dyed acrylic fibre – prospects in asia · gel dyeing: advantages • best for uniform dyeing...

Dyed Acrylic Fibre –

Prospects in Asia

B. Chaudhuri

Chief Marketing

Office for Acrylic Fiber business of Aditya Birla Group, Thai Acrylic

8th China International Acrylonitrile & Acrylic Fiber Forum

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Dyed Acrylic Fibre - Prospects in Asia

Presented By:

Biswajit Chaudhuri Ashwini Chotani Eklovya Bajaj Chief Marketing Officer Regional Manager Manager – China Sales Acrylic Fiber businessAditya Birla Group


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Major Businesses - Leadership Position• Viscose Staple Fibre – The largest producer in the World• Aluminum – Worlds most cost efficient aluminum producer

Hindalco-Novelis – Largest aluminum rolling company)• Insulators – The 4th largest producer• Carbon Black - The 4th largest producer• Acrylic Fibre - The 5th largest producer

• Cement – The 9th largest producer• Fertilizers – Amongst the best energy efficient fertilizer plants• Textiles , BPO , Copper etc

•

, , TAF

Capacity (TPA) Turnover ( Rs Crs)

Thai Acrylic Fibre Co. Ltd 113,000 1,300Alexandria Fiber Co.SAE 36,000 300Total 149,000 1,600


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Highest recognition for Highest recognition for Quality Management in Quality Management in the World the World First company in SouthFirst company in South--East Asia to have East Asia to have received this honor in 35 received this honor in 35 years of Award historyyears of Award history

Japan Quality Medal

The National Quality Award The National Quality Award of Thailand,of Thailand,

The Highest Recognition in The Highest Recognition in ThailandThailand


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Different Stages of Dyeing Acrylic Fibre/ Yarn

•Fiber Stage Dyeing ( Stock Dyeing )

•Tow Stage Dyeing ( Stock dyeing )

•Dope stage Dyeing ( Pigment Dyed )

•Gel stage Dyeing ( Gel Dyed )

•Non Bulk Yarn Stage Dyeing

•High Bulk Hank Dyeing

•Fabric Stage Dyeing

•Garment Stage Dyeing

Different Stages of Dyeing Acrylic Fibre


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Type of dyeing Advantages Remarks

Yarn dyeing • Soft feed,• Small lots • Batch to Batch variation

Tow dyeing• Small lots• Better uniformity in yarn• Shrinkable yarn

• Medium size lots with uniform not possible

• Low Tow to top performance

Fiber dyeing • Uniform color in mixing

of • Medium size

• 10-15% lower speed in spg. Compared to gel dyed

• Shade variation in each dyeing batch

Gel dyeing

• Very uniform color possible in very large size lot

• Uniform quality • Easy processing

• Minimum lot size in 3-5 mt/col or 10-15 mt/col

Advantages of different types of dyeing- Yarn stage

Stock Dyeing( Fibre & Tow )

Masses of loose fibers

are placed in large drums into which

dye is pumped and circulated.

Small lot size can be dyed .

Shade Variation from batch to batch

It is not advisable for Bigger lot size

Huge water consumption

High Chemical consumption

Water treatment plant required


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Yarn Dyeing

Cone DyeingNon-bulk yarn Cones are immersed into a dye bath for dyeing.Lot to Lot variation is a common issue. Shade Variation between cone and with in coneOnly non-bulk yarn can be dyed with small lot size.Huge water consumption High Chemical consumptionWater treatment plant required

Yarn Dyeing – High Bulk

Hank Dyeing

High -bulk yarn hanks are immersed into a dye bath for dyeing . Pre-shrinkage of yarn is done before Dyeing.

Lot to Lot variation is a common issue.

Acrylic High Bulk yarn are dyed with small lot size.

Not suitable for bigger Export order.

Good hand feel can be observed in the final fabric.


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Yarn dyeing

Yarn dyeingn dyeing require:

12 Kg water per kg of yarn.( Material to liquor ratio 1:12)

10~12 Kg steam required / Kg of yarn.

10 ~30 gm of cationic softener, acid & other chemicals.

Additional power cost approx 1.5~2.0 KWH/ Kg of yarn.

A Lot of effluent water is generated in fibre & yarn dyeing (Fibre to liquor ratio approx. 1:5).

Effluent water treatment plant -capital investment high.

Strict pollution norms to followed as per country laws.


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Yarn dyeing

Storage of Hazardous chemical & dyes which affect human life.

Investment in boiler is very costly and prone frequent maintenance.

Yarn dyeing cost high approx. 0.5~1.0 USD$/Kg.

Extra manpower and m/c used for drying, hank to cone etc. (0.4USD$)

Is not ecofriendly

Dope DyeingDope Dyeing


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Pigment dyed

• Colorant is added to the spinning solution before the polymer mix is extruded as fibre .

• High wash fastness

• High light fastness. ( more than 7 )

• High UV resistance

• Bigger lot can be produced without any shade variation .

• Application in Outdoor Fabrics, automotive fabrics, carpeting, etc.

Gel Dyeing

Dyeing is quick less than 30 seconds without addition of chemicals.


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Gel Dying: Definition

A Method in which Cationic Dyeing is incorporated in the spinning

process of fibre manufacturing in a way to get the OPTIMUM

UNIFORMITY in the final product.

Gel Dyeing

• In the wet spinning of Acrylic fiber, dope is prepared first for extrusion into a solvent solution, then the drawing, rinsing, oiling and drying stages follow for eventual densification. The process is completed with subsequent crimping, crimp-setting and cutting.

• Before being dried for densification, Acrylic fiber remains gel-swollen, or in other words, spongy, a state which allows the absorption of cationic dye liquor. In short, gel dyeing is the inclusion of the dyeing and fixing processes after the rinsing stage of spinning.


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Gel Dyed Versus Conventional Dyed

Gel Dyeing: Advantages

• Best for Uniform Dyeing & Big Lots. (Lot size >150 MT even is possible).

• Tow Breaking & Spinning performance of Gel Dyed Tow & Fibre is the best and waste generation is lower compared to acrylic dyed by any other method.

• Most Environment friendly process amongst all acrylic dyeing methods. Water requirement is five times less compared to conventional tow dyeing; No extra Energy requirement and negligible dyestuff losses.

• Spinners do not have to follow strict pollution norms.

• Consistency in shade reproduction.


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Gel Dyeing: Advantages

• Dyeing Economy: Lower Energy, Water and Dye requirements and material Handling.

• Better fastness levels: Light, Rubbing & Hot processing.

• Availability of Shrinkable Dyed acrylic in Box-cut permits various innovative blends on the cotton-spinning system.

Gel Dyed: Limitations

• Gel Dyeing Technology is difficult and restricted to few suppliers. Hence sufficient quantity is not available to meet the demand.

• Minimum Lot size: Lot size less than 2.5 MT is a constraint.

• Lead Time is higher vis-s-vis yarn dyeing.


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Gel Dyed : GREEN Fibre

Less dyeing cost approx. – 0.3USD /Kg over Ecru fibreNo inventory of hazardous dyes & chemicals.No investment for boiler cost.Shade development cost and time not required.Steam and water no extra cost No extra manpower & m/c for making hank and again convert in cone.

Present demand of dyed fibre is 250,000 MT/Year.

We estimate that by 2015 the total demand for

dyed acrylic fibre would be 350,000 MT / Yr. which

is about 15~17% of total world demand.

Demand of Gel dyed


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Growth Potential for Gel dyed Acrylic

India 20,000

China 50,000

Iran 15,000

Middle East 10,000

Africa 10,000

dyed acrylic fibre – prospects in asia · gel dyeing: advantages • best for uniform dyeing...

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