Textile Dyeing and Supply Chain Challenges

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Questions and Answers

What is the primary effect of setting nylon fabrics before dyeing?

  • Increases dye uptake
  • Enhances fabric durability
  • Decreases dye uptake (correct)
  • Improves colorfastness

What challenge do dyers face in the contemporary textile supply chain?

  • Higher operational costs
  • Balancing quality with environmental requirements (correct)
  • Limited access to dyes
  • Increasing demand for synthetic fabrics

Why might setting nylon fabrics after dyeing result in an undesirable effect?

  • It causes fading of the color
  • It reduces the fabric's tensile strength
  • It increases color bleed during washing
  • It may cause yellowing of the shade (correct)

What is the significance of collaboration among all parties in the textile supply chain?

<p>To ensure environmental compliance and safety (A)</p> Signup and view all the answers

What aspect of consumer expectations has changed in the modern textile market?

<p>Greater emphasis on product quality and longevity (B)</p> Signup and view all the answers

What is the primary factor influencing how dye adheres to fabric?

<p>Chemical reactions between the dye and the fibres (B)</p> Signup and view all the answers

Which of the following statements about light and color perception is true?

<p>Light stimulates the eye and produces the sensation of vision. (C)</p> Signup and view all the answers

What is the range of visible light wavelengths that the human eye can perceive?

<p>380 to 770 nm (D)</p> Signup and view all the answers

Which component of the eye is primarily responsible for interpreting color?

<p>Cones (B)</p> Signup and view all the answers

Which of the following is NOT a type of radiation immediately associated with the visible light spectrum?

<p>Gamma radiation (D)</p> Signup and view all the answers

What is essential when describing a color beyond basic terms like 'red' or 'blue'?

<p>Understanding wavelength absorption (C)</p> Signup and view all the answers

What is a common outcome of color theory in textiles?

<p>Greater visual appeal to consumers (B)</p> Signup and view all the answers

Which of the following aspects directly influences the choice of dyeing machinery?

<p>Types of dye and dyeing conditions (C)</p> Signup and view all the answers

Which attribute of color refers to its recognition as being predominantly red, green, or blue?

<p>Hue (D)</p> Signup and view all the answers

What is the primary goal of using instrumental color matching systems?

<p>To quantify the difference between two colors (C)</p> Signup and view all the answers

What are the three main components of the Munsell color system?

<p>Hue, value, chroma (D)</p> Signup and view all the answers

Which method is preferred for color matching in dyeing processes?

<p>Instrumental color match prediction (D)</p> Signup and view all the answers

What is metamerism in the context of color matching?

<p>The perception of color difference under varying light sources (B)</p> Signup and view all the answers

What does the term 'strength' in colors refer to?

<p>The color yield of a dye compared to a standard (A)</p> Signup and view all the answers

Which factor impacts the human perception of color across the spectrum?

<p>The ability of the substrate to reflect light (B)</p> Signup and view all the answers

How many main classes of dyestuff are generally recognized?

<p>10 (B)</p> Signup and view all the answers

Which of the following is NOT a factor in selecting dyes for a specific fiber?

<p>Cold weather resistance (A)</p> Signup and view all the answers

Which of the following elements is taken into account in mathematical color difference equations?

<p>Light absorption, scattering, and reflection (B)</p> Signup and view all the answers

What is a critical factor when using spectrophotometers in color assessment?

<p>The accuracy of the reflectance data (C)</p> Signup and view all the answers

How do spectrophotometric curves assist dyers?

<p>By replicating reflectance data for color matching (D)</p> Signup and view all the answers

What constitutes the reflectance values measured by instrumental systems?

<p>The percentage of light reflected from the surface at specific wavelengths (B)</p> Signup and view all the answers

What is the primary purpose of an instrumental match prediction system in dyeing?

<p>To select the dye recipe by analyzing reflectance curves (A)</p> Signup and view all the answers

Which of the following fastness grades is deemed acceptable for general apparel?

<p>4 (A), 5 (C)</p> Signup and view all the answers

What does substantivity refer to in the dyeing process?

<p>The rate at which dye is absorbed by a fiber (B)</p> Signup and view all the answers

Which type of fastness is NOT a common requirement for dyed materials?

<p>Chemical resistance (C)</p> Signup and view all the answers

Why is it important for the dyer to be aware of the customer’s fastness requirements?

<p>To select the best dye recipe during the prediction and selection stage (B)</p> Signup and view all the answers

What is the primary concern regarding azo dyes?

<p>They can break down into carcinogenic compounds (A)</p> Signup and view all the answers

How is light fastness generally graded?

<p>1 to 8 (A)</p> Signup and view all the answers

Which of the following factors does NOT affect the dyeing conditions?

<p>Size of the dyeing machinery (B)</p> Signup and view all the answers

Which type of acid dye has the poorest washing fastness properties?

<p>Levelling dyes (A)</p> Signup and view all the answers

What is the effect of high substantivity in dyes?

<p>Need for modified processing conditions (A)</p> Signup and view all the answers

What is a characteristic of metal-complex dyes compared to traditional acid dyes?

<p>They generally have superior fastness properties. (C)</p> Signup and view all the answers

What might a dyer adjust to enhance dye migration during the dyeing process?

<p>Processing conditions (C)</p> Signup and view all the answers

Which method is primarily used today for applying mordant dyes?

<p>Afterchrome (C)</p> Signup and view all the answers

What is the key distinction of reactive dyes?

<p>They react chemically with the fibre. (D)</p> Signup and view all the answers

Which organization is NOT mentioned as a contributor to dye fastness testing standards?

<p>Union of European Dyestuff Manufacturers (C)</p> Signup and view all the answers

Which of the following statements about nylon fibres is accurate?

<p>They may suffer from dyeing problems due to manufacturing variations. (A)</p> Signup and view all the answers

What is the overall aim when selecting dyes and application methods?

<p>To achieve successful and uniform dyeing (B)</p> Signup and view all the answers

Why do retailers develop their own Restricted Substances List (RSL)?

<p>To help address environmental concerns (A)</p> Signup and view all the answers

Which of the following dye categories offers the best fastness properties when applied?

<p>Mordant dyes (D)</p> Signup and view all the answers

For which application do super-milling dyes require specific control over the dyeing process?

<p>Achieving brightness (A)</p> Signup and view all the answers

What does the term 'migration' refer to in the context of dyeing?

<p>The movement of dye from one part of a material to another (D)</p> Signup and view all the answers

What is the minimum grade for color fastness that is generally deemed acceptable for commercial use?

<p>4 (A)</p> Signup and view all the answers

What is the main characteristic of milling dyes?

<p>They have good levelling properties. (D)</p> Signup and view all the answers

Acid dyes are categorized based on which properties?

<p>Levelling and fastness properties (B)</p> Signup and view all the answers

What colour characteristics are typical of mordant dyes?

<p>Dull shades such as black and navy (C)</p> Signup and view all the answers

What is a common application method for reactive dyes?

<p>Alkaline wash after dyeing (C)</p> Signup and view all the answers

Which dyestuff group is essential for achieving exceptional dye fastness in superwash wool?

<p>Reactive dyes (B)</p> Signup and view all the answers

What environmental concern arises from the use of mordant dyes?

<p>Residual toxic chromium in effluent (A)</p> Signup and view all the answers

What is the primary difference between 1:1 and 1:2 metal-complex dyes?

<p>The number of dye molecules per metal atom (B)</p> Signup and view all the answers

What is a common choice for dyeing tubular knitted fabric?

<p>Jet machinery (D)</p> Signup and view all the answers

Which dyeing method allows for the addition of dyes before the extrusion of filaments?

<p>Dope dyeing (C)</p> Signup and view all the answers

What type of dyes are used for cellulose diacetate and triacetate fibres?

<p>Disperse dyes (B)</p> Signup and view all the answers

What is typically added to direct dyeing processes to promote dye exhaustion?

<p>Sodium chloride (B)</p> Signup and view all the answers

Which of the following characteristics is true for reactive dyes?

<p>They offer excellent colour fastness (C)</p> Signup and view all the answers

What is a disadvantage of using direct dyes?

<p>Poor colour fastness (A)</p> Signup and view all the answers

Which machinery is preferred for dyeing garments?

<p>Paddle machines (B), Rotary machines (D)</p> Signup and view all the answers

What is a common application process of reactive dyes?

<p>Exhaustion, fixation, and post-dye washing (D)</p> Signup and view all the answers

Why is dope dyeing considered valuable for synthetic fibres like polypropylene?

<p>It minimizes water absorption (D)</p> Signup and view all the answers

What is the key characteristic of direct dyes in relation to fabric processing?

<p>They offer good application ease (B)</p> Signup and view all the answers

What is a typical property of cellulose fibres regarding dyeing?

<p>They require high temperature for dyeing (C)</p> Signup and view all the answers

What type of dyeing method is recommended for printing fabrics?

<p>Screen printing (D)</p> Signup and view all the answers

What happens to unreacted dye during the post-dye washing phase of reactive dyeing?

<p>It is removed to improve fastness (D)</p> Signup and view all the answers

What is the main drawback of using reactive dyes in terms of their application?

<p>They require a specific temperature range (A)</p> Signup and view all the answers

What is the purpose of minimizing the liquor-to-goods ratio in reactive dyeing?

<p>To reduce the proportion of hydrolysed dye (B)</p> Signup and view all the answers

Which compound is essential for forming the leuco compound in vat dyeing?

<p>Sodium hydrosulphite (B)</p> Signup and view all the answers

What is the final step after dyeing with vat dyes to achieve optimum color fastness?

<p>Soaping with a detergent (A)</p> Signup and view all the answers

Which of the following is a major limitation of vat dyes?

<p>High cost and difficulty of application (A)</p> Signup and view all the answers

What type of fabrics are typically dyed with sulphur dyes?

<p>Dull, dark shades on heavier fabrics (A)</p> Signup and view all the answers

What is a significant environmental concern associated with sulphur dyes?

<p>Discharge of sodium sulphide into effluents (A)</p> Signup and view all the answers

Azoic dyes are primarily formed through a reaction involving which two components?

<p>A coupling component and a diazonium salt (B)</p> Signup and view all the answers

What process is necessary to achieve dye fixation for azoic dyes?

<p>Oxidation of the pigment (D)</p> Signup and view all the answers

Which type of fiber is associated with the use of protein dyes?

<p>Animal protein fibers (C)</p> Signup and view all the answers

What is the main characteristic of vat dyes in comparison to other dye types?

<p>Excellent fastness properties (D)</p> Signup and view all the answers

Which is a common use for vat dyes due to their properties?

<p>Outdoor fabrics requiring durability (C)</p> Signup and view all the answers

What occurs during the vatting process using sodium sulphide?

<p>Creation of alkaline conditions for dyeing (B)</p> Signup and view all the answers

What is the role of hydrogen peroxide in the dyeing process?

<p>To oxidize and develop the shade (C)</p> Signup and view all the answers

Which factor must be controlled during the application of the coupling component in azoic dyeing?

<p>Temperature and liquor-to-goods ratio (D)</p> Signup and view all the answers

Flashcards

Color

The sensation produced by the interaction of light with an object, creating a visual impression.

Visible light spectrum

The range of electromagnetic radiation visible to the human eye, spanning wavelengths from 380 to 770 nanometers.

Light absorption

The process by which certain wavelengths of light are absorbed by an object, while others are reflected.

Photoreceptor cells

Specialized cells at the back of the eye sensitive to different wavelengths of light, converting light signals into electrical impulses.

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Visual cortex

The part of the brain that interprets electrical signals from the photoreceptor cells, creating the perception of color.

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Spectrophotometric curve

A graphical representation of the amount of light absorbed at different wavelengths by a substance.

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Wavelength and hue

The relationship between the specific wavelength of light absorbed by a substance and the resulting color perceived by the viewer.

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Color description and measurement

The way in which color is described and measured, using precise terms and systems.

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Hue

The actual color of an object.

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Value

Refers to how light or dark a color appears.

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Chroma

Indicates the intensity or purity of a color. It's how vivid or dull a color appears.

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Munsell Color System

A system for organizing and classifying colors using hue, value, and chroma.

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Pantone Color System

A system for describing and matching colors using reference standards.

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Instrumental Color Difference Equation

A method that uses mathematical formulas to quantify the difference between two colors. These formulas account for factors like light absorption and scattering.

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Kubelka-Munk Model

A theoretical model that helps understand light absorption, scattering, and reflection in colored materials.

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Spectrophotometer

A device that measures the intensity of light reflected by an object across different wavelengths.

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Dye Selection Procedure

A system for selecting suitable dyes to achieve a desired shade.

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Traditional Visual Selection

A visual method of selecting dyes by comparing shade cards and existing shade libraries.

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Instrumental Color Match Prediction

A process that uses computer software and spectral data to predict dye combinations for achieving a specific shade.

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Metamerism

The difference in color perception between two objects under different light sources.

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Illuminant Conditions

A set of conditions under which a color match should be assessed, including store lighting, artificial daylight, and tungsten-filament light.

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Reflectance Curve

The extent to which a dyed material reflects light across different wavelengths.

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Dye Compatibility

The process of selecting dyes that have compatible properties and will perform well together during the dyeing process.

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Fastness to Detergent Washing

A measure of how well a dyed material resists color change due to washing with a detergent.

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Fastness to Perspiration

A measure of how well a dyed material resists color change due to perspiration.

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Fastness to Rubbing (Wet and Dry)

A measure of how well a dyed material resists color change due to rubbing.

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Fastness to Light

A measure of how well a dyed material resists color change due to exposure to light.

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Grey Scale

A system used to assess color fastness, with grades ranging from 1 (very poor) to 5 (excellent).

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Substantivity

The attraction between a dye and a fiber, affecting how quickly the dye bonds to the material.

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Migration

The ability of a dye to move within a fiber or fabric during processing.

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Strike Rate

The rate at which a dye is taken up by a fiber, influenced by its substantivity.

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Preparation for Dyeing

The process of preparing fabrics and fibers before dyeing, ensuring good dye uptake.

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Movement of Goods

The movement of fabric through the dye liquor, or the movement of liquor through the fabric, essential for even dyeing.

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Liquor-to-Goods Ratio

The amount of dye liquor compared to the weight of the material being dyed.

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Process Control

The ability to control the dyeing process, ensuring consistent and uniform results.

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Machinery for Dyeing

The use of different machinery designed to dye various forms of materials, from loose fibers to garments.

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Restricted Substance

Any substance that could potentially cause harm to humans or the environment.

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Restricted Substances List (RSL)

A list of restricted substances that suppliers must comply with, focusing on environmental and safety concerns.

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Dope Dyeing

A type of dyeing where dyes or pigments are added to a synthetic polymer solution before it is extruded into filaments, resulting in excellent color fastness.

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Reactive Dye

A type of dye that forms strong bonds with cellulose fibers, providing excellent color fastness.

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Direct Dye

A type of dye that has good affinity for cellulosic fibers, but is generally less bright and has poorer color fastness compared to reactive dyes.

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Dye Exhaustion

The process of transferring dye from the dyebath to the fiber.

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Dye Fixation

The chemical reaction that fixes the dye to the fiber, providing color fastness.

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Post-Dye Washing

The final step in reactive dyeing where any excess dye is removed to ensure acceptable color fastness.

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Cellulosic Fibers

Cellulose-based fibers, including cotton, flax, and regenerated fibers like rayon.

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Printing

The process of applying dyes or pigments to a surface to create patterns or designs.

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Continuous Printing

A type of printing technique where a thickened dye paste is applied to fabric using engraved rollers or patterned screens.

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Transfer Printing

A type of printing technique that involves transferring dye from a previously impregnated paper onto fabric using heat.

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Leather Dyeing

A method of dyeing where dyes are applied to leather in its raw form.

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Dope Dyeing

A process where dyes are applied to synthetic polymers in solution, creating a strong and permanent color throughout the fiber.

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Hydrophobic

The characteristic of fibers that resist absorbing water.

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Electrolyte Addition

The addition of substances like sodium chloride or sodium sulphate to the dyebath to promote dye exhaustion.

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Barré

Uneven dyeing leading to visible stripes in fabrics, caused by variations along the length of the yarn.

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Nylon Setting

A process to stabilize nylon fabrics, either heat or steam setting, before or after dyeing.

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Dye Uptake and Nylon Setting

A common issue where setting nylon before dyeing reduces dye uptake, while setting after dyeing can cause yellowing.

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Dyer's Challenge

The challenge of maintaining product quality within a budget while complying with environmental regulations.

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Supply Chain Collaboration

Collaboration between all parties involved - retailers, designers, dyers, and manufacturers - to create a sustainable product with optimal quality and safety.

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Reactive Dyeing

A type of dyeing where dyes react chemically with the fabric fibers, forming a permanent bond. These dyes are highly colorfast, but require special conditions for application.

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Hydrolysis

The breakdown of a dye molecule in water, leading to a loss of color and fastness. It's a common problem in reactive dyeing.

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Vat Dye

A type of dye that requires a reducing agent and alkaline conditions to form a soluble and substantive (able to bind to the fabric) form. They are known for outstanding color fastness.

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Vatting

The process of converting an insoluble vat dye into a soluble and reactive form using a reducing agent and alkali.

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Reducing Agent

A chemical used to reduce the vat dye into its soluble form. It allows the dye to penetrate the fabric fibers.

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Alkali

A chemical used to create alkaline conditions necessary for vatting. It helps the dye to react with the fabric.

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Solubilized Vat Dye

A water-soluble form of a vat dye that is ready to bind to the fabric, bypassing the vatting process. It's useful for lighter shades.

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Sulphur Dye

A class of dyes used for dark, dull shades, known for their good wet fastness. They are inexpensive but can be less lightfast and chlorine-resistant.

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Soaping

The process of removing excess dye, reducing the overall shade, and improving color fastness. It's a common step in dyeing.

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Azoic Dye

A type of dye that forms an insoluble pigment directly on the fabric by the reaction of two separate components: a coupling component and a diazonium salt.

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Coupling Component

A component of azoic dye that binds to the fabric and reacts with the diazonium salt to form the final color.

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Diazonium Salt

A component of azoic dye that reacts with the coupling component to form the final colored pigment on the fabric.

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Diazonium Salt

A chemical compound with a specific molecular structure that can react with other molecules to form a colored pigment.

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Acid dyes

Dyes applied under acidic conditions, offering ease of application, a wide color range, and good fastness properties.

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Levelling, Milling, and Super-milling acid dyes

Acid dyes categorized by their leveling abilities and resulting fastness properties.

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Levelling-acid dyes

Dyes that have good leveling properties and are applied with sulfuric acid to achieve exhaustion, but have poor wash fastness.

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Milling-acid dyes

Acid dyes with greater substantivity to the fiber, resulting in better fastness but poorer leveling properties.

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Super-milling acid dyes

Acid dyes that offer excellent fastness, applied similar to milling-acid dyes with additional control for even dye application.

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Metal-complex dyes

Acid dyes where a metal atom (usually chromium) is incorporated into the dye molecule during production.

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1:1 metal-complex dyes

Metal-complex dyes with a 1:1 ratio of metal atoms (usually chromium) to dye molecules.

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1:2 metal-complex dyes

Metal-complex dyes with a 1:2 ratio of metal atoms (usually chromium) to dye molecules.

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Mordant dyes

Acid dyes capable of reacting with chromium, resulting in excellent wet fastness.

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Prechrome method

Mordant dye application method where the mordant is applied before dyeing.

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Metachrome method

Mordant dye application method where the dye and mordant are applied simultaneously.

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Afterchrome method

Mordant dye application method where the mordant is applied after the dye.

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After-treatment for reactive dyes

A process used to remove unfixed dye from the fabric after dyeing with reactive dyes, particularly for darker shades.

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Polyamide fibers

Synthetic polyamide fibers, commonly nylon 6 and nylon 6.6, susceptible to variations in their manufacture that can affect dyeing.

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Study Notes

Dyeing Fabrics: Chemistry, Physics, and Processes

  • Dyeing fabrics involves a complex interplay of chemistry and physics
  • The visual perception of color is subjective but measurable through wavelengths of reflected light.
  • Dyes adhere to fabrics via chemical reactions with fibers, varying types suited to different fibers and conditions.
  • Key factors in dyeing are selecting appropriate dyes and applying them under suitable conditions, impacting machinery choice.

Color Theory and Perception

  • Color is a perception, not an intrinsic property of an object, a sensation based on light's interaction with the eye.
  • Light is radiant energy, measured in nanometers (nm). Visible light ranges from 380-770 nm.
  • When light hits an object, some wavelengths are absorbed, others reflected. Reflected light signals the eye, which the brain interprets as color.
  • Different wavelengths create different colours.

Color Description and Measurement

  • Color description needs precision beyond basic terms (e.g., red, green). Attributes include:
    • Hue: the dominant color (e.g., red, green).
    • Strength/Intensity/Chroma: color's intensity relative to a standard.
    • Brightness/Value: lightness or darkness of the color.
  • Color atlases (e.g., Munsell, Pantone) standardize color description.
  • Instrumental systems (spectrophotometers) quantify color differences precisely.

Instrumental Color Match and Shade Assessment

  • Mathematical color difference equations account for light absorption/reflection and human perception variations.
  • Spectrophotometers accurately measure reflected light.
  • Systems like CMC, BFD, and CIE-94 are used.
  • Instrumental systems enable precise color matching and prediction of dye recipes.

Selection of Dyes: Achieving the Desired Shade

  • Dye selection involves choosing appropriate dyes for the fiber and desired shade.
  • Two main color-matching methods:
    • Visual: uses shade libraries and supplier cards, a trial-and-error process.
    • Instrumental: uses spectral data of dyes in a computer database to predict a matching recipe.
  • Predictive systems work with spectral data (reflectance values at various wavelengths) to generate dye recipes.

Dye Compatibility and Metamerism

  • Dyes within a class may differ in application rates, so compatibility is critical.
  • Metamerism: color difference changes under different light sources.
  • Instrumental systems predict metamerism between standards and potential dye combinations.

Color Fastness

  • Fastness requirements depend on the end-use and subsequent processing.
  • Widely used by organizations like the British Standards Institution and the International Organization for Standardization.
  • Fastness is assessed by comparing staining on adjacent fabrics vs gray scales, graded 1-5 (1 poor, 5 excellent).
  • Light fastness is graded 1-8.
  • Considerations for choosing dyes based on fastness requirements and related processing stages(shrink-resisting, easy-care resins, etc.)

Environmental Considerations in Dyeing

  • Dyes may contain formaldehyde, heavy metals or banned azo dyes; effluents need careful consideration.
  • Azo dyes, while common (70% globally), may produce carcinogenic compounds under specific conditions.
  • Retailers provide restrictive substance lists (RSLs) that dyers must follow to mitigate potential risks.

The Dyeing Process: Conditions and Machinery

  • Dyeing conditions must be appropriate for a given fabric and the chosen dyestuff
  • Balance between dye substantivity (attraction to fiber) and migration properties (movement within material) is essential.
  • Substantivity affects dye uptake rate, while migration affects evenness of dyeing.
  • Processing conditions (liquor-to-goods ratio, machinary circulation) must suit the selected dyeing machinery.

Textile Materials and Dyeing Machines

  • Various physical forms of textile materials (loose fibres, slubbing, tops, yarns, fabrics, garments) necessitate different machinery.
  • Dyeing machines vary in configuration (hank processing, package form, jet machinery, winch machinery, paddle machines, rotary machines etc.).

Other Textile Coloration Methods

  • Dyes and pigments can be used for printing fabrics (continuous, semi-continuous, screen, transfer, digital).
  • Leather is dyed in hide form using specific dye types.
  • Dope dyeing adds dyes/pigments to polymer solutions before extrusion.

Classes of Dyes for Different Fiber Types

  • Dye selection for specific fibers.

Cellulosic Fiber Dyes

  • Different cellulose fibers often require different dye types and conditions. Key dye types explained:
    • Direct: Good substantivity, easy application, limited brightness/fastness.
    • Reactive: Bright colours, excellent fastness due to chemical bonds with cellulose.
    • Vat: Very good fastness, however limited colours and higher price.
    • Sulphur dyes: Inexpensive, dark colours, potential environmental impacts.
    • Azoic: Insoluble pigments formed within fibre by reaction of two components, good wet/light fastness.

Protein Fiber Dyes

  • Animal hair fibres (wool, cashmere) and silk share similar dyeing characteristics and can be dyed with many similar dyes. Key dye types explained:
    • Acid dyes: Various types depending on leveling/fastness, good brightness, use in pale, bright shades.
    • Metal-complex dyes: Use metal atoms in dye molecule for deeper shades, good fastness but duller.
    • Mordant dyes (chrome dyes): React with chromium, excellent wet fastness, limited colour range.

Polyamide Fiber Dyes

  • Nylon fibres (nylon 6 and 6.6) are vulnerable to variations in manufacturing that can affect dyeing. Common issue: barré (color stripes). Selection of dyes and adjustment of processes can reduce barré.

Overall Dyeing Challenges

  • Future focus should be on technological optimisation for safety, performance and environmental compliance.
  • Communication, input from stakeholders, and technological advancements across the supply chain are essential for improved sustainability.

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