Optimisation of the disperse dyeing process using dyebath analysis

A competitive market forces textile manufacturers to continuously look for ways to increase productivity and resource efficiency. Taking the exhaust dyeing of polyester with disperse dyes as an example, it is shown that detailed process analysis using, among other methods, dyebath monitoring can yield considerable benefits. In the case examined, process cycles for a typical trichromic set of dyes could be shortened by 13% and dye unlevelness on the substrate reduced by 45%. The study confirmed that for optimum performance, process profiles need to be machine-specific since the maximum temperature gradient that yielded commercially acceptable unlevelness varied significantly from one machine to another machine.