[For Pastel, Light, Medium & Dark Shades]
EXHAUSTIBLE PIGMENT DYEING SYSTEM RECOMMENDED FOR EXCELLENT DYEING RESULTS
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ZYCO-PLUS is one of the most comprehensive Pigment Dyeing Systems. ZYCO-PLUSSystem consists of following, which can be applied by Exhaust Dyeing Method:
[a] ZYTREAT range of pretreatments for garments (Cationic / Anionic)
[b] ZYTROL range of binders (Zytrol-600 / Zytrol-616)
[c] ZYCRON range of pigment emulsions
[d] CATALYST-MX
ZYCO-PLUS is designed to give excellent levelling, exhaustability of colours, ease of application and excellent crock & wash fastness properties.
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- Proper desizing/scouring/bleaching must be carried out to ensure complete removal of sizes/fats/waxes, etc. from the cellulosic material prior to dyeing.
- Now this ready to dye material can be subjected to ZYCO-PLUS System as per shade requirement.
In ZYCO-PLUS System, first step is to pretreat the fabric with ZYTREAT(CATIONIC)at 3-5% level on weight of the garments (WOG). ZYTREAT (CATIONIC) is applied as wet-to-wet application with 15-20 minutes of exhaust time at garment to liquor ratio of 1:7 or 1:10 (bath temperature should be room temperature to 70° C).
ZYTREAT (ANIONIC) is to be used for achieving special solid dyeing look. It is applied at a level of 1-5% of weight of garments (WOG). ZYTREAT (ANIONIC) is applied as wet-to-wet application with 20-30 minutes of exhaust time at garment to liquor ratio of 1:7 or 1:10 (bath temperature should be room temperature).
One of the critical aspects of pigment dyeing is to keep RPM of the dyeing equipment as low as possible. Best results are seen at 10-12 RPM with backward and forward mechanism.
The dyer should choose the ZYCRON range of pigment emulsions based on depth of colour to be achieved:
- For pastels and light colours upto 3-4%, one should use the combination of:
ZYTREAT (CATIONIC)
ZYCRON (PL range)
ZYTROL-616 (Binder)
CATALYST-MX
- For medium and darker shades with ABRADED look, one should use following combinations:
ZYTREAT (CATIONIC)
ZYCRON (MD range)
ZYTROL-600 (Binder)
CATALYST-MX
ZYTREAT (ANIONIC)
ZYCRON (PL range)
ZYTROL-600 (Binder)
CATALYST-MX
The CATALYST-MX should be used in ZYCO-PLUS System to improve crock & washing fastness properties.
for pastel & light shades
EXHAUST DYEING METHOD WITH ZYCRON (PL) AND ZYTROL-616 FOR PASTEL & LIGHT SHADES
ZYCO-PLUS is the only known Pigment Dyeing System to give excellent levelled uniform pastel type of colours. Most of the existing products give specky and non-uniform dyeing.
In order to simplify the system and to avoid repeated weighing, we recommend preparation and pre-mixing of following stock solution for ZYCRON (PL) range.
Prepare stock solution as follows and mix it thoroughly:
10% ZYCRON (PL) Pigment Emulsion
15% ZYTROL-616
1% CATALYST-MX
74% Water
- Place the goods, treated with ZYTREAT (CATIONIC), in the machine at room temperature & fill water to achieve 1:15 material to liquor ratio (Water quality is not critical. Soft water is recommended).
- Add Acetic acid to make pH 4-5.
- As per percentage shade requirement on fabric weight basis, take dilution of above prepared stock solution and divide it into four or more proportions. Dividing in 4 parts is not critical, but add incremental quantities to get uniform results.
- Add first portion of stock solution at the room temperature in the machine and start dyeing.
- The pigment and binder particles will start adsorbing on the garments and dyeing solution will start becoming lighter and clearer. Add next colour installments after earlier addition has been exhausted at regular intervals. Keep adding the stock solution to continue the exhaustion.
- Add last colour instalment and keep it for 15-20 minutes till the bath is clear. Typically, one expects ZYCRON (PL) range to exhaust completely.
- Drop the bath and rinse with cold water for 5 minutes. The garments with ZYCRON (PL) and ZYTROL-616 give excellent soft feel; only if needed give softener treatment.
- Hydroextract the goods and dry.
Test the wet & dry rubbing fastness and washing fastness 24 hours after complete drying of the fabric.
for medium & dark shades with ABRADED look
EXHAUST DYEING METHOD WITH ZYCRON (MD) AND ZYTROL-600 FOR MEDIUM & DARK SHADES WITH ABRADED LOOK
The garments treated with ZYTREAT (CATIONIC) should be taken for pigment dyeing at material to liquor ratio of 1:15. ZYCRON (MD) colour combination can be added slowly after diluting it to 5-10% level in water. Divide the pigment solution in four parts and start the addition of first lot.
After it has been exhausted, start raising temperature of the water bath to 75-80° C at the rate of 2° C/minute. Continue addition of additional ZYCRON (MD) pigment solution.
Continue the exhaustion at 75-80°C for 45 minutes or more till maximum exhaustion is achieved. For very dark shades, some pigment colour is expected to remain in solution which should be drained out and the dyeing machine be filled with fresh water.
Mix ZYTROL-600 with CATALYST-MX (10:1 proportion) in water and add to the exhaust bath and continue to heat to 40-45° C till most of it is exhausted. The water should be almost clear. ZYTROL-600 is normally recommended to use @ 1.5 – 2.0 parts for every part of ZYCRON Pigment emulsion.
Now dyeing machine should be drained and garments can be given a cold rinse followed with softener treatment or soaping or enzyme treatment as per need. The goods are then hydroextrated and sent for drying.
for medium & dark shades with SOLID look
EXHAUST DYEING METHOD WITH ZYCRON (PL) AND ZYTROL-600 FOR MEDIUM & DARK SHADES WITH SOLID LOOK
The garments treated with ZYTREAT (ANIONIC) should be taken for pigment dyeing at material to liquor ratio of 1:15. Add acetic acid to make pH 4-5. ZYCRON (PL) colour combination can be added slowly after diluting it to 5-10% level in water. Divide the pigment solution in four parts and start the addition of first lot.
After it has been exhausted, start raising temperature of the water bath to 75-80° C at the rate of 2° C/minute. Continue addition of additional ZYCRON (PL) pigment solution.
Continue the exhaustion at 75-80°C for 45 minutes or more till maximum exhaustion is achieved. For very dark shades, some pigment colour is expected to remain in solution which should be drained out and the dyeing machine be filled with fresh water.
Mix ZYTROL-600 with CATALYST-MX (10:1 proportion) in water and add to the exhaust bath and continue to heat upto 40-45°C till most of it is exhausted. The water should be almost clear. ZYTROL-600 is normally recommended to use @ 1.5 – 2.0 parts for every part of ZYCRON Pigment emulsion.
Now dyeing machine should be drained and garments can be given a cold rinse followed with softener treatment or soaping or enzyme treatment as per need. The goods are then hydroextrated and sent for drying.
Preparation of the goods is important with a view to achieve uniform dye appearance. Fabric should be properly scoured and bleached to avoid defects due to the presence of Residual Alkali, Softeners, Oils, Soils, etc.
