Remazol Ultra RGB

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

7Q3-3534sro.ppt/pfM&I TMTS EXH CEL 28. August 2007

- 2 -

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

Münchberg (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


- 3 -

Bio-data

Since 2001

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

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


- 4 -

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


- 5 -

Warm reactive dye technology

Warm reactive

dyes

The Market for Reactive Dyes:

Levafix CA Levafix E/EA/EN/ Remazol Specialities

Remazol Ultra RGB

Remazol Remazol A

ExhaustCPBContinuous

FastnessDyeing performanceTotal cost of production

• • •• • •• • •

• • • • • •

••• • ••

FastnessDyeing performanceTotal cost of production

FastnessDyeing performanceDyes costTotal cost of production


- 6 -

Remazol Ultra Yellow RGBNStrong, low photochromic Yellow component for deep ternary shades with good fastness properties.

Remazol Navy RGB 150%Cost effective Navy with very good build-up behaviour for mediumto deep shades. Basis for colour constant recipes. Dischargeable.

Remazol Ultra Red RGBCost 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 RGBTinctorial strong Red. Highest possible build-up for deepest red andbrown shades. Outstanding wash-off properties. Dischargeable.

The Remazol Ultra RGB dyes at a glance

1% 3% 6%

Remazol Ultra Orange RGBStrong build-up, dull Orange for bordeaux, dark brown and olive shades.Dischargeable


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The Remazol Ultra RGB supplementary dyes

1% 3% 6%

2% 4% 7%

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

Remazol Golden Yellow RGB conc.Cost-effective yellow for trichromatic shades. 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.

Remazol Deep Black RGB Economical strong build up Black with good Fastness properties. Dischargeable.


- 8 -

Remazol Ultra RGB: Flexibility in shading

• Remazol Golden Yellow RGB conc

• Remazol Red RGB

• Remazol Ultra Carmine RGB

• Remazol Blue RGB

• Remazol Deep Black RGB

Ultra RedRGB

NavyRGB 150%

Ultra YellowRGBN

Ultra OrangeRGB

Further components in the Remazol RGB range:


- 9 -

Remazol RGB:Economical selection for all deep ternary shades

Gold

en

Y

ello

w

Ora

ng

e

Red

Bord

eau

x

Navy

Dark

Bro

wn

Fore

st G

reen

Dark

Oliv

e

Remazol Ultra Yellow RGBN x x x x x x

Remazol Ultra Orange RGB x x x x x

Remazol Ultra Red RGB x x x x x x x

Remazol Ultra Carmine RGB x x

Remazol Navy RGB 150% x x x x x


- 10 -

High build up in exhaust application

Key to avoiding dye overload is to form thecovalent bonds with the cellulose fibre atan applied percentage of dye where thefixation graph is steep.

The rate of fixation levels off withsaturation of the availablesites in the fibre

Development of Best Available Technology for reactive dyeing of cellulose fibres

hydrolysisfixationWaterWater

DyeDye

CelluloseCellulose


- 11 -

Build up of Remazol UltraCarmine RGB andRemazol UltraRed RGB vs. C.I. Reactive Red 239

0

1

2

3

4

5

6

7

0 1 2 3 4 5 6 7 8 9 10dye conc. [%]

Colo

ur in

tensity

valu

e

Remazol UltraRed RGB Remazol UltraCarmine RGB C.I. Reactive Red 239 (140%)


- 12 -

Significant less dye is neededto achieve the required depth of shade

0.9 %

4.0 %

0.7 %

2.5 %

6.0 %

0,47%1,24%

2,28%

0

1

2

3

4

5

6

7

8

9

10

11

12

1/3 SD 1/1 SD 2/1 SD

dye conc. [%]

C. I. Reactive Yellow 176 (133%) Remazol UltraYellow RGBNRemazol Ultra Orange RGB

not

ach

ievable

1.0%

8.3%

3.8%

0.7%

1.9%

3.2%

0.6%

1.3%

2.1%

0

1

2

3

4

5

6

7

8

9

10

1/3 SD 1/1 SD 2/1 SD

dye conc. [%]

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

>12%


- 13 -

Ultra RGB Technology C.I. Reactive

total: 3.4% total: 6.4%

C. I. Reactive Yellow 176 (133%)3.9%C. I. Reactive Red 239 (140%) 1.5%C. I. Reactive Black 005 (133%)1.0%

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

% Dye required for Dark Brown shade exhaust application

Dark Brown

Best Available Technology - ExhaustSignificant less dye is needed to achieve the required shade

- 47%- 47%- 47%- 47%


- 14 -

Remazol Ultra RGB Commodities

Dark Brown

-40%-40%-40%-40%

100 g/l salt 60 g/l salt 100 g/l salt 100 g/l salt

Remazol Ultra RGBDue to high strength and build-up, significant less salt is needed

Reduces costs in purchasing, warehousing and handling

close

CostCostCostCost


- 15 -

Remazol RGBThe 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

Normal salt consumptionof a dyehouse with commodity products60 g/l salt:

Salt consumption withRemazol Ultra RGB45 g/l salt:

1.5 t salt/day4.5 t salt/day** 6 t salt/day*10 t fabric/day

100,000 l waterx g/l salt

1,440 t salt/year* 1,080 t salt/year**240 working days/year = 360 t salt/year

ExamplExamplee

ExamplExamplee SavingsSavingsSavingsSavings

CostCostCostCost

close


- 16 -

Exhaust application


- 17 -

Remazol Ultra RGB: Flexible in exhaust application

Standard process(e. g. Cotton knit)

Temperature rise(e. g. no dosing equipment)

Migration process(100% Viscose, yarn package)

Application process Basic recipe

Basic recipe: x % Remazol Ultra RGB 1 g/l

Sera Lube M-CF1 g/l Sera Wet C-NR

Detailed Information see pattern cardBasic recipe: x % Remazol Ultra RGB

1 g/l Sera Lube M-CF1 g/l Sera Wet C-NR

Detailed Information see pattern card

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

1 g/l Sera Wet C-NR

Detailed Information see pattern card


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Homogeneous on-tone build-up

20‘ 10‘

10‘

10‘

10‘

10‘

10‘

10‘

10‘

10‘

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

25 °C

60 °CSoda ash

NaClDye

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

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

on-tone build-up

off-tone build-up


- 19 -

Remazol Ultra RGBUp to 25% reduction in dyeing time

SaltAuxiliaries

10´

DyesMixedalkali

45' 80 min

60°C

SaltAuxiliaries

10´

DyesMixedalkali

45'50 min

60°C

Standard

Remazol Ultra RGB

time savingtime saving

30 min!30 min!time savingtime saving

30 min!30 min!

competitor recommendation

DyStar recommendationhomogeneous dye combinationrapid process


- 20 -

Remazol Ultra RGBExcellent wash-off properties can increase productivity

0

100

200

300

400

500

600

700

1st rinsing (50 °C) neutralisation (50 °C)

1st soaping bath(95 °C)

2nd soaping bath(95 °C)

rinsing (80 °C) rinsing cold

4%Remazol UltraCarmine RGB

C. I. Reactive Red 239

optical density at 525 nm

Saving:Saving: 1 soaping bath1 soaping bathSaving:Saving:

1 soaping bath1 soaping bath

Rinsing baths of bulk trials withRemazol UltraCarmine RGB

11 22 33 44 55

11

22

33 44 55


- 21 -

Remazol Ultra RGBThe reduced dyeing time leads to potential cost savings of high productivity

Benefits from reduced processing time per batch

ExamplExamplee

ExamplExamplee

360 h : 5 h 40'/per batch

Production withcommodities

Production with Remazol RGB

17 h/day**18 h 30'/day* 1 h 30'/day3 batches à *6 h 10';**5 h 40'

240 working days/year 4,080 h/year**4,440 h/year* 360 h/year

63 batches more/year +-

SavingsSavingsSavingsSavings


- 22 -

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

Remazol Ultra Yellow RGBN % 1.25 Remazol Ultra Red RGB % 1.56 Remazol Navy RGB 150% % 0.67 NaCl g/l 60.00 Soda ash g/l 5.00 NaOH 50% ml/l 1.7 Liquor ratio 1 : 10 Procedure 60 °C Isothermal

deltaE

0,00

0,50

1,00

1,5010% overfill

10% underfill

20% overfill

20% underfill

- salt

+ salt

-Soda ash

+Soda ash

- 15'

+ 15'

-5 °C

+5 °C

-Liq ratio

+Liq ratio

Total colour difference dE

delta E

0,00

0,50

1,00

1,5010% overfill

10% underfill

20% overfill

20% underfill

- salt

+ salt

-Soda ash

+Soda ash

- 15'

+ 15'

-5 °C

+5 °C

-Liq ratio

+Liq ratio

close


- 23 -

Excellent lab to bulk and pilot to bulk reproducibility

Process Machine kg Pass/ Fail [dE] against control CMC 2 : 1

Sample

Thies EcoSoft 80 Control

Thies MiniSoft 5 0.4

Thies MiniSoft 5 0.2

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

0.6

Remazol Ultra Yellow RGBN % 1.98 NaCl 70 g/l

Remazol Ultra Red RGB % 1.08 Soda ash 17 g/l

Remazol Navy RGB 150% % 0.72 Liquor ratio 1 : 8

Salt/Auxiliaries

60°C 10'

10'

60'

Dye Alkali

25°C

Salt/Auxiliaries

Dye

10'

10'

60'

Alkali

60°C

1°C/min

close


- 24 -

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%

Production capacitywith commodites

Production capacity with Remazol RGB

ExamplExamplee

ExamplExamplee

600 kg fabric/day 660 kg fabric/dayx 200 kg/fabric = 60 kg fabric/day

3.3 batches/day3.0 batches/day 0.3 batches/daybatches/day =

158.4 t fabric/year*144 t fabric/year*x 240 working days/year =

14.4 t fabric/year* = with a one rope machine* = with a one rope machine

AdditionalAdditionalproductionproductionAdditionalAdditionalproductionproduction

SpeedSpeedSpeedSpeed

SecuritySecuritySecuritySecurity

close


- 25 -

Continuous application


- 26 -

Remazol Ultra RGB: Flexible in padding application

Cold Pad Batch(CPB)

Pad Dry Pad Steam(PDPS)

Econtrol

winding and dwelling padding

fabric alkalidyestuff

Washing off

Basic recipe: x g/l Remazol Ultra RGB10 g/l Sera Gal M-IP

2 g/l Sera Wet C-AS5 - 10 g/l Sera CON M-LU

Chemical pad:250 g/l salt20 g/l soda ash

3-6 ml/l caustic soda 50%

Basic recipe: x g/l Remazol Ultra RGB10 g/l Sera Gal M-IP

2 g/l Sera Wet C-AS5 - 10 g/l Sera CON M-LU

20 g/l soda ash 3.5 – 14 ml/l caustic soda 50%

Basic recipe: x g/l Remazol Ultra RGB2 g/l Sera Wet C-AS

Alkali system according to climate conditions and/or preference

Application process Basic recipe


- 27 -

Significant less dye is needed to achieve the required shade

C. I. Reactive Remazol Ultra RGB

-39%-39%-39%-39%

C. I. Reactive Yellow 176 (133%)54.0g/lC. I. Reactive Red 239 (140%) 19.3 g/lC. I. Reactive Black 005 (133%)11.0 g/l

Remazol Ultra Yellow RGBN 22.0 g/lRemazol UltraRed RGB 22.0 g/lRemazol Navy RGB 150% 7.8 g/l

Dark Brown84.3 g/l

51.8 g/l


- 28 -

Robustness in Cold Pad BatchStandard:

Remazol UltraYellow RGBN 4 g/l Silicate 50 m/l

Remazol UltraRed RGB 24 g/l NaOH 50% 14 ml/l

Remazol Navy RGB 150% 10 g/l batching time 12 h

delE delC delH

1 0.05 -0.01 0.03

2 0.16 0.06 0.05

3 0.14 0.10 0.06

4 0.04 0.02 0.03

5 0.11 0.09 0.05

6 0.31 0.23 0.01

7 0.18 0.09 0.02

8 0.13 0.03 0.05

1 2 3 4as standard as standard as standard as standard but 16 h batchingbut 16 h batching but 24 h batching but 17 ml/l NaOH 50% but 17 ml/l NaOH 50%

5 6 7 8as standard as standard as standard as standardbut 24 h batching but 20 ml/l NaOH 50% but 16 h batching but 24 h batchingand 17 ml/l NaOH 50% and 20 ml/l NaOH 50% and 20 ml/l NaOH 50%


- 29 -

Advantages of Remazol Ultra RGB in pad applicationGood lab to bulk reproducibility in cold pad-batch:

Drying cabinet 10 min, 70°CDrying cabinet 30 min, 50°CMicrowave 8 min

Standard


- 30 -

Fastness


- 31 -

3.0% Remazol Ultra Yellow RGBN

0.6%2.4% 0.6%2.4%

3.0% Remazol UltraRed RGB3.0% Remazol Navy RGB 150% 2.4%0.6% 1.8%1.2% 1.2%1.8% 0.6%2.4%

2.4%0.6% 2.4%0.6%0.6%1.8% 0.6% 0.6%1.2% 1.2% 0.6%0.6% 1.8%

1.2%1.8% 1.2%1.8%0.6%1.8%0.6%

1.8%1.2%1.8%1.2% 1.2%1.2%0.6% 0.6%1.2%1.2%

(1) Light fastness (B02)(2) Perborate light fastness (M&S, C9A)(3) Wash fastness (M&S C10A)(4) Fastness to Chlorine 10 ppm

(1) 4-5(2) pass(3) 4-5(4) 4

(1) 3-4(2) pass(3) 3-4(4) 4

(1) 4-5(2) pass(3) 4-5(4) 4

(1) 4(2) pass(3) 4-5(4) 4

(1) 4(2) pass(3) 4-5(4) 4-5

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

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

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

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

(1) 4-5(2) pass(3) 4-5(4) 4-5

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

(1) 3-4(2) pass(3) 4(4) 4

(1) 3-4(2) pass(3) 4(4) 4

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

(1) 4-5(2) pass(3) 4-5(4) 4-5

(1) 3-4(2) pass(3) 4(4) 3-4

(1) 3-4(2) pass(3) 4(4) 4

(1) 3-4(2) pass(3) 4(4) 4

(1) 4-5(2) pass(3) 4-5(4) 4-5

(1) 3-4(2) pass(3) 4(4) 4

(1) 3-4(2) pass(3) 4(4) 3-4


- 32 -

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

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

3-43-4

CommoditiesYellow 176/Red 239/Black 005


- 33 -

CostCostCostCost

Conclution

Benefits offered by Remazol Ultra RGB technology

Shade reproducibility Standard fastness

requirements Eco-compliance

Shorter production cycles Right-First-Time performance Robustness

Less dyestuff Less water Less energy Reduced stock costs

Reduced costs

Higher productivity

Standardisation limits

SpeedSpeedSpeedSpeed

SecuritySecuritySecuritySecurity

Documents

Remazol Ultra RGB