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ITMA birmingham 2003

‘Color Confidence’ from Dystar

DyStar, the world’s leading textile dyes company, will have a stand at the ITMA international textile machinery exhibition in Birmingham, UK (Hall 8, Booth DC8-6E). Under the slogan “Come to see - Controlled Coloration/Color Confidence” the company will be presenting new products, technologies and services designed to raise quality and productivity in textile finishing. The focus will be on cooperations with leading textile machinery manufacturers. The main projects that will be presented at ITMA are outlined briefly below. Luft-roto plus - Economical exhaust dyeing technology with environmental benefits The Luft-roto plus and selected Levafix, Remazol and Procion reactive dyes can reduce exhaust dyeing cycles for cellulosics by up to 30 percent and virtually halve water and chemical requirements. This technology was developed in cooperation with Thies. Positioning the soft flow jet on the lifting side of the machine and a skimming unit before the creel optimises throughput of the goods, resulting in an ultra-low liquor ratio. The wet rope is opened by an air transport system and plaited in the water-free fabric sump by a synchronised plaiter.

The rotating fabric chamber functions by weight so no external drive is required. This prevents damage to the fabric during treatment.

Innodye/InnoVat - The flexible new jet dyeing concept

Innodye/InnoVat is a flexible and economical new jet dyeing technology. Developed in conjunction with Brazzoli, this economical system allows rapid and efficient dyeing with Levafix, Procion and Remazol reactive dyes and Indanthren vat dyes. This technology therefore meets demands for increased flexibility and improved colour fastness. The concept comprises the Innodye dyeing unit and the InnoVat dyeing process developed specifically for this unit. The Innodye unit uses unique vacuum technology that opens up completely new process options. It includes a patented traversing mechanism with a movable material basket. Innodye/InnoVat therefore ensures level dyeings even on problematic substrates.

Econtrol - The reliable and economical new continuous dyeing process

Econtrol is a rapid and reliable method of dyeing a wide range of substrates. It does not require steaming or curing and ensures high reproducibility and excellent fixation. Econtrol is a registered trademark of DyStar. It was developed in conjunction with Monforts and is based on the Thermex hot flue technology. Econtrol is environment-friendly and dyeing can be carried out without silicate, urea and salt, thus reducing recipe costs and effluent load. Econtrol is easy to use in the lab and lab-to-bulk reproducibility is very good. Excellent reproducibility and high fastness levels can be obtained on both lightweight and heavyweight cotton, viscose and Lyocell qualities with selected Levafix and Remazol reactive dyes.

Fluidyer - For rapid and reliable dyeing of carpets and pile

Fluidyer technology from Kusters and quality dyes from DyStar help dyehouses achieve their aims faster, more economically and more reliably. This modern unit allows colour changes within seconds, thus raising productivity. Benefits include accurate dosing and uniform application, leading to exceptionally good reproducibility. Unlike conventional technology, the Fluidyer applies the liquor directly to the fabric through rows of holes, giving liquor pick-ups of 80-350 per cent. Since the liquor requirement can be calculated accurately in advance, the process has both economic and ecological advantages: it minimises residual liquor and rinsewater requirements. Further cost and time savings result from the ability to dye bleached/pre-scoured goods wet-on-wet. Fluidyer technology has been used to dye carpets since the early eighties. A joint development project by DyStar and Kusters has developed this technology for dyeing pile fabrics. The world’s only Fluidyer pilot plant, located in the service laboratory at DyStar’s new headquarters in Frankfurt am Main, Germany, is available for test dyeings for customers.

Electrochemistry - The revolution in vat dyeing

The electrochemical dyeing process, which is patented by DyStar, has a range of technical, ecological and economic benefits: shorter and more reliable processes, better reproducibility, lower effluent costs and better quality articles. This technology was developed in collaboration with Thies and the Institute for Textile Chemistry and Textile Physics of Innsbruck university in Dornbirn, Austria. It is suitable for Indanthren vat dyes, Indigo and Cassulfon sulphur dyes. While conventional dyeing methods use reducing agents that cannot be regenerated and are discharged in the effluent at the end of the dyeing process, the new electrochemical process uses an electric current. This reduces the amount of processing chemicals required and cuts the effluent load. Practical trials are currently being carried out on this revolutionary new dyeing process in preparation for market launch.

Electrochemical decolorisation of textile effluent

Another application for electrochemistry in the textile industry is the decolorisation of effluent. This technology does not require chemicals or the disposal of residues. Electrochemical decolorisation is based on the principle that electrons in an electric current split textile dyes into smaller, colourless parts that are more readily biodegradable. A cooperation agreement has been concluded with Benninger on the marketing of this environment-friendly technology. Pilot trials show that this technology can remove over 80 percent of colour from dyehouse effluent, especially effluent contaminated with reactive dyes. It is particularly effective for treating effluent from continuous dyeing which contains high dye concentrations.

Digital textile printing - Jettex inks are the key to success

DyStar is playing a key role in the development of digital textile printing. It markets Jettex reactive and acid inks for piezo and bubble jet printers. Further inks are currently being developed. Staff at DyStar’s laboratory use all common digital printing processes to test the suitable of Jettex inks for practical application. New high-speed printing machinery is expected to be unveiled at this year’s ITMA, providing new impetus for this technology.

Tangible benefits for textile finishers

As the world’s leading textile dyes supplier, DyStar collaborates with a wide range of companies throughout the textile industry, including machinery manufacturers, fibre producers, detergent suppliers, retailers and manufacturers of well-known brands.DyStar invests three to four percent of annual sales in R&D to enable it to offer customers innovative products and application processes and extensive technical advice to help them cut costs, improve quality, raise productivity and enhance their competitive position.