Solution Dyed Yarn vs. Conventionally Dyed Yarn and Fabric

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1 Solution Dyed Yarn vs. Conventionally Dyed Yarn and Fabric Public Ignaz Franzen Masterbatches AFMA 2009

2 Table of Content Definitions Technical Advantages and Disadvantages Economics Colorant Selections Shade Matching Input Requirements Conclusion Slide 2 / 28

3 Definition of Solution Dyed Yarn Colorant (Masterbatch) is added to polymer melt in spin extruder Fibers and filaments are already colored coming out of the spinnerets Tailor made Masterbatch or Single Pigment Concentrates are used Commonly called Pigments in the industry Solution Dyed is a poor choice of a technical term Better choice would be mass dyed, dope dyed, spin dyed Only Acrylic fibers are truly solution dyed Slide 3 / 28

4 Definition Conventionally Dyed Various methods Package dyed Bath dyed Piece dyed Commonly called Bath Dyed Slide 4 / 28

5 Conventionally Dyed Yarn Solution Dyed Yarn Dyeing of synthetic fibers and filaments Conventional Bath Dyeing Solution Dying = Mass Dyeing Spinning Process Spinning and Dying Yarn Package Dyeing 2 Steps 1 Step Slide 5 / 28

6 Coloration of Synthetic Fibers and Yarn Conventionally Dyed Dyes Dye Baths Additional Step Dust Energy intensive Drying, water extraction Water usage Generation of waste water Labor intensive Chemicals and Additives Pre-treatment After-treatment High flexibility Lower cost for deep/saturated shades Solution Dyed Masterbatch (colorants) aka pigments Dosing unit of spin extruder Less labor intensive - Color change needs time and polymer purge Limited flexibility Lower costs for less chromatic shades, e.g. Black, Grey. Beige Slide 6 / 28

7 Production of Conventional Synthetic Yarn and Fibers CP Spinning Line Extrusion Spinning of Polymer Chips Chips out of Silo/Crystallizer/Dryer Pump Static Mixer Polymer Melt Filtration Spin beam Spin position, Spin pump, Spinnerets - Large units >200,000 lbs / day - smaller, more flexible units Slide 7 / 28

8 Production of Solution Dyed Yarn and Fibers Extrusion spinning: Masterbatch addition with Gravimetric feeder CP Line: Masterbatch addition with Side Feed Extruder Slide 8 / 28

9 Solution Dyed vs. Conventionally Dyed Advantages - Disadvantages Property Colorats Light Fastness Bleach Resistance Wash Fastness Migration Resistance Crocking Sublimation Oligomers Labor Solution Dyed Pigments and Polymer Soluble Dyestuffs Not present + Conventially Dyed Acid Dyes, Disperse Dyes Generated in autoclave - Slide 9 / 28

10 Solution Dyed vs. Conventionally Dyed Advantages - Disadvantages Property Equipment Space Color Uniformity Environment / Water usage Environment / Energy Flexibiliy Metamerism Color Development Color Communication Cost Number of SKU s Solution Dyed None Same as white yarn - + / / - - Conventially Dyed Very high Higher than solution dyed + + / / - + Slide 10 / 28

11 Cost Comparison Solution Dyed Conventionally Dyed

12 Cost of Solution Dyeing Masterbatch Polymer waste at start-up and shut down or color change Additional pack changes compared to raw white yarn production Masterbatch handling and storage Color check Additional cost of solution dyed yarn to raw white yarn: $0.10 / lb for light shades $ $0.50 / lb for dark shades Slide 12 / 28

13 Cost of Conventional Dyeing Raw white yarn bobbins Back winding onto bobbins that can be dyed Energy to heat up dye bath Labor Dyes Drying Last winding after dyeing and drying Chemicals and additives to remove oligomers etc. Water Waste water treatment Re-dyeing of off shades Slide 13 / 28

14 Cost of Conventional Dyeing 0.7 Euro/kg = $0.45/lb Slide 14 / 28

15 Solution Dyed vs. Bath Dyed Slide 15 / 28

16 Bath dyeing vs. Solution dyeing Slide 16 / 28

17 Bath dyeing vs. Solution dyeing Slide 17 / 28

18 Bath dyeing vs. Solution dyeing Slide 18 / 28

19 Bath dyeing vs. Solution dyeing Solution dying has a cost advantage at low Masterbatch dosing rates Other advantages of solution dying are: Superior fastness properties Color reproducibility and consistency Absence of bloomers which in bath dyeing can leave a grey surface film and can cause tension problems at further processing steps Combo Masterbatches to add color and functionality to yarn No drying and re-winding steps Greener Yarn, less Carbon Footprint No water usage Slide 19 / 28

20 Criteria for shade matching of Solution Dyed Yarn Slide 20 / 28

21 Requirements of pigment selections for Solution Dyeing Selection criteria 1. Shade 2. Colour strength 3. Hiding power 4. Effects 5. Heat resistance 6. Dispersion behaviour 7. Influence of moisture 8. Pigment orientation 9. Light fastness 10. Weathering fastness 11. Migration fastness 12. Influence of polymers 13. Abrasion 14. Physiological properties 15. Contact to chemicals 16. Industrial toxicology 17. Price/ Coloration costs Slide 21 / 28

22 Slide 22 / 28

23 Clariant Fiber Lab Slide 23 / 28

24 Clariant Fiber Lab Slide 24 / 28

25 Clariant Capabilities for Solution Dyed Fibers Pilot Fiber Lines for POY/DTY, DFY, BCF Single Pigment Concentrate Technology Extensive Library of Existing Shades Global Database of Colorant Properties Global Technical Network Centers of Technology for PES, Nylon and PP 30+ years of experience Local Service Slide 25 / 28

26 Conclusion There is advantage of both dyeing methods for man made fibers Solution dyed fibers is only a small fraction of all dyed fibers As the environmental concerns and green movements increase in North America, the advantages of Solution Dying will become more obvious The yarn manufacturer has to have basic understanding of color. Good color communication between his customer as well as the Masterbatch supplier is essential to be successful in the production of solution dyed yarn! Slide 26 / 28

27 Special Thanks To: Francis Baud, Global Head of Fiber Segment Clariant Masterbatches Martin Teige, Head of Technical Service Fibers, Clariant Germany AFMA and MJ Hour, Clariant TLP Division, for the opportunity to do this presentation Slide 27 / 28

28 Public Ignaz Franzen Masterbatches Questions?

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