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 which helps denim producers to 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 like Turkey, India, and Pakistan. With the recent breakthrough, they are now announcing a salt-less dyeing solution for the denim industry.
This new technology is awarded important ECO certificates and offers high flexibility for dyeing small lot sizes, reduced water usage and effluent discharge lower impact on yarn in the dyeing process and simplified recipe changes.
The new spray dyeing technology combines DyStar Indigo Vat 40 per cent Solution, Sera Con C-RDA (a unique organic reducing agent) and the effective optimisation of spraying parameters of the EPO patented RotoDyer and the RotoCoater spraying technology.
Although rotary atomizers have been established for several decades in the textile industry they were mainly used for rewetting textiles with moisture. But recent cost pressure and a global demand for more sustainable solutions were motivators for the R&D of the industry and led to the recent technology leap.
On sheet dyeing ranges (slasher), with process and layout modifications, coatings including DyStar Indigo Coat, Cassulfon, Remazol /Levafix, and Imperon dyes can be applied by spray dyeing as well. The spray application of fixing agents and oxidation chemicals can be integrated into sheet dyeing (slasher) as well as rope dyeing machines.
DyStar Indigo Vat 40 per cent Solution has always been a step ahead of the cleanest dyeing process on the market for the denim industry. This is another innovative step to offer best-available technology to the industry.