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
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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
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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
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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
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
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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.
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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:
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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
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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
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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%)
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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%
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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%
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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
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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
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Exhaust application
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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
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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
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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
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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
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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
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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
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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
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Continuous application
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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
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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
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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%
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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
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Fastness
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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
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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
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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