Textile Dyeing Operations Research Articles

Digital transformation to empower smart production for Industry 3.5 and an empirical study for textile dyeing

Most of traditional industries in emerging countries may not be ready to migrate for Industry 4.0 directly. There is a need of effective solutions to support digital transformation of traditional industries. Textile industry is facing global competition for mass customization to address dynamic customer demands. To enable the challenge from mass production to build-on-demand with small lot size and diversified product mixes, this study aims to develop a solution to support traditional industries to adopt smart manufacturing and empower digital transformation. Following a framework as systematic approach to collect, identify, and analyze related steps and decisions for an organization, a decision support system for dyeing machine scheduling is developed to empower smart manufacturing and break down information silos. In particular, setup time for textile dyeing operations is sequence-dependent, and products of different types and colors require setups for tank cleaning. The results have shown the practical viability of the proposed approach and Industry 3.5. Indeed, the developed solution has been implemented in a textile company in Taiwan.

Extraction of polyphenolic substances from bark as natural colorants for wool dyeing

In Europe, considerable amounts of bark are available from wood‐processing industries such as forestry and timber production. Polyphenolic components can be collected by hot water extraction. The extracted compounds can then be applied as colorants in textile dyeing operations. In this study, a comparative assessment of four different tree species with regard to their colouristic potential for wool dyeing was performed. Aqueous extracts from alder, ash tree, spruce and oak bark were prepared and analysed for their total phenolic content and ultraviolet (UV) absorption at 360–370 nm. The extracts were used for meta‐mordant dyeing by adding iron sulphate mordant (FeSO4 × 7H2O). For comparison, iron salt‐based dye lakes were prepared and used in dyeing experiments. For each tree species, a specific correlation between the total phenolic content of the dyebath and the colour depth in terms of K/S and CIELab coordinates was observed, both for the aqueous extracts and the dye lakes. Based on this relationship, standardisation and quality control of raw materials and dye lakes can be installed as important stages in the industrialisation of natural colorants from bark. The preparation of concentrated dye lakes permits formation of a concentrated colorant as dye product, which then can be standardised and delivered to textile dyehouses, similar to synthetic dyes. The preparation of dye lakes offers a relevant route towards achieving the commercialisation of bark extracts as natural colorants.

Recycling of rose wastes for use in natural plant dye and industrial applications

In today’s world, with people’s increasing tendencies toward environmental consciousness and healthy living, organic products raise more and more interest in the textile sector. In textile dyeing operations, many synthetic dyes and auxiliary chemicals are currently in use. Production steps of these synthetic chemicals and discharging chemicals to the aquatic media after utilizing in textile dyeing operations can have toxic and pollutant effects on human and environmental health. Classical natural dyeing techniques are quite expensive, and there are no industrial application processes for the classical natural dyeing techniques. After industrial treatments, plant products such as Rosa damascena flowers produce considerable amounts of wastes that contain natural dyes. This industrial waste from rose flowers could serve as a source for the extraction of natural dyes. In this study, we investigated the industrial waste rose flowers used for dyeing of wool yarn and an industrial process designed for using herbal pulps as natural dyes. This industrial process using rose waste and wool yarn was on an industrial scale. Mordants were selected from non-toxic metal salts and some organic acids. Colour strength and fastness properties (washing, rubbing and light properties) of the yarn were tested. Test results of the dyeing demonstrated that herbal pulps have the potential to be used as a source for natural dyestuff extraction at low cost and show additional possibilities for industrial application. The Pb2+ adsorption capacity of the ultimate rose pulp was investigated, and the results show that the rose pulp that remains after dye extraction can be used as an adsorbent.

Aluminium based dye lakes from plant extracts for textile coloration

Production of concentrated natural dyes is a pre-requisite for a re-introduction of plant colorant based dyes into modern textile dyeing operations. Aluminium salts such as Al2(SO4)3.14-15H2O or KAl(SO4)2.12H2O can be used to precipitate extracted plant dyes from aqueous extracts at pH 5.0–5.5. Onion peel, Canadian Goldenrod and pomegranate peel were studied as representative sources for dye extraction. As an average 5% w/w of the extracted dry plant material could be collected as precipitate. After dissolving these residues in diluted oxalic acid, the quality of the dye lake was characterised by photometric analysis of the total phenol content in the dry using the Folin-Ciocalteau method, determination of the aluminium content and measurement of the absorbance at 400 nm. Representative values of TPH in the dry solid dyestuff range from 20 to 40% and representative values for the aluminium content were determined with 3–5% w/w. Colour strength of the dissolved lakes was determined in dyeing experiments using different substrates and mordants followed by measurement of CIELab coordinates and K/S value according Kubelka-Munk function. Compared to the direct use of plant extracts the colour strength of the lakes is lower, however chroma of the dyeings is higher, as the lake formation also represents a dye purification step.

Production of a concentrated natural dye from Canadian Goldenrod ( Solidago canadensis) extracts

The dyestuff content in plant sources is rather low, usually in the order of a few % of the mass of dry plant material. Introduction of plant dyes into technical scale textile dyeing operations thus requires handling, extraction and disposal of huge amounts of plant material. The precipitation of a solid, dyestuff-containing residue by addition of FeSO 4·7H 2O to the aqueous plant extract yields a highly concentrated plant dye. In this work Canadian Goldenrod ( Solidago canadensis) was used as representative case to study production of a concentrated solid plant dye. An iron content of 5% w/w of the dry precipitate was analysed by photometry (1,10-Phenanthroliniumchloride). The content of total phenolics (TPH) calculated as gallic acid monohydrate equivalents according the Folin-Ciocalteau method, was determined with 45% w/w. The dyestuff precipitate was tested in standard dyeing experiments. Shade and colour depth were found comparable to dyeings obtained with direct use of plant extracts. Use of a concentrated natural dye product offers new approaches with regard to standardisation of dyestuff quality, handling and applicable dyeing techniques.

Anthocyanin dyes extracted from grape pomace for the purpose of textile dyeing

Pomace from different grape varieties was studied with regard to the content of extractable anthocyanins. Total anthocyanin concentrations of 24.5-126 mg dm(-3) were found in the extracts. The amount of extractable pigment was dependent on the variety of grape. The extracts were applied in textile dyeing operations using cotton fabric pre-mordanted with tannin as textile substrate. Red/violet shades were obtained that showed good water-fastness; however, limited light-fastness indicated need for improvement to fulfil requirements for textile application. Colour measurement by means of CIE-Lab coordinates and Kubelka-Munk value showed a direct correlation between extractable anthocyanin concentration and colour depth of the dyed material. Thus the analytically determined concentration of anthocyanins in the aqueous extract can serve as a measure of quality of grape pomace as raw material for textile dyeing application. Copyright © 2007 Society of Chemical Industry.

Natural dyes in modern textile dyehouses — how to combine experiences of two centuries to meet the demands of the future?

Plant materials which are available from farming regions in the moderate Austrian climate were investigated to serve as sources for natural dyes in textile dyeing operations. The extraction of the dye components from the plant materials was performed with boiling water without addition of chemicals or solvents. Based upon a rigorous selection of possible plant sources, a selection of natural dyestuffs applicable in a one-bath dyeing step was established. A broad variation in shade and color depth can be achieved by applying mixtures of natural dyestuffs in various combinations of iron- and alum-mordants. More than 60% of tested dyeings achieved acceptable fastness properties. On the basis of the developed natural dyestuff-based dyeing procedures, a comparison was made between the effluents from processes based upon them and those based upon the current ‘state-of-the-art’ techniques utilizing synthetic dyes. The comparison revealed that a lowering of the chemical load released with waste water can be expected by shifting to the plant-based dyes.

Energy and water conservation through recycle of dyeing wastewater using dynamic Zr(IV)-PAA membranes

The textile dyeing operations consumes large amounts of process water and thermal energy. The wastewater resulting from these operations contains various types of contaminants of organic and inorganic origin. This wastewater has an above average temperature. The possibility of renovating and recycling a major portion of this wastewater would reduce the water and energy consumption by these dyeing operations. This paper presents pilot plant test results of using Zr(IV)-PAA dynamic RO membrane modules for treating dyeing wastewater. Using these results, a mathematical model was presented to evaluate the design parameters and economic feasibility of a 1000 m 3/day plant for treating and recycling dyeing wastewater. The economic results show that a net profit could be obtained by recycling product water.

The desalting and recycling of wastewaters from textile dyeing operations using reverse osmosis

The wastewater from the textile dyeing operations was separated into a concentrate stream, rich in salts and dyes, and a purified product water stream using reverse osmosis membranes. Three membrane materials and three module configurations were used, namely : polyamide (hollow fine fiber configuration ), cellulose acetate ( spiral wound and tubular configurations ) and hydrous Zr(IV)- polyacrylate ( tubular configuration ). The modules were tested for periods ranging from 600 hours to more than 1000 hours under actual field conditions. Membrane flux and rejection were monitored throughout the operation and samples of the feed and product water were analysed chemically. The successful operation of the R.O. equipment under field conditions demonstrated the applicability of this process in the desalination of dyeing wastewater.