DyStar, a global dyestuff and chemical manufacturer and solution provider, and RotaSpray, developer of rotating atomizers for tailor-made conceptions in dyeing and finishing of warp yarn, fabric, and nonwovens, have developed their indigo spray dyeing procedure for production on a bulk level, helping denim producers reduce their environmental impact.
The solution was first introduced at ITMA Milan in 2015. Since then, DyStar and RotaSpray have been working together to develop it further and make it available for bulk production in important denim markets such as Turkey, India, and Pakistan. With the recent breakthrough, they are now announcing a salt-less dyeing solution for the denim industry.
This new technology has received important ECO certificates and offers high flexibility for dyeing small lot sizes, reduced water usage and effluent discharge, lower impact on yarn during the dyeing process, and simplified recipe changes.
Indigo Spray Dyeing Moves to Bulk Production
The new spray dyeing technology combines DyStar Indigo Vat 40% Solution, Sera® Con C-RDA, a unique organic reducing agent, and the effective optimisation of spraying parameters for the EPO-patented RotoDyer® and RotoCoater® spraying technologies.
Although rotary atomizers have been established for several decades in the textile industry, they were mainly used for rewetting textiles with moisture. Recent cost pressure and global demand for more sustainable solutions motivated further research and development and led to this technology leap.
Application on Slasher and Rope Dyeing Machines
On sheet dyeing ranges, also known as slasher ranges, coatings including DyStar Indigo Coat, Cassulfon®, Remazol®/Levafix®, and Imperon® dyes can also be applied by spray dyeing following process and layout modifications.
The spray application of fixing agents and oxidation chemicals can be integrated into both sheet dyeing ranges and rope dyeing machines, extending the potential use of the technology across different denim production formats.
Read more: Evolution of Terry Towel Printing with DyStar’s Jettex® Digital Inks
DyStar Indigo Vat 40% Supports Cleaner Denim Processing
DyStar Indigo Vat 40% Solution has remained at the forefront of cleaner dyeing processes for the denim industry. The bulk spray application system represents another step toward offering best-available technology for more flexible and resource-efficient production.
