Source: Technical Service, Atul Ltd (Colors Division), Valsad, Gujarat, India


Globally, the textile industry is witnessing a paradigm shift in the Concepts, Applications and Technology of wet processing. The influencing factors for this shift are considered to be cost pressures, high quality demands, environment regulations, fashion trends & supply chain logistics.


The above factors have forced the Dyers to formulate strategies to cope up with the following major challenges:


Increase productivity: Focus on RFT (Right-First-Time), RET (Right-Every-Time), shorter process cycles.

Cost optimisation: Use of high tinctorial dyes, multifunctional auxiliaries, reduction in utility cost.

Shortened processing: Robust recipes, quick lab-dips.

Flexibility in operation: ability to process short run.

Eco- concerns: AOX, COD, TDS, Fluorine content, etc

Stringent demands: higher fastness ratings, shade consistency.


The global scenario of class of dyes applied on cellulose (Figure 1), clearly shows the enormous importance of Reactive dyes. The segment wise application of Reactive dyes (Figure 2) reveals that the demand for warm dyeing is on the rise.


The globalisation of the textile supply chain has increased competition, thereby forcing the Indian dyers to look beyond the recipe costs and increase overall production efficiencies and also to reduce the hidden costs like power cost, water cost, steam cost and effluent treatment cost. This translates to the dyestuff manufacturers as the need to develop high strength dyes with better wash-off profile and higher wet fastness properties

 

Keeping the above factors in view, Atul has developed TULAREVS XL range, a state-of-the-art Reactive system, manufactured using innovative membrane technology, to meet stringent fastness requirements (like that of M&S fastness) and deliver high reproducibility from laboratory to bulk (RFT) and also from Bulk to Bulk (RET)

Features

Benefits

q    Outstanding tinctorial Strength


Economic deep shades at lower depths

q    Compact range having similar dyeing profile


q    High salt solubility

On tone built-up, excellent levelness & reproducibility.


Shortened dyeing cycle with Salt-atStart.

q    Molecular re-engineered Reactive system for better bonding with cellulose


Achieves high fixation levels.

Less dye in effluent.

Outstanding wet fastness properties


q    Easy wash-off performance

Water, time & energy saving

 

The elements of the range and their special features / positioning are as follows:

 Yellow XL-3R

 Basic golden yellow for trichromies

 Orange XL-3R

 Strong orange for economic dark shades

 Red XL

 Economic bright bluish red

 Red XL-B

 Deep red for dark trichromies

 Red XL-2B

 Bluish red for medium shades

 Navy XL-G

 Greenish blue for basic trichromies

 Navy XL-B

 Economic navy blue

 Black XL-N

 Neutral black with very good fastness properties

 Black XL-G

 Greenish black for deep shades

 Black XL-R

 Reddish black for Jet black shades with superior fastness

 

 

The higher tinctorial values, excellent build-up and easy wash-off properties of newly developed TULAREVS XL range are particularly useful for production of cost effective deep shades, with excellent fastness properties. Ultimately these benefits on one hand would help the customer to reduce the effluent load and on the other support the garment deliveries in shorter lead-time, which is the need of the day.


Dark shades are achieved from lower concentrations of TULAREVS XL dyes compared to other available commodity & specialty reactive dye systems (Figure 3 & 4). In the illustration, the difference in salt concentration is 25%, which translates as lower salt in the effluent and lesser salt to wash-off). This less amount of salt and less hydrolysed colour results in reduced water consumption during washing off resulting in an overall savings in effluent treatment.


Figure - 3


TULAREVS XL


Significantly less dye is needed to achieve the target shade (Dark Brown)


 


TULAREVS XL

Specialty VS/ BF

Commodity VS

Yellow XL-3R - 0.90%

Red XL-B - 0.90%

Navy XL-G - 0.90%

Yellow - 1.42%

Red - 2.02%

Navy - 1.00%

C. I. Reactive Orange 107 - 1.44%

C. I. Reactive Red 198 - 1.98%

C. I. Reactive Black 5 - 1.20%


A comparison of the % dye needed to achieve the same colour value with TULAREVS Red XL-B Vs competition products is shown below.


Figure - 4


 

To conclude - this new technology Reactive dye system

  • Offers value for money
  • Provides uniform level dyeing & superior shade build-up
  • Confers optimum all round fastness properties
  • Improves reproducibility.
  • Highly recommended for exhaust dyeing of cotton yarn, knits and woven goods.


For further information on this product range & individual product performance in terms of


  • Solubility under varying salt concentrations & temp conditions
  • Substantivity- Exhaustion- Fixation (SEF) profile
  • Leveling & Migration behaviour
  • Shade build-up in self & on-tone behaviour in combination
  • Robustness to dye bath variables Liquor, Time, Temp, Electrolyte & Alkali (LTTEA)
  • Standard depths & corresponding fastness data
  • Wash off profile
  • Effect of post dyeing - fixing & finishing
  • Affinity of dye hydrolysate & minimal back staining
  • Durability to repeated home laundry washes
  • Methods for wash down & stripping
  • Dischargeability,


About the Author


For more information kindly contact at co.rb@atul.co.in



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