Chemical Consumption for Dyeing Fabric

by | May 15, 2019 | IE

Chemical consumption

Chemical consumption are the main ingredients used with dyes and auxiliaries means the aids or helper to get better results like levelness, adsorption, crease free and other quality parameters. But WATER (H2O) is the important  ingredient needed in all dyeing…

  • We can say that we save 55 lac BDT for last seven month as compared with previous year. We Sale Clothing Inventory Management Software ERP for Sale
  • 2019 January to July dyes chemicals cost= 64899261.0 Tk, Production= 1908754.0 Kg
  • 2020 January to July dyes chemicals cost= 59391698.0 Tk, Production=2192949.0 Kg
  • Switch off the power when not in use. Total production increased=284195.0 kg
  • Lab. Dyeing machines must not be operated without cooling water. Production Increased=16.58 %
  • Considering product mix we can say productivity increased= 16.58 %
  • Total cost decreased=5507563.0 Tk
  • Cost decreased= 17.22 %
  • Consumption on sales’2009= 9.09%
  • Consumption on sales ‘2010=7.84 %( updated 29.07.2010)
  • Net savings = 5507563.0 Tk (for last seven months)
  • Gross savings= (5507563+ 1602859) = 7110422.0 Tk (because production increased= 16.58 %)

L : R    1 : 8

600C Dyeing

CIBA f/w % <  0.3 0.3 – 0.5 0.5 – 1.0 1.0 – 2.0 2.0 – 3.0 > 3.0
Salt g/l 10 20 30 40 50 60
Soda ash g/l 5 5 7.5 10 5 5
NaOH (50%) g/l nil nil nil nil 0.3 0.5
Cibacel DBC g/l 1-1.5 1.0-1.5 1.0 1.0 1.0 1.0
Anti-crease g/l 1.0 1.0 1.0 1.0 1.0 1.0

L : R    1 : 8

600C Dyeing

Levafix % <  0.2 0.2 – 1.0 1.0-2.0 2.0-3.0 3.0-5.0 >5
Salt g/l 10 20 30 40 50-60 80
Soda ash     (no NaOH) g/l 2 5 8 10 10 12
NaOH (50%)    (no soda ash) g/l   0.3 0.7 0.9 1.2 1.4
Cibacel DBC g/l 1-1.5 1.0-1.5 1.0 1.0 1.0 1.0
Anti-crease g/l 1.0 1.0 1.0 1.0 1.0 1.0

L: R  1: 8

600C Dyeing

Remazol % <0.2 0.2-0.5 0.5-1.0 1.0-20 2.0-3.0 3.0-5.0 >5.0
salt g/l 10 20 30 40 50 60 80
Soda ash g/l 5 5 7.5 10 5 5 5
NaOH(50%) g/l nil nil nil nil 0.5 0.5 0.7
Dekol S g/l 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Anti crease g/l 1.0 1.0 1.0 1.0 1.0 1.0 1.0

L: R  1 : 8

820C Dyeing

Procion % <  0.5 0.5- 1.0 1.0-1.5 1.5-2.0 2.0-2.5 >2.5
Salt g/l 30 60 60 70 80 90
Soda ash g/l 5 10 15 15 15 20
Dekol S g/l 1.0 1.0 1.0 1.0 1.0 1.0
Anti crease g/l 1.0 1.0 1.0 1.0 1.0 1.0

L : R    1:8

920C Dyeing

Procion % <  0.5 0.5- 1.0 1.0-1.5 1.5-2.0 2.0-2.5 >2.5
Salt g/l 40 60 70 80 90 90
Soda ash g/l 10 10 15 15 15 20
Dekol S g/l 1.0 1.0 1.0 1.0 1.0 1.0
Anti crease g/l 1.0 1.0 1.0 1.0 1.0 1.0

Buyer Questionary for a Factory

  • Does factory have safe chemicals usage? (provide Oeko Tex )
  • Does factory maintain Lab test?
  • Does factory have available fire equipment?
  • First Aid kits are sufficient?
  • Environmental Management
  • Are all evacuation route marked clearly?
  • Is there found any necked cable?
  • Are all safety issues of cutting /sewing/ finishing/ washing/ printing followed?
  • Keep the working area, machine, and everything always clean. Put everything in its proper place and have a proper place for everything. Does factory maintain updated photograph on each section for fire fighters & rescue team?
  • Does factory maintain a tracker for recording of production activity including chemical usage per style/ date of production for easier tracking system?
  • Does factory provide proper instruction for safety equipment usage?
  • Are workers regularly trained on the usage of PPE?
  • Does factory provide training on Fire / first aid?
  • Does factory provide Health & Safety Awareness training?
  • Emergency exit sign are sufficient?
  • Does factory have written standard operating procedure/ work instruction?
  • Does factory post sign of personnel protective usage?
  • Is there sign of no smoking?
  • Is there sign of high voltage?
  • Are there signs for occupational health & safety awareness?
  • Does factory have emergency team?
  • Are there sufficient rubber mat for Ironman?
  • Does factory conduct Fire drill on monthly basis?
  • Does factory checked fire equipment regularly?
  • Does factory have proper waste water treatment? (proved with independent lab analysis)
  • Is the fire alarm active?
  • Does factory have sufficient Eye Washer?
  • Does factory have License from government?
  • Does factory have proper collecting tank?

Chemical Materials Calculation

laboratory dyeing machine can dye fabric, yarn or even some accessories like button, zipper and loose fibre but main products are the knitted fabrics. Knitted fabrics have different constructions and GSM (weight of fabric in one square meter) and this have different dye pick-up or adsorption. Table given below shows the common fabrics produced at and used in laboratory.

Style Blend Finished GSM
Single Jersey (SJ) 100%  cotton 115 – 270
Single jersey (SJ) PC and CVC 100 – 300
Back Pique/La Coste 100 % cotton/PC/CVC 150 – 250
Polo Pique/Honey comb 100% cotton/PC/CVC 150 – 240
Jumbo Pique 100% cotton 200 – 250
Twill pique 100% cotton 180 – 250
Bubble knit 100% cotton 200 –250
Rib 1×1, 2×2 100% cotton/w/lycra 180 – 280
Herring bone 100% cotton/PC 180 – 280
Special design 100% cotton/PC As required