Cold Pad-Batch dyeing method for cotton fabric dyeing with reactive dyes using ultrasonic energy

Reactive dyes are vastly used in dyeing and printing of cotton fibre. These dyes have a distinctive reactive nature due to active groups which form covalent bonds with -OH groups of cotton through substitution and/or addition mechanism. Among many methods used for dyeing cotton with reactive dyes, the Cold Pad Batch (CPB) method is relatively more environment friendly due to high dye fixation and non requirement of thermal energy. The dyed fabric production rate is low due to requirement of at least twelve hours batching time for dye fixation. The proposed CPB method for dyeing cotton involves ultrasonic energy resulting into a one third decrease in batching time. The dyeing of cotton fibre was carried out with CI reactive red 195 and CI reactive black 5 by conventional and ultrasonic (US) method. The study showed that the use of ultrasonic energy not only shortens the batching time but the alkalis concentrations can considerably be reduced. In this case, the colour strength (K/S) and dye fixation (%F) also enhances without any adverse effect on colour fastness of the dyed fabric. The appearance of dyed fibre surface using scanning electron microscope (SEM) showed relative straightening of fibre convolutions and significant swelling of the fibre upon ultrasonic application. The total colour difference values ΔE (CMC) for the proposed method, were found within close proximity to the conventionally dyed sample.     

Ultrasound for low temperature dyeing of wool with acid dye

The possibility of reducing the temperature of conventional wool dyeing with an acid levelling dye using ultrasound was studied in order to reach exhaustion values comparable to those obtained with the standard procedure at 98 °C, obtaining dyed samples of good quality. The aim was to develop a laboratory method that could be transferred at industrial level, reducing both the energy consumption and fiber damage caused by the prolonged exposure to high temperature without the use of polluting auxiliary agents.Dyeings of wool fabrics were carried out in the temperature range between 60 °C and 80 °C using either mechanical or ultrasound agitation of the bath and coupling the two methods to compare the results. For each dyeing, the exhaustion curves of the dye bath were determined and the better results of dyeing kinetics were obtained with ultrasound coupled with mechanical stirring. Hence the corresponding half dyeing times, absorption rate constants according to Cegarra-Puente modified equation and ultrasonic efficiency were calculated in comparison with mechanical stirring alone. In the presence of ultrasound the absorption rate constants increased by at least 50%, at each temperature, confirming the synergic effect of sonication on the dyeing kinetics. Moreover the apparent activation energies were also evaluated and the positive effect of ultrasound was ascribed to the pre-exponential factor of the Arrhenius equation. It was also shown that the effect of ultrasound at 60 °C was just on the dye bath, practically unaffecting the wool fiber surface, as confirmed by the results of SEM analysis.Finally, fastness tests to rubbing and domestic laundering yielded good values for samples dyed in ultrasound assisted process even at the lower temperature. These results suggest the possibility, thanks to the use of ultrasound, to obtain a well equalized dyeing on wool working yet at 60 °C, a temperature process strongly lower than 98 °C, currently used in industry, which damages the mechanical properties of the fibers.     

Ecofriendly laccase–hydrogen peroxide/ultrasound-assisted bleaching of linen fabrics and its influence on dyeing efficiency

This study evaluates the bleaching efficiency of enzymatically scoured linen fabrics using a combined laccase–hydrogen peroxide bleaching process with and without ultrasonic energy, with the goal of obtaining fabrics with high whiteness levels, well preserved tensile strength and higher dye uptake. The effect of the laccase enzyme and the combined laccase–hydrogen peroxide bleaching process with and without ultrasound has been investigated with regard to whiteness value, tensile strength, dyeing efficiency and dyeing kinetics using both reactive and cationic dyes. The bleached linen fabrics were characterized using X-ray diffraction and by measuring tensile strength and lightness. The dyeing efficiency and kinetics were characterized by measuring dye uptake and colour fastness. The results indicated that ultrasound was an effective technique in the combined laccase–hydrogen peroxide bleaching process of linen fabrics. The whiteness values expressed as lightness of linen fabrics is enhanced by using ultrasonic energy. The measured colour strength values were found to be slightly better for combined laccase–hydrogen peroxide/ultrasound-assisted bleached fabrics than for combined laccase–hydrogen peroxide for both reactive and cationic dyes. The fastness properties of the fabrics dyed with reactive dye were better than those obtained when using cationic dye. The time/dye uptake isotherms were also enhanced when using combined laccase–hydrogen peroxide/ultrasound-assisted bleached fabric, which confirms the efficiency of ultrasound in the combined oxidative bleaching process. The dyeing rate constant, half-time of dyeing and dyeing efficiency have been calculated and discussed.     

Effects of ultrasonic energy on dyeing of polyamide (microfibre)/Lycra blends

Although ultrasonic energy is widely used cleaning and degreasing of parts and assemblies in automotive and other industries, the use of ultrasonic energy in an industrial scale for textile washing is very new. This is due to the complexity of controlling the combination of chemical and mechanical effects, whereas with degreasing of machine parts only the mechanical effects is applied. The use of ultrasonic energy in dyeing PA/Lycra fabrics with reactive dyes has been studied spectrophotometrically in this work. PA/Lycra (85/15) blends have been dyed using conventional and ultrasonic dyeing techniques with three reactive dyes containing different chromophore and reactive groups. The dyeing carried out conventionally and by the use of ultrasonic techniques. The results were compared in terms of percentage exhaustion; total dye transferred to the washing bath after dyeing and the fastness properties.     

Ultrasonic dyeing of cellulose nanofibers

Textile dyeing assisted by ultrasonic energy has attained a greater interest in recent years. We report ultrasonic dyeing of nanofibers for the very first time. We chose cellulose nanofibers and dyed with two reactive dyes, CI reactive black 5 and CI reactive red 195. The cellulose nanofibers were prepared by electrospinning of cellulose acetate (CA) followed by deacetylation. The FTIR results confirmed complete conversion of CA into cellulose nanofibers. Dyeing parameters optimized were dyeing temperature, dyeing time and dye concentrations for each class of the dye used. Results revealed that the ultrasonic dyeing produced higher color yield (K/S values) than the conventional dyeing. The color fastness test results depicted good dye fixation. SEM analysis evidenced that ultrasonic energy during dyeing do not affect surface morphology of nanofibers. The results conclude successful dyeing of cellulose nanofibers using ultrasonic energy with better color yield and color fastness results than conventional dyeing.     

Staining of wool using the reaction products of ABTS oxidation by laccase: synergetic effects of ultrasound and cyclic voltammetry

The effects of ultrasound on 2,2'-Azinobis(3-ethylbenzothiazoline-6-sulfonate) enzymatic oxidation by laccase (Trametes villosa) has been studied by means of cyclic voltammetry. The reaction was allowed to proceed in the presence of a piece of wool and the coloration depth of the wool fabric was measured by means of K/S. It was observed that cyclic voltammetry is influenced the dyeing process and higher K/S values were obtained when the cyclic voltammetry was combined with the ultrasonic irradiation. Moreover, the K/S value is the sum of the values obtained when the wool staining is done in just the presence of cyclic voltammetry or in just the presence of ultrasound. The results obtained on the indigo carmine decolourization gives information on the importance of controlling the amount of ABTS(+) formed during the ultrasonication process.     

Ultrasonic assisted dyeing: Dyeing of acrylic fabrics C.I. Astrazon Basic Red 5BL 200%

The dyeing of acrylic fabrics using C.I. Astrazon Basic Red 5BL 200% has been studied with both conventional and ultrasonic techniques. The effect of dye concentration, dye bath pH, ultrasonic power, dyeing time and temperature were studied and the resulting shades obtained by dyeing with both techniques were compared. Colour strength values obtained were found to be higher with ultrasonic than with conventional heating. The results of fastness properties of the dyed fabrics were studied. X-ray and Scanning Electron Microscope SEM were carried out on dyed samples using both methods of dyeing to find out an explanation for the better dyeability of acrylic fabrics with (US) method. Dyeing kinetics of acrylic fabrics using C.I. Astrazon Basic Red 5BL 200% using conventional and ultrasonic conditions were compared. The time/dye-uptake isotherms are revealing the enhanced dye-uptake in the second phase of dyeing. The values of dyeing rate constant, half-time of dyeing and standard affinity and ultrasonic efficiency have been calculated and discussed.     

Ultrasonic-assisted dyeing of Nylon-6 nanofibers

We first time report ultrasonic dyeing of the Nylon 6 nanofibers with two disperse dyes CI Disperse blue 56 and CI Disperse Red 167:1 by utilising ultrasonic energy during dyeing process. The Nylon 6 nanofibers were fabricated via electrospinning and dyed via batchwise method with and without sonication. Results revealed that ultrasonic dyeing produce higher color yield (K/S values) and substantially reduces dyeing time from 60 min for conventional dyeing to 30 min can be attributed to breakage of dye aggregate, transient cavitation near nanofiber surface and mass transfer within/between nanofibers. Color fastness results exhibited good to very good dye fixation. SEM images exhibit insignificant effect of sonication on morphology of the nanofibers. Our research results demonstrate ultrasonic dyeing as a better dyeing technique for Nylon 6 nanofibers with higher color yield and substantially reduced dyeing time.     

Ultrasonic effects on electroorganic processes Part 6. Formation of cupric carboxylates at a reactive copper anode in carboxylic acid solutions

Current efficiency for the formation of highly soluble cupric acetate at a reactive (consumable) copper anode in an acetic acid solution was increased almost independently of current density under ultrasonic irradiation. On the other hand, the efficiency for sparingly soluble cupric oxalate depended complicatedly on current density. At a low current density region less than 4 mA cm(-2), ultrasonic irradiation caused an increase in the current efficiency, while at higher current densities no ultrasonic effect was observed because of the formation of a rigid oxalate film on the anode surface. This paper is the first report of ultrasonic effects on an electrochemical reaction at a reactive (consumable) anode which is stoichiometrically involved in the reaction leading to the formation of products derived from anode metal.     

Studies on the use of power ultrasound in leather dyeing

Uses of power ultrasound for acceleration/performing the chemical as well as physical processes are gaining importance. In conventional leather processing, the diffusion of chemicals through the pores of the skin/hide is achieved by the mechanical agitation caused by the paddle or drumming action. In this work, the use of power ultrasound in the dyeing of leather has been studied with the aim to improve the exhaustion of dye for a given processing time, to reduce the dyeing time and to improve the quality of dyed leather. The effect of power ultrasound in the dyeing of full chrome cow crust leather in a stationary condition is compared with dyeing in the absence of ultrasound as a control experiment both in a stationary as well as conventional drumming condition. An ultrasonic cleaner (150 W and 33 kHz) was used for the experiments. Actual power dissipated into the system was calculated from the calorimetric measurement. Experiments were carried out with variation in type of dye, amount of dye offer, temperature and time. The results show that there is a significant improvement in the percentage exhaustion of dye due to the presence of ultrasound, when compared to dyeing in absence of ultrasound. Experiments on equilibrium dye uptake carried out with or without ultrasound suggest that ultrasound help to improve the kinetics of leather dyeing. The results indicate that leathers dyed in presence of ultrasound have higher colour values, better dye penetration and fastness properties compared to control leathers. The physical testing results show that strength properties of the dyed leathers are not affected due to the application of ultrasound under the given process conditions. Apparent diffusion coefficient during the initial stage of dyeing process, both in presence and in absence of ultrasound was calculated. The values show that ultrasound helps in improving the apparent diffusion coefficient more for the difficult dyeing conditions such as in the case of metal-complex dyes having bigger aggregate size compared to less difficult dyeing conditions.     

Ultrasound energy to accelerate dye uptake and dye–fiber interaction of reactive dye on knitted cotton fabric at low temperatures

Acoustic cavitation formed due to propagation of ultrasound wave inside a dye bath was successfully used to dye cotton fabric with a reactive dye at lower temperatures. The energy input to the system during sonication was 0.7 W/cm². This was within the energy range that contributes towards forming cavitation during ultra-sonication. The influence of ultrasound treatment on dye particle size and fiber morphology is discussed. Particle size analysis of the dye bath revealed ultra-sonication energy was capable of de-agglomeration of hydrolyzed dye molecules during dyeing. SEM micrograph and AFM topographical image of the fiber surface revealed fiber morphology remains unchanged after the sonication. The study was extended in understanding the contribution of ultrasound method of dyeing towards achieving good color strength on the fabric, compared to the normal heating method of dyeing. Study showed color strength obtained using ultra sound method of dyeing is higher compared to normal heating dyeing. Ultrasound energy was able to achieve the good color strength on cotton fabric at very low temperature such as 30 °C, which was approximately 230% more than the color strength achieved in normal heating method of dyeing. This indicates that energy input to the system using ultrasound was capable of acting as an effective alternative method of dyeing knitted cotton fabrics with reactive dye.     

Influence of laser irradiation on the optical and structural properties of poly(ethylene terephthalate) fibres

Laser irradiation has been previously investigated for achieving uniform heating of polyethylene terephthalate (PET) fibres in the hot-drawing stage of the production process, so as to obtain better fibre mechanical properties. The optical properties and dye uptake of PET fibres also depend on the polymer chain orientation and crystallinity within the fibre structure. This paper reports an investigation of a concept whereby laser irradiation and interferometry could be used to modify and trace a small change in the optical properties of a PET monofilament fibre, but the corresponding change in the dye uptake would not be detected visually. A copper vapour laser (550-580 nm wavelengths) was used to expose consecutive 4 mm lengths along a running length of monofilament to 39.8 W cm⁻², at a pulse rate of 9.89 kHz in order to modify, in a controlled way, the polymer crystallinity and orientation. A 3D finite element simulation, based on uncoupled heat-transfer analysis, indicated that rapid heating and cooling could be obtained with the laser to give the small changes required. Irradiated and untreated samples were analysed by interferometry and a 0.16% change was detected in the birefringence profiles, corresponding to a small reduction in the degree of orientation and crystallinity of the irradiated samples. Density measurements and wide-angle X-ray scattering (WAXS) analysis confirmed the change in crystallinity. Tests conducted for dye adsorption and tensile strength showed a small increase in the former and only a very small decrease in the latter. It was concluded that these changes in property provide the opportunity for a laser-irradiated PET monofilament fibre to be used as a subtle tracer element in brand labels for textile garments as an anti-counterfeit measure.     

Effects of ultrasonic energy on the wash fastness of reactive dyes

The field of ultrasonic is still making strides towards perfection, but already many applications of ultrasonic energy have been found in science and technology. There is also a field called sonochemistry where ultrasonic energy is used to create some chemical and mechanical effects on matter immersed or solved in liquids. It was presumed that ultrasonic textile washing could be a competitive alternative to conventional textile washing techniques; and as such the following experiments were conducted. In this study, the effects of ultrasonic energy on the wash fastness of reactive dyes, which have three different reactive groups, were investigated. After dyeing with the conventional method, the samples were applied with three types of washing processes simultaneously (conventional, ultrasonic probe and ultrasonic bath) and comparisons were made. Three different fixing agents were used in the washing processes. Colourfastness, staining fastness, magnitude of total colour difference (DeltaE) and lightness difference of the colour (DeltaL) values of dyed samples were measured.     

The effects of ultrasonic agitation in laundering on the properties of wool fabrics

This paper investigates the use of ultrasonic agitation as a method for reducing felting and area shrinkage during the laundering of wool fabric. Work was conducted to evaluate the changes in fibre and fabric properties after repeated exposure to ultrasonic agitation, and also the effectiveness of ultrasonic treatment to remove common stains. Fabric colour, appearance, tensile strength, dimensional stability and thickness were measured before and after each test. Ultrasonic agitation produced fine cracks in the scale structure of the fibre, but these had negligible effects on the strength and colour when compared to hand washing. Ultrasonic agitation caused less fibre migration than hand washing, with a reduced rate of thickness increase and felting. Ultrasonic agitation increased the level of stain removed from the fabric when compared with hand washing.     

Surface enhanced Raman spectroscopic investigation of orchil dyed wool from Roccella tinctoria and Lasallia pustulata

In this work Raman spectroscopic techniques have been utilized to characterize the vibrational spectral features of orchil dyed wool samples. Specifically, it is noted by surface enhanced Raman spectroscopy that wool dyed purple with two historically used orchil species (Roccella tinctoria and Lasallia pustulata) show spectral differences possibly owing to their specific dye‐precursor constituents. The additional natural dyestuff woad (Isatis tinctoria L.) overdyeing the R. tinctoria orchil dyed wool is a further challenge when distinguishing the mixed dye components given by the co‐adsorption of the dyestuffs as permitted by the selection rules of surface enhanced Raman spectroscopy. Furthermore, the effects of dilution of the L. pustulata species in its spectral detection have been assessed along with the evaluation of subsequent lichen extract boiling before dyeing which resulted in the detection of a degraded form of the orchil dye. Proof of concept included the surface enhanced Raman spectroscopy (SERS) investigation of a purple dyed tapestry (XVI century) which permitted an aged orchil dye to be determined. This contribution utilizes SERS as a fast, reproducible and specific method for both orchil dye detection and alteration induced by degradation. Copyright © 2014 John Wiley & Sons, Ltd.     

Affinity of protein fibres towards sulfation

Wool, Bombyx mori and Antheraea pernyi (Tussah) silk fibres were treated with chlorosulfonic acid in pyridine and investigated by FT‐IR and FT‐Raman spectroscopies as well as mechanical measurements. The reactivity towards sulfation was found to decrease along the series: wool > Bombyx mori silk fibroin > Tussah silk fibroin, in agreement with weight gain which decreased along the same series. Accordingly, Tussah silk maintained its intrinsic tensile properties essentially unchanged upon the treatment, while for Bombyx mori silk fibroin, the tensile performance decreased sharply especially at longer reaction times. Sulfated wool was characterized by an increased fibre extensibility. New IR and Raman bands attributable to various vibrations of sulfated groups were detected in sulfated wool and to a lower extent in Bombyx mori silk fibroin fibres; all the fibres underwent conformational rearrangements upon sulfation, independent of the sulfation yield. Wool fibres treated with chlorosulfonic acid in pyridine bound considerable amounts of sulfate mainly through the hydroxyl groups of serine, threonine and tyrosine. Also, tryptophan and basic amino acids were found to participate to the reaction. B. mori silk fibroin fibres appeared to bind a minor amount of sulfate groups mainly trough the hydroxyl groups of Ser. Weight gain, spectroscopic and mechanical data are discussed in relation to the difference in fibre morphology, structure and crystallinity, as well as to the amount and accessibility of potentially reactive amino acids. Copyright © 2012 John Wiley & Sons, Ltd.     

Ultrasound mediation for one-pot sonosynthesis and deposition of magnetite nanoparticles on cotton/polyester fabric as a novel magnetic,photocatalytic, sonocatalytic,antibacterial and antifungal textile

A magnetic cotton/polyester fabric with photocatalytic, sonocatalytic, antibacterial and antifungal activities was successfully prepared through in-situ sonosynthesis method under ultrasound irradiation. The process involved the oxidation of Fe²⁺ to Fe³⁺ via hydroxyl radicals generated through bubbles collapse in ultrasonic bath. The treated samples were analyzed by X-ray diffraction, field emission scanning electron microscopy, energy dispersive X-ray spectroscopy and vibrating sample magnetometry. Photocatalytic and sonocatalytic activities of magnetite treated fabrics were also evaluated toward Reactive Blue 2 decoloration under sunlight and ultrasound irradiation. Central composite design based on response surface methodology was applied to study the influence of iron precursor, pH and surfactant concentration to obtain appropriate amount for the best magnetism. Findings suggested the potential of one-pot sonochemical method to synthesize and fabricate Fe₃O₄ nanoparticles on cotton/polyester fabric possessing appropriate saturation magnetization, 95% antibacterial efficiency against Staphylococcus aureus and 99% antifungal effect against Candida albicans, 87% and 70% dye photocatalytic and sonocatalytic decoloration along with enhanced mechanical properties using only one iron rich precursor at low temperature.     

Ultrasonic dyeing of cationized cotton fabric with natural dye. Part 1: cationization of cotton using Solfix E

The dyeing of cationized cotton fabric with Solfix E using colouring matter extracted from Cochineal dye has been studied using both conventional and ultrasonic techniques. Factors affecting dye extraction such as ultrasound power, particle size, extraction temperature and time were studied. The results indicated that the extraction by ultrasound at 300 W was more effective at lower temperature and time than conventional extraction. The effect of various factors of dye bath such as pH, salt concentration, ultrasound power, dyeing time and temperature were investigated. The colour strength values obtained were found to be higher with ultrasound than with conventional techniques. The results of fastness properties of the dyed fabrics were fair to good. The scanning electron microscope (SEM) images of the morphological and X-ray analyzes were measured for cationized cotton fabrics dyed with both conventional and ultrasound methods, thus showing the sonicator efficiency.     

Impact on textile properties of polyester with laser

Modification of the textile properties of polyester due to laser irradiation were studied and these properties included fibre weight and diameter, tensile strength and elongation, yarn abrasion, bending, surface lustre, wetting, air permeability as well as crystallinity. Properties such as wettability and air permeability were positively affected while properties of fibre weight and diameter, tensile strength, yarn abrasion and bending were adversely affected. In this study, laser irradiation used was not found to affect the bulk properties of polymer due to its low penetration depth, and hence, the effect of laser irradiation on bulk and structural properties was limited. However, the performance and comfort properties of the laser-irradiated polyester could be significantly affected by laser irradiation.     

Destabilization of ultrafine bubbles in water using indirect ultrasonic irradiation

Ultrafine bubble (UFB) is a bubble with a diameter of less than 1 μm. Little attention has been paid to the defoaming and removal of UFBs. This study proposes a method to destabilize UFBs by using indirect ultrasonic irradiation. Besides, the destabilization mechanism of UFB was investigated. The ultrasonic frequency was 1.6 MHz and the dissipated power was 30 W. UFB dispersions were prepared using two different types of bubble generators: pressurized dissolution method and swirling liquid flow method. The effects of ultrasonic irradiation on the stability of UFBs were evaluated by particle tracking analysis (PTA) and electrophoretic zeta potential measurement. Results showed that the indirect ultrasonic irradiation for 30 min reduced the number concentration of UFBs by 90% regardless of the generation method. This destabilization was attributed to a decrease in the magnitude of zeta potential of UFBs due to the changes in pH and electrical conductivity. These changes in the electrochemical properties were caused by the formation of nitric acid. To study the destabilization mechanism, the pH of the UFB dispersions were modified by titration; the chemical and mechanical effects of ultrasound were separately examined. It was found that not only the chemical effect caused by the formation of nitric acid but also the mechanical effect contributed to the destabilization of UFB. Feasibility studies were also performed for UFBs in an aqueous surfactant solution and UFBs in a solid particle dispersion. The proposed method selectively destabilized UFBs in the solutions.