarn, but also thousands of
filaments in each piece of yarn, yielding rich, brilliant colors. Penetration is
complete
• It produces superior results compared to sublimation printing and
conventional dyeing, but that is just the beginning of its advantages.

39. Types of plasma dyeing
Atmospheric pressure
plasma technique
Dielectric-Barrier
Discharge
Corona Discharge
Glow Discharge

40. Advantages
• Plasma dyeing technology reduces detrimental impact on the environment
• The result is more beautiful color
• Substantially less water and chemicals discharged
• Maximum color durability
• Producing luxuriously brilliant color
• Soil resistant , flame resistant
• Plasma treatment modified the fiber surface rather than its interior

41. Foam dyeing
• In case of foam dyeing , the main dyeing element is foam. For
that’s this dyeing is called foam dyeing
• A fabric is padded with foam formed from an aqueous solution
of a dyestuff, a foaming agent and a carrier for the dye stuff and
the padded fabric is maintained at elevated temperature to fix
the dye

42. Foam dyeing

43. advantages
• Improved dye pre fixture
• Improved migration of the dye into the fiber.
• Higher color yields in the fabric even after relatively short
dyeing times.
• Improved dimensional stability of the dyed fabric

45. Microwave dyeing
• Microwave dyeing takes into account only the dielectric and
the thermal properties. The dielectric property refers to the
intrinsic electrical properties that affect the dyeing by dipolar
rotation of the dye and influences the microwave field upon
the dipoles.
• The aqueous solution of dye has two components which are
polar, in the high frequency microwave field oscillating at
2450MHz. It influences the vibrational energy in the water
molecules and the dye molecules.

46. Microwave dyeing

47. Microwave dyeing
• The heating mechanism through ionic conduction, which is a type of
resistance heating.
• Depending on the acceleration of the ions through the dye solution, it
results in collision of dye molecules with the molecules of the fiber.
• The mordant helps and affects the penetration of the dye and also the
depth to which the penetration takes place in the fabric.
• This makes microwave superior to conventional dyeing techniques.

48. Advantages
• The major advantages of using microwaves for industrial
processing are rapid heat transfer, volumetric and selective
heating,
• compactness of equipment, speed of switching on and off
and pollution-free
• environment as there are no products of combustion.

49. Cont…
• Microwave processing, an inherently dry and fumeless
process is
• environmentally cleaner particularly in comparison to
processes which require
• additional media for heat transfer.

50. Dyeing with nanoparticle
• The way of Textile coloration by Nano-tech. is very fascinating
as no dyeing and finishing will take place, which means no toxic
chemicals, waste water and would consume less energy and
resources to produce.
• For the Pigments found in butterflies (melanin's etc.) can be
produced by Nano-technology in only yellow, orange-yellow,
red, black, and brown colors and Green,

51. Cont..
• blue and violet color comes from layers of nanoparticle
separated by layers of air.
• monolayer is in a pattern of mosaic tiles, where each tile of
pattern has different structural features as well as tiny gap
among them for light refraction.
• The thickness of the layers changes the color we see.

52. Dyeing with nanoparticle

53. Conclusion
We talk about saving water every day, but have we ever considered that this vital natural resource is
vastly being wasted and polluted in the process of textile dyeing. It is obviously not possible to cut
down the process of dyeing altogether. The textile industry is the heaviest industrial consumer of
water. By 2030, it is estimated that the world demand for fresh water will increase by 40 percent
with the increased population, and by 2050, an estimated billion-plus people will also lack the
water they need for daily living. Up to 26 gallons (100 liters) of water are needed to dye just two
pounds (one kilogram) of cotton fabric . so we need to waterless dyeing . water auxiliaries less
dyeing also minimize the energy, time , chemicals and auxiliaries

54. Thank you