Lab Report on

Dip Dyeing process on twill fabric

Course Title: Apparel Engineering- |||

Course Code: AE-1003

Submitted To
Md. Shamsuzzaman
Lecturer In Textile Engineering

Submitted By
Imam Hossain
Roll: 1106
Batch: 51B
Department: Textile Engineering

Submission date: 02/12/2020

Introduction:
Garment dyeing is a process of imparting color materials to fully fashioned garments like as
shirts, pants, twill garments, jackets, pullover, T-shirt, Polo shirt, sweaters etc. The garments are
usually dyed before finishing with various trimmings or accessories. In textile coloration it is not
so far initiated in our country but it is more popular outside our country like as France, Italy,
Spain, Germany, Canada, North America, turkey, Israel, Japan, USA, Uk, China etc.

Garment dyeing is an opposition of the conventional method of making garments from

previously dyed fabrics. Knitted fabrics, twill weave fabrics and/or other woven fabrics made
from cotton yarns are subjected to garment dyeing. Garments made of cotton material are easy
to dye up but besides cotton several other fabrics can be found in whole or partially made of
wool, silk, nylon, polyester or acrylic are subjected to garment dyeing.

Dip Dyeing:
In garments dyeing, dip dyeing is becoming more popular day by day as the fashion trend and
customer demand. Due to cheap and easy process it is as popular to the manufacturers. It is also
as called gradient dyeing. It is the process, the fully fashioned garments are arranged to dip into a
dye bath (vessel, bucket, bowl etc) accordingly a pre-determined area or height. This process
runs again and again. According to demand, garments are to be soaked into dye bath up to a
certain limit for enough time. To dye up the garment as deeper shade to light shade from bottom
to top the gradient time will be maintained for certain area of the garment.
 Process flowchart for DIP Dyeing on twill fabric

• Scouring (80°C)
• Neutralization (With Acetic Acid)
• Enzyme (At 45°C Temp and PH-4.5-5.5)
• Dyeing (90°C Temp for 3-5 Minutes)
• After Treatment (Fixing Agent)
• Softener (Commercial Softening Agent)
• Bath Drop

Normally garment dyeing runs with two types dyestuffs available in the market.

1. Direct Dyes
2. Reactive Dyes
a) Hot Brad
b) Cold Brand

For dip dyeing we use direct dye though it has low color fastness property, moreover it takes less
time for color fixation

Necessary Items:

• Dye Bath ( Vessel, bucket, bowl or any other container)

• Hanger
• Washing Machine
• Stirrer
• Rubber gloves

Pretreatment: As the fabric is not ready for dyeing after making cloths, it is treated with caustic
soda and peroxide solution to perform pretreatment process which helps to make it more
absorbent and free from natural color as well as other impurities.
 Recipe:

• Caustic Soda (NaOH)-2gm/l

• Per-Oxide (H2O2)-4gm/l
• Detergent-1gm/l
• Temp-80°C
• Time-15min

Working Procedure:
A lot of garments are now taken into the dyeing machine for easy performing the pretreatment
process (Good to know that, scouring, dyeing or any normal wash can also be done into a
washing machine). Now add Caustic Soda, Hydrogen peroxide and Detergents according to the
above recipe. Now maintain the liquor ratio at 1:10 at 80°C. Now perform this treatment for 15
minutes. Well scoured garments are treated as more absorbent, where color permanency will be
high. In this process the garments are to be more absorbent, removing the natural or unwanted
colors to make genuine white, oils as well as other impurities. Good scouring plays an important
role during dyeing, color fastness and appearance. The whole materials are now subjected to
rinse wash to remove the caustic and other chemicals. Now the garments are neutralized with
Acetic Acid so that any of the caustic soda does not exist with the material. The PH of Acetic
acid should be kept into 4.5 to 5.

Note: If the garments are made with zipper of cotton tape frequently be torn during the scouring
process, so nylon or polyester tape is recommended to use here.

Enzyme: After scouring process the full quantity of garment needs to treat with enzyme which
will help to remove the hairiness and projectile fibers as well as make the garments ready for
dyeing. You can use Acid enzyme as 2gm/l at 45-55°C for 15 minutes. After enzymatic
treatment one or two rinse wash to be done for washing it properly. (PH during enzymatic
treatment keeps in 4.5 to 5)

Recipe: We have used this for dyeing 380 Pcs baby girls shorts.
• Direct Dye-355gm
• Salt (Glubar Salt)-10gm/l
• Labeling & Wetting Agent-1gm/l
• Water-2500L
• Temp-95°C
• Time-5min

Working Procedure:
 Make the dye bath ready with direct dye as normal dyeing procedure. At first we will be sure the
garment is made from scoured and bleached fabric, otherwise scouring or pre treatment will have
to complete. After adding dyes, salt and wetting agents it needs to stir to make the dye bath
properly. For getting more color fastness and reduce fixation hours we can use some binding
agents as we need. The temperature of dye bath remains around 90-95°C.

The garment which is used to dyeing need to attach with hanger or something else to hang it
from, then water uses to wet the garment properly before taking it underneath the dye bath. Now
start to place the garment into the dye bath as desired height. You may require helps in doing this
so as not to spill the dye everywhere. Once the garment has been soaking in the dye bath for long
enough time then remove it carefully so that color spot does not transfer to the non-dyed portion.
If so, run the garment, from non-dyed section to dyed section, under warm water until water runs
clear. This will remove any excess dye from the garment. Continue the process till your desired
shade is developed and maintain the shade at different areas of the garment. To get as deeper to
lighter shade at bottom to top you can soak the garment into dye bath as long enough time. The
process of dip dyeing is not so crucial but it takes extra precautions, care and many more times.
During dyeing it will take spraying some water to the garment to wet it and helps to absorb
colors by the material.

Once your desired shade produced it needs to take it into a washing machine.

After Treatment:
It is the process usually doing after dyeing for color fixation and color permanency as well as
improving the color fastness. This is a chemical treatment so as for this a typical recipe is given
below.

Recipe:

• Commercial Fixer-0.5gm/l
• Softener (Cationic)-0.5 gm/l
• Temp-40°C
• Time-3-5 minutes
• M:L ratio- 1:10

Working Procedure:
After completing the dyeing it will be required some process to have sufficient dye molecules
penetration to the most inner part of the fibers. In the dye bath now adds the fixing agent
(Commercial Fixer) according to the recipe. Temperature in this bath will keep at 40°C and
treatment time is 3-5 minutes. By this treatment the material will be treated as finally colored.
Most of the dye particles will finally enter into the core of fibers and the fiber will swell at some
extent so that the pores of fibers will be reduced and dye materials cannot come out from the
innermost part. It will increase the color fastness of the materials. Before this treatment is started
a rinse wash will be done to remove extra dyes which adhere with the materials and after this
process also another rinse will be done to remove unfixable dyes or sediment dyes at the bottom
of the dye bath. Now softener is added to the bath to make the material softer, improving hand
feel and brightness.

Now just hanging up the garments for 20 minutes to squeeze extra water (Do not use hydro
extractor to reduce staining or uneven color adhering). You can use oven to dry the garments as
well, you can get prominence color performance without staining or shade variation. Now the
garments are cured at curing chamber at 150-200°C to dry finally and properly. You can use
dryer for a while at the final stage.

Conclusion: Dip dyeing is a new technique to produce unique design on garments.

100% cotton yarns made garment can be applied to dip dyeing. Preparing a dyeing
bath with direct or reactive dye where garments are to be dipped to a certain area
as per requirements. Depends on depth of shade dipping time will be fixed. Usually
5 to 7 times a garments is dipped into dye-bath and rinsing is done. Then successive
after dyeing treatments are to be done for color fixation and finally curing would
be done. Hanger is used to grip the garments and uniform dipping into bath. Dip
dyeing garments can give more unique and aesthetic looking but bulk production
is not much workable due to some limitations.