What is the Yarn Dyeing Process?
The yarn dyeing process is the 3rd step of the t-shirt manufacturing process, it comes after the ginning and spinning process. This is the step where the yarn is colored according to the desired result. This is remarked as a crucial step where the dull fibers are colored to make it lively and appealing to the wholesalers and retailers to buy t-shirts in bulk. The yarn dyeing process is used to make certain types of fabric: stripe knit fabric, woven fabric, and solid dyed yarn fabric.
Types of Yarn Dyeing Processes
Package Yarn Dyeing Process
Package dyeing is also called cone dyeing. This is the most commonly used dyeing process in the textile industry particularly in t-shirt city. The yarn is first transferred from the normal cones to perforated cones. It is important to use perforated cones because the dyebath needs to penetrate from inside to outside, which is not possible otherwise. The cones are now stacked together, and it is inserted in a huge boiler. In the reserve tank, the dye, auxiliary chemical, and water are added that is transferred to the main tank at the time of process.
In this machine, the HTTP method is applied, which means High Temperature and High Pressure. In this process, boiling takes place in order to penetrate the dye to the core of the cone, but it is not enough, that is why high pressure is also created. In this dyeing process, the dye first goes from inside to outside for 4 minutes. Then the dye is transferred from outside to inside for 6 minutes. This process mentioned is done nearly 6 times to dye the yarn properly. This dyeing process takes not more than 1 hour to complete. This dyeing process is done under 130 degrees of temperature. This is the most common dyeing process used by t-shirt manufacturers in Tirupur.
Hank Yarn Dyeing Process
In this dyeing process, we lose the yarn and wound it on a coil. This hank is then dipped in a dye bath to absorb the color. In this yarn dyeing process, color retention is at its best level as the yarn is loosened up. The yarn, after dyeing, has a soft feel, and the result is quite rich. This process of yarn dyeing can be done by both hands and with the help of machinery. Hank dyeing is not a popular dyeing process in the textile industry. We can use this dyeing method in order to dye lofty wool, acrylic yarn and in the process of carpet manufacturing.
The steps of the hank dyeing process are:
Step 1: The skein is first looped on a hook, and it is washed to open the fiber to receive dye.
Step 2: The skein is sunk into a dye bath for 48 hours
Step 3: The process of immersing the skein in the dye bath is repeated until the desired color appears.
Step 4: The skein is then steamed so that the dye sticks permanently to the yarn
Space Yarn Dyeing Process
The space dyeing process is used when the yarn has to be dyed with multiple colors. In this yarn dyeing process, more than one color is given to the yarn, unlike hank dyeing and package dyeing. The yarn is multicolored throughout the length of the yarn. Space dyeing is also referred to as dip dyeing yarn. This dyeing process in the textile industry is used in manufacturing fabric such as plaids, checks, and iridescent. This dyeing process is only possible because of a chemical named mordant.
Mordant
Mordant is the chemical that makes the space yarn dyeing process possible. This chemical holds the color of the dye in its place. Mordants are metal molecules with a valency of 2 or more. Mordant ensures the permanency of the dye. In this process, complex coordination is used where the nearby dye atoms bond with the mordant atoms so strongly that water can’t break them. [Source]
There are 3 ways to apply this chemical.
i) Pre Mordanting
ii) Meta Mordanting
iii) Post Mordanting
Warp Beam Yarn Dyeing Process
The steps of Warp Dyeing Process are as follows:
Step 1: Certain numbers of yarn are wrapped on the warp beam
Step 2: The yarn wrapped on the beam is washed with a cleaning agent to make sure that there are no oil or foreign particles that can affect the dyeing process.
Step 3: In the reserve tank, dye and auxiliary chemicals are mixed with water to prepare a dye bath.
Step 4: A Warp beam is inserted into the dyeing machine. It is carefully inserted to make sure dye would evenly spread over the yarn.
Step 5: The dye bath is pumped to the main tank from the reserve tank, and a certain amount of temperature and pressure is maintained according to the dyeing recipe. In the case of auxiliary dyeing, high temperature, and high pressure is maintained.
Step 6: The yarn is rinsed properly to make sure there is no chemical and extra dye left on the yarn surface.
Step 7: For soft and rich yarn, softening agents are applied to the yarn
Step 8: The drying of the yarn takes place
Step 9: After dyeing the yarn, the yarn is transferred to the hanks or cone for storage purposes.
Originally Written By Catcheyes
