Both traditional and modern industrial dyeing processes aim to create products with modern, refined colors. However, VieChemol SR technology helps optimize the dyeing process for factories. At the same time, VieChemol SR also helps improve the quality of the finished product. Let’s explore the difference between the traditional industrial dyeing process and VieChemol SR chemical technology in the following article.
1. Improvements in the Industrial Dyeing Process
The dyeing process directly affects the quality, colorfastness, and aesthetic appeal of the fabric. Dyeing helps to cover the natural color of the fibers. In addition, dyeing can also enhance the features of the fabric.
Dyeing technology is constantly being improved to optimize the process and enhance the value of the finished product. In the early days, humans already knew how to use natural materials to create dyes. This manual process required meticulousness, patience, and was highly dependent on natural conditions. However, this method was time-consuming, labor-intensive, and could not be used for mass production.
The industrial revolution opened the door to synthetic dyes. At the same time, dyeing techniques were also greatly improved, helping the dyeing industry to develop.
2. Understanding the Traditional Industrial Dyeing Process
Basically, all fabric dyeing processes must go through a fabric cleaning step. However, traditional industrial dyeing is a manual and very time-consuming method.
2.1. The Traditional Industrial Dyeing Process (for white) typically goes through the following 4 steps:
- Step 1: Scouring and Cleaning the Fabric: This is the step of scouring the greige fabric. There is a lot of oil, sizing (gelatin), sediment, dust, and stains left after weaving. Through this step, the greige fabric will be cleaned. This process usually takes 120-180 minutes.
- Step 2: Hot Washing: This is the step to clean the bleach from step 1. At the same time, it rinses away any remaining sediment to make the fabric completely clean. This process usually takes 60 minutes.
- Step 3: pH Balancing: This is an extremely important step. It helps the fabric achieve a standard white color and prevents color bleeding and unevenness. This process usually takes 30 minutes.
- Step 4: Cold Washing: This is the step to rinse off the chemicals used and prepare the fabric for production. This process usually takes 15-20 minutes.
2.2. The Traditional Industrial Dyeing Process (for dark colors) typically goes through the following 11 steps:
- Step 1: Scouring and Cleaning the Fabric: This is the step of scouring the greige fabric. There is a lot of oil, sizing (gelatin), sediment, dust, and stains left after weaving. Through this step, the greige fabric will be cleaned. This process usually takes 120-180 minutes.
- Step 2: Hot Washing: This is the step to clean the bleach from step 1. At the same time, it rinses away any remaining sediment to make the fabric completely clean. This process usually takes 60 minutes.
- Step 3: pH Balancing: This is an extremely important step. It helps the fabric achieve a standard white color and prevents color bleeding and unevenness. This process usually takes 30 minutes.
- Step 4: Cold Washing: This is the step to rinse off the chemicals used and prepare the fabric for use. This process usually takes 15-20 minutes.
- Step 5: Fabric Dyeing: Add the corresponding chemicals and dyes to dye the fabric. This process usually takes 300 minutes.
- Step 6: Cold Washing: This is the step to rinse off the excess dye on the fabric from step 5. This process usually takes 15-20 minutes.
- Step 7: pH Balancing: This is an extremely important step. It helps the fabric achieve the desired dark color and prevents color bleeding and unevenness. This process usually takes 30-45 minutes.
- Step 8: Hot Washing: This is the step to clean the chemicals from step 7 and fix the color for the fabric.
- Step 9: Hot Washing: Continue to clean the chemicals from step 8.
- Step 10: Hot Washing:
- Step 11: Cold Washing, Ready for Use:
Using the old dyeing method, it takes an average of nearly 5 hours a day to dye a white fabric to a standard color. And it takes more than 10 hours a day to dye a dark-colored fabric as required. These parameters are measured based on the operating capacity of one machine.
In reality, the traditional industrial dyeing process is very time-consuming, costly, and labor-intensive. If a factory wants to increase production, it must have more machines and a skilled workforce to ensure factory productivity and product quality. In addition, the issue of environmental waste is also a major concern for factories and local governments. Therefore, with the old process, factories often face difficulties if they want to expand production.
3. Understanding the Industrial Dyeing Process with VieChemol SR
VieChemol SR is a non-ionic surfactant used in the wetting, scouring, and bleaching process in the dyeing industry. The scouring chemical VieChemol SR can remove oil from spinning machines and knitting lubricants, while preventing impurities from redepositing.
3.1. The Industrial Dyeing Process (for white) using VieChemol SR is described as follows:
- Step 1: Scouring: Use the VieChemol SR scouring chemical to clean the greige fabric to a standard white color. This process usually takes 120 minutes.
- Step 2: Cold Washing: This is the step to rinse off the chemicals used and prepare the fabric for production. This process usually takes 30-40 minutes.
3.2. The Industrial Dyeing Process (for dark colors) using VieChemol SR is described as follows:
- Step 1: Scouring: Use the VieChemol SR scouring chemical to clean the greige fabric to a standard white color. This process usually takes 120 minutes.
- Step 2: Fabric Dyeing: Begin dyeing the fabric with the required chemicals and dyes. This process usually takes 190 minutes.
- Step 3: Washing and Rinsing: Hot wash for 7 stages to rinse off the dye and chemicals. This process usually takes about 150 minutes.
Overall, the dyeing process combined with the VieChemol SR chemical takes less than 3 hours for white and 7.5 hours for dark colors per day. In addition, the quality of the finished product is significantly improved. Factories can save time, energy, and labor in the fabric treatment process. From there, they can optimize the production process and ensure product quality. As a result, expanding production also becomes easier.
VieChemol SR has become an ideal solution in the modern textile dyeing industry. In addition, VieChemol SR is extremely environmentally friendly. So factories do not have to worry about the waste treatment process after production.
4. Comparison of Traditional Dyeing and VieChemol SR Processes
To better understand the difference between the traditional dyeing process and VieChemol SR chemical technology, please follow the comparison criteria below:
4.1. Performance and Product Quality
- Traditional Dyeing Process: The fabric colors are refined and modern, but efficiency is not high, and it requires highly skilled labor.
- Dyeing Process with VieChemol SR: Ensures uniform color and high colorfastness, along with high production efficiency thanks to the optimized process.
4.2. Resource Savings and Environmental Protection
- Traditional Dyeing Process: Uses synthetic chemicals, which can cause environmental pollution if not handled properly, and consumes a lot of energy (electricity, water) during the dyeing process.
- Dyeing Process with VieChemol SR: Uses environmentally friendly synthetic chemicals, limits environmental pollution, and the optimized treatment process saves significant energy.
4.3. Cost and Competitiveness
- Traditional Dyeing Process: High costs for raw materials, energy, and labor.
- Dyeing Process with VieChemol SR: High costs for raw materials, energy, and labor.
4.4. Flexibility and Process Complexity
- Traditional Dyeing Process: The process is long, cumbersome, and manual, so it requires a lot of personnel.
- Dyeing Process with VieChemol SR: The process is short, has a formula, and is automated thanks to machinery.
5. Application of Modern Dyeing Technology
With the traditional dyeing method, the process to get a standard white fabric takes quite a long time. With the advent of the advanced scouring chemical VieChemol SR, factories will save more than half the time and energy compared to the old process. VieChemol becomes a perfect choice for fabric dyeing factories that want to improve their production process and optimize costs.
If you are looking for a scouring chemical that supports a modern dyeing process, do not miss VieChemol SR – an effective, cost-saving, and environmentally friendly scouring solution. Contact VieTextile today for a consultation:
- Phone: +84 (0) 901809309
- Email: info@vietextile.com
- Office: 82C Quach Dinh Bao, Phu Thanh Ward, Tan Phu District, Ho Chi Minh City
