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Remazol Ultra RGB

The new generation of


Reactive dyestuffs for deep shades

Remazol Ultra Yellow RGBN Remazol Ultra Orange RGB Remazol Ultra Red RGB Remazol Ultra Carmine RGB Remazol Navy RGB

Bio-data

Name: Roland Schamberger

Title: Dipl. Textile Engineer


Age: 37 years
1988-1990 Training in a Textile lab and Knitted fabric dyehouse in Germany 1992-1995 Study leading to Textile Engineer with focus on Environmental Technology in Textile Industry at Textile college in Mnchberg (Germany) 1995-1996 Project study on pollution of wastewater in German Printing Factory 1996-1997 Additional education for Quality- and Environmental Management at DEKRA Academy 1998-2001 Lab Manager and Deputy Dyehouse Manager in a German Dyehouse

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Bio-data

Since 2001
Technologist in Global Technical Marketing and Textile Solutions DyStar Textilfarben GmbH & Co KG at

Responsible for:
International Support of Reactive Dying in Exhaust Application New product launch phase of new Remazol dyes Technical Marketing of Remazol dyes Internal and External training for Reactive dyes in Exhaust Application

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SDC International Conference Mumbai 2007

Outline of Presentation
Economical selection for dark shades Remazol Ultra RGB dyes in Exhaust application Remazol Ultra RGB dyes in CPB and Continue application Fastnesses Conclusion

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Warm reactive dye technology

The Market for Reactive Dyes:


Levafix CA Levafix E/EA/EN/ Remazol Specialities Remazol Ultra RGB
Fastness Dyeing performance Total cost of production

Warm reactive dyes

Fastness Dyeing performance Total cost of production

Remazol Remazol A

Fastness Dyeing performance Dyes cost Total cost of production

Exhaust CPB Continuous

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The Remazol Ultra RGB dyes at a glance

1%

3%

6%

Remazol Ultra Yellow RGBN


Strong, low photochromic Yellow component for deep ternary shades with good fastness properties.

Remazol Ultra Orange RGB


Strong build-up, dull Orange for bordeaux, dark brown and olive shades. Dischargeable

Remazol Ultra Red RGB


Cost effective and tinctorially strong Red with excellent build-up behaviour for medium to deep shades. Perfect wash-off properties. Very homogenous dyeing behaviour in combination with Remazol Ultra Yellow RGBN and Navy RGB.

Remazol Ultra Carmine RGB


Tinctorial strong Red. Highest possible build-up for deepest red and brown shades. Outstanding wash-off properties. Dischargeable.

Remazol Navy RGB 150%


Cost effective Navy with very good build-up behaviour for medium to deep shades. Basis for colour constant recipes. Dischargeable.
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The Remazol Ultra RGB supplementary dyes

1%

3%

6%

Remazol Golden Yellow RGB conc.


Cost-effective yellow for trichromatic shades. Dischargeable.

Remazol Blue RGB


Blue component with higher lightfastness when small quantities of blue shading components are required. Dischargeable.

2%

4%

7%

Remazol Deep Black RGB


Economical strong build up Black with good Fastness properties. Dischargeable.

Remazol Deep Black GWF


Remazol Deep Black GWF combines flexibility in application with highest fastness performance. The new dischargeable Deep Black meets the most stringent fastness specifications to fulfils the highest retailer/brand and market requirements. It can be used in exhaust, CPB and in all continuous application processes. Dischargeable.
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Remazol Ultra RGB: Flexibility in shading


Ultra Yellow RGBN Ultra Orange RGB

Further components in the Remazol RGB range:


Ultra Red RGB

Navy RGB 150%

Remazol Golden Yellow RGB conc Remazol Red RGB Remazol Ultra Carmine RGB Remazol Blue RGB Remazol Deep Black RGB

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Remazol RGB: Economical selection for all deep ternary shades


Golden Yellow Orange Red Bordeaux Navy Dark Brown Forest Green Dark Olive

Remazol Ultra Yellow RGBN Remazol Ultra Orange RGB Remazol Ultra Red RGB Remazol Ultra Carmine RGB Remazol Navy RGB 150%
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x x x x x x

x x

x x

x x

x x x x

x x x

x
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Development of Best Available Technology for reactive dyeing of cellulose fibres

High build up in exhaust application


Key to avoiding dye overload is to form the covalent bonds with the cellulose fibre at an applied percentage of dye where the fixation graph is steep. The rate of fixation levels off with saturation of the available sites in the fibre

Cellulose
fixation hydrolysis

Water

Dye

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Build up of Remazol UltraCarmine RGB and Remazol UltraRed RGB vs. C.I. Reactive Red 239
Remazol UltraRed RGB Remazol UltraCarmine RGB C.I. Reactive Red 239 (140% )

7 6
Colour intensity value

5 4 3 2 1 0 0 1 2 3 4 5
dye conc. [% ]

10

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Significant less dye is needed to achieve the required depth of shade


dye conc. [% ] 12 11 10 9 8 7 6 5 4 3 2 1 0 1/3 SD
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0.9 % 0.7 % 0,47% 2.5 % 1,24% 2,28% 4.0 %
>12%

dye conc. [% ] 10 9 8

C. I. Reactive Yellow 176 (133% ) Remazol UltraYellow RGBN Remazol Ultra Orange RGB
not achievable

C. I. Reactive Red 239 (140% ) Remazol Ultra Red RGB Remazol Ultra Carmine RGB
8.3%

7 6
6.0 %

5 4 3 2 1 0
1.9% 1.0% 0.7% 0.6% 1.3% 2.1% 3.8% 3.2%

1/1 SD

2/1 SD

1/3 SD

1/1 SD

2/1 SD
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Best Available Technology - Exhaust


Significant less dye is needed to achieve the required shade

Dark Brown
Remazol Golden Yellow RGB conc. 1.7% Remazol UltraRed RGB 0.9% Remazol Navy RGB 150% 0.8%

- 47%

C. I. Reactive Yellow 176 (133%) C. I. Reactive Red 239 (140%) C. I. Reactive Black 005 (133%)

3.9% 1.5% 1.0%

total: 3.4%

total: 6.4%

Ultra RGB Technology

C.I. Reactive

% Dye required for Dark Brown shade exhaust application


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Cost

Remazol Ultra RGB


Due to high strength and build-up, significant less salt is needed Reduces costs in purchasing, warehousing and handling

Dark Brown

-40%

100 g/l salt

60 g/l salt

100 g/l salt

100 g/l salt

Remazol Ultra RGB


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Commodities
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Cost

Remazol RGB
The reduction of salt requirements leads to significant cost savings per year Reduce salt consumption of up to 30% at a LR of 10:1 with new Remazol Ultra RGB dyes
Example
Normal salt consumption of a dyehouse with commodity products 60 g/l salt:
Savings

Salt consumption with Remazol Ultra RGB 45 g/l salt:

10 t fabric/day 100,000 l water x g/l salt


240 working days/year =

6 t salt/day*
1,440 t salt/year*

4.5 t salt/day**
1,080 t salt/year**

1.5 t salt/day
360 t salt/year

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Exhaust application

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Remazol Ultra RGB: Flexible in exhaust application


Application process
Basic recipe:

Basic recipe
x % 1 g/l 1 g/l Remazol Ultra RGB Sera Lube M-CF Sera Wet C-NR

Standard process (e. g. Cotton knit)

Detailed Information see pattern card

Temperature rise (e. g. no dosing equipment)

Basic recipe:

x % 1 g/l 1 g/l

Remazol Ultra RGB Sera Lube M-CF Sera Wet C-NR

Detailed Information see pattern card Basic recipe: x 1 1 % g/l g/l Remazol Ultra RGB Sera Lube M-CF Sera Wet C-NR

Migration process (100% Viscose, yarn package)

Detailed Information see pattern card

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Homogeneous on-tone build-up


NaCl Dye 20 25 C M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 Soda ash 10 10 10 10 10 10 10 10 10 60 C

on-tone build-up
Remazol Ultra Yellow RGBN Remazol Ultra Red RGB Remazol Navy RGB 150%

Reactive Yellow S-3R Reactive Red S-2B Reactive Navy S-G

off-tone build-up
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Remazol Ultra RGB


Up to 25% reduction in dyeing time

Standard
competitor recommendation

Salt Auxiliaries 60C 10

Dyes

Mixed alkali

45' 80 min
time saving

Remazol Ultra RGB


DyStar recommendation homogeneous dye combination rapid process

30 min!
Salt Mixed Auxiliaries Dyes alkali 60C 10 45'

50 min

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Remazol Ultra RGB


Excellent wash-off properties can increase productivity
optical density at 525 nm
700 600 500 400 300 200 100 0 1st rinsing (50 C) neutralisation (50 C)
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4% Remazol UltraCarmine RGB C. I. Reactive Red 239

Saving:
1 soaping bath
1 2 3 4 5

Rinsing baths of bulk trials with Remazol UltraCarmine RGB

1st soaping bath (95 C)

2nd soaping bath (95 C)

rinsing (80 C)

rinsing cold

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Remazol Ultra RGB


The reduced dyeing time leads to potential cost savings of high productivity

Benefits from reduced processing time per batch


Example
Production with commodities
3 batches *6 h 10';**5 h 40' Savings

Production with Remazol RGB 17 h/day** 1 h 30'/day

18 h 30'/day*

240 working days/year

4,440 h/year*

4,080 h/year**

360 h/year

360 h : 5 h 40'/per batch

63 batches more/year

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Total colour difference dE


delt aE 10%overf ill

Remazol Ultra Yellow RGBN Remazol Ultra Red RGB Remazol Navy RGB 150% NaCl Soda ash NaOH 50% Liquor ratio Procedure

% 1.25 % 1.56 % 0.67 g/ l 60.00 g/ l 5.00 ml/ l 1.7 1 : 10 60 C Isothermal

+Liq rat io -Liq rat io

1,50 1,00 0,50 0,00

10%underf ill 20%overf ill

+5 C

20%underf ill

-5 C

- salt

+ 15' - 15' +Soda ash

+ salt -Soda ash

delta E

1 0%overfill

C. I. Reactive Yellow 176 C. I. Reactive Red 239 C. I. Reactive Black 005 NaCl Soda ash NaOH 50% Liquor ratio Procedure
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% 2.5 % 2.2 % 1.5 g/ l 100.00 g/ l 5.00 ml/ l 2.0 1 : 10 60 C Isothermal

+Liq ratio -Liq ratio +5 C -5 C +1 5' -1 5'

1 ,50 1 ,00 0,50 0,00

1 0%underfill 20%overfill 20%underfill - salt +salt -Soda ash

+Soda ash

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Excellent lab to bulk and pilot to bulk reproducibility


Remazol Ultra Yellow RGBN Remazol Ultra Red RGB Remazol Navy RGB 150% % % % 1.98 1.08 0.72 NaCl Soda ash Liquor ratio 70 g/ l 17 g/ l 1:8

Process

M achine

kg

Pass/ Fail [dE]


against control CM C 2 : 1

Sample

Thies EcoSoft
Salt/Auxiliarie s 60C 10 ' Dye Alkali

80 5 5

Control 0.4 0.2

10 '

60 '

Thies MiniSoft Thies MiniSoft

Alkali Salt/Auxiliarie s 60C Dye 25C 10 ' 10 ' 1C/min 60 '

Lab process
(Temp-rise Alkali 1 add. at 60C)

0.6

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Speed Security

Remazol RGB
"Right-First-Time" performance in exhaust dyeing can deliver significant cost savings of high productivity Increase the RFT with Remazol RGB up to 10%
Example
Production capacity with commodites Production capacity with Remazol RGB
Additional production

batches/day = x 200 kg/fabric =

3.0 batches/day

3.3 batches/day

0.3 batches/day 60 kg fabric/day 14.4 t fabric/year

600 kg fabric/day
144 t fabric/year*
* = with a one rope machine

660 kg fabric/day
158.4 t fabric/year*
* = with a one rope machine

x 240 working days/year =

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Continuous application

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Remazol Ultra RGB: Flexible in padding application


Application process
Basic recipe:

Basic recipe
x g/l 2 g/l Remazol Ultra RGB Sera Wet C-AS

Cold Pad Batch (CPB)

fabric

alkali dyestuff winding and dwelling Washing off

Alkali system according to climate conditions and/or preference

padding

Basic recipe:

Pad Dry Pad Steam (PDPS)

x g/l 10 g/l 2 g/l 5 - 10 g/l Chemical pad: 250 g/l 20 g/l 3-6 ml/l
Basic recipe: x g/l 10 g/l 2 g/l 5 - 10 g/l 20 g/l 3.5 14 ml/l

Remazol Ultra RGB Sera Gal M-IP Sera Wet C-AS Sera CON M-LU salt soda ash caustic soda 50%
Remazol Ultra RGB Sera Gal M-IP Sera Wet C-AS Sera CON M-LU soda ash caustic soda 50%

Econtrol

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Significant less dye is needed to achieve the required shade


Dark Brown
84.3 g/l
-39%

51.8 g/l
C. I. Reactive Yellow 176 (133%) C. I. Reactive Red 239 (140%) C. I. Reactive Black 005 (133%) 54.0 g/l 19.3 g/l 11.0 g/l Remazol Ultra Yellow RGBN Remazol UltraRed RGB Remazol Navy RGB 150% 22.0 g/l 22.0 g/l 7.8 g/l

C. I. Reactive
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Remazol Ultra RGB


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Robustness in Cold Pad Batch


Standard: Remazol UltraYellow RGBN Remazol UltraRed RGB Remazol Navy RGB 150% 4 g/ l 24 g/ l 10 g/ l Silicate NaOH 50% batching time 50 m/ l 14 ml/ l 12 h

1
as standard but 16 h batching

2
as standard but 24 h batching

3
as standard but 17 ml/l NaOH 50%

4
as standard but 16 h batching but 17 ml/l NaOH 50%

delE delC delH 1 0.05 2 0.16 3 0.14 4 0.04 5 0.11 6 0.31 7 0.18 8 0.13 -0.01 0.03 0.06 0.10 0.02 0.09 0.23 0.09 0.03 0.05 0.06 0.03 0.05 0.01 0.02 0.05

5
as standard but 24 h batching and 17 ml/l NaOH 50% M&I TMTS EXH CEL

6
as standard but 20 ml/l NaOH 50%

7
as standard but 16 h batching and 20 ml/l NaOH 50%

8
as standard but 24 h batching and 20 ml/l NaOH 50%
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Advantages of Remazol Ultra RGB in pad application Good lab to bulk reproducibility in cold pad-batch:

Microwave 8 min

Drying cabinet 30 min, 50C

Drying cabinet 10 min, 70C

Standard

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Fastness

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(1) (2) (3) (4)

Light fastness (B02) Perborate light fastness (M&S, C9A) Wash fastness (M&S C10A) Fastness to Chlorine 10 ppm

3.0% Remazol Ultra Yellow RGBN

(1) (2) (3) (4)


0.6% 2.4%

4-5 pass 4-5 4


2.4% 0.6%

(1) (2) (3) (4)


1.2% 1.8%

3-4 pass 3-4 4


0.6% 1.8% 0.6%

(1) (2) (3) (4)

4-5 pass 4-5 4


1.8% 1.2%

(1) (2) (3) (4)


1.8% 1.2%

3-4 pass 4 4
1.2% 1.2% 0.6%

(1) (2) (3) (4)

3-4 pass 4 3-4


0.6% 1.2% 1.2%

(1) (2) (3) (4)

4-5 pass 4-5 4-5


1.2% 1.8%

(1) (2) (3) (4)


2.4% 0.6%

3-4 pass 4 4
1.8% 0.6% 0.6%

(1) (2) (3) (4)

3-4 pass 4 4
1.2% 0.6% 1.2%

(1) (2) (3) (4)

3-4 pass 4 3-4


0.6% 0.6% 1.8%

(1) (2) (3) (4)

4-5 pass 4-5 4-5


0.6% 2.4%

(1) (2) (3) (4)

4 pass 4 4
2.4% 0.6%

(1) (2) (3) (4)

3-4 pass 4 4
1.8% 1.2%

(1) (2) (3) (4)

3-4 pass 4 4
1.2% 1.8%

(1) (2) (3) (4)

4 pass 4 4
0.6% 2.4%

(1) (2) (3) (4)

4-5 pass 4-5 4-5


3.0% Remazol UltraRed RGB

3.0% Remazol Navy RGB 150%

(1) (2) (3) (4)

4 pass 4 4

(1) (2) (3) (4)

4 pass 4 4

(1) (2) (3) (4)

4 pass 4 4

(1) (2) (3) (4)

4 pass 4 4

(1) (2) (3) (4)

4 pass 4-5 4-5

(1) (2) (3) (4)

4 pass 4-5 4

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Fastness comparison
Commodities
Yellow 176/Red 239/Black 005

Light fastness (B02) Perborate light fastness (M&S, C9A) Wash fastness (M&S, C10A) Fastness to chlorine 10 ppm

Remazol Ultra RGB


Ultra Yellow RGBN/Ultra Red RGB/Navy RGB 150%


1 1-2 2 2-3 3


3-4 3-4
4 4-5 5


M &S C9A pass pass pass pass pass pass fail fail fail fail fail fail fail fail fail fail fail fail fail fail fail 1 1-2 2 2-3 3


4-5 5 M &S C9A pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass pass

3-4 3-4

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Conclution

Benefits offered by Remazol Ultra RGB technology


Reduced costs
Less dyestuff

Less water

Cost

Less energy Reduced stock costs

Higher productivity

Speed

Shorter production cycles Right-First-Time performance Robustness

Standardisation limits

Shade reproducibility Standard fastness requirements Eco-compliance

Security

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