Water is an important resource in the textile industry that is used extensively for dyeing fabrics. This large water usage leads to significant water pollution from textile dyeing waste. The document discusses several alternative dyeing methods that can reduce water consumption such as bio-scouring, solvent dyeing, air dyeing, plasma dyeing, and compressed CO2 dyeing. These alternative methods aim to lower the environmental impact of the textile industry by reducing water and chemical usage.

2. Total Textile Process at a Glance

4. Water is very important resources in our Ecology. We use this resource in
different purposes. In textile, water is a part & parcel component without this
nothing can be dyed properly. We use a huge quantity of water in dyeing section.
As a result waste water is increased makes water pollution and thus the amount
of this vital resources is reduced.

6. Batch Dyeing
50%
Preparation
27%
Finishing
13%
Boilers
10%
Usage of Water In Textile
Batch Dyeing Preparation Finishing Boilers

9. Water Resources are limited and we need to handle them
reasonably and responsibly. The environmental impact of textile
production is considerable due to the vast quantity of water
required and the variety of chemicals used that generates waste.
Therefore, Water consumption Should be reduced in textile.

10.  Bio-Scouring Method
 Solvent Dyeing
 Air Dyeing
 Plasma Dyeing
 Enzyme Dyeing
 Compressed & Pressurized CO2 Dyeing

11. In bio- scouring process only one bath is used before
the actual dyeing starts, whereas in conventional
process a minimum of 5 baths are used. This leads to
a total 4 bath saving. Considering an MLR of 1:7, the
total amount of water that will be saved is about 28
liters for every Kg. processed. For a unit doing a 30
Mt. of bleaching every day, the amount of water that
will be saved is 840,000 Liters per day. On annual
basis the amounts comes to be 306600,000 liters of
water.

12. With pectinases(enzyme) have shown promise in replacing the traditional alkakine
scouring treatment. Some auxiliaries’ suppliers have introduced an enzymatic
process to remove hydrophobic and other non-cellulosic components forn cotton.
The new bio-scouring process operates at mils pH conditions over a broad
temperature range and can be applied using equipment such as jet machines. It is
claimed that, due to a better bleach ability of enzyme-scoured textiles, bleaching
con be carried out with reduced amounts of bleaching chemicals and auxiliaries.
Bio-scouring enzymes actually make the substrate more hydrophilic (which could
explain better bleach ability), but they are not able to destroy wax and seeds which
are therefore removed in the subsequent bleaching process. There is no need for
the use of caustic soda in enzymatic scouring. So this process reduced pollution
loads, high TDS, BOD and COD in the effluent.

14. A solvent dye is a dye soluble in organic solvents. It is usually
used as a solution in an organic solvent. Solvent dyeing is a
dyeing process carried out from a continuous non-acqueous
phase. Here solvent is used as dyeing media. But water may be
added to assist dyeing process. Since the introduction of
hydrophobic fibers like cellulose acetate in 1920’s solvent have
been considered for Dyeing because it was not possible to dye
such Fibres with ionic dyes and water.

15. Some solvents of chlorinated hydrocarbons of aliphatic series
posses most of the mentioned requirements and hence are being
used as solvents are extensively used such as –
1. Tri-chloro Ethylen (TCE).
2. Per-chloro Ethylen (PCE).
3. Methyl Chloroform (MC).
All three solvents are almost equally suitable but tri-chloroethylene
has very high stability to decomposition and hence isomers
preferable.

16. Air Dye technology manages the application of color to
textiles without the use of water.It was developed and
patented by Colorep, a California-based sustainable
technology company.The process of making textiles can
require several dozen gallons of water for each pound of
clothing. The Air Dye process employs air instead of water
to help the dyes penetrate fibers, a process that uses no
water and requires less energy than traditional methods of
dyeing, The technology works only on Synthetic
material and is currently available only in the United States.

17. Airflow Dyeing Machine

19. Evaporate
Curve
Gas

21. AirDye® Technology
AirDye Solids AirDye Singles AirDye Wovens AirDye Contrast
AirDye Solids dyes both
sides of a fabric a single
color.
AirDye Singles prints one
side of fabric while
leaving the other side
undyed.
AirDye Wovens
simulates dyed woven
jacquard and dobby
weave.
AirDye contrast dyes
opposite sides of fabric
two different colors.
Print-to-Solid AirDye Imprints Print-Contrast Print-Squared
Print-to-Solid prints one side
of fabric and dyes the other.
AirDye Imprints dyes or
prints an image or logo
on fabric.
Print-Contrast prints
opposite sides of fabric
with different designs.
Print-Squared prints
opposite sides of fabric
with the same design.

22. 1. Water and Chemical (Disperse agent, Leveling agent, and RC agent) is needlessness
2. Drain treatment and Dryer is needlessness
3. CO2 is possible for recovery use(Recovery Rate 96%)
4. From these merits, we can say that Super- critical Dyeing and Treatment contributes to the
environmental damage and it is not influenced by water resources.
5. 43% of energy reduction is possible.

23. Low liquor ratio based dying machine

25. Plasma, as a very reactive material, can be used to
modify the surface of a certain substrate (typically
known as plasma activation or plasma
modification), depositing chemical materials (plasma
polymerisation or plasma grafting) to impart some
desired properties, removing substances (plasma
cleaning or plasma etching), which were previously
deposited on the substrate (Pane, et al 2001).

26. Plasma technology is a surface-sensitive
method that allows selective modification in
the nm-range. By introducing energy into a
gas, quasi-neutral plasma can be generated
consisting of neutral particles, electrically
charged particles and highly reactive
radicals. If a textile to be functionalized is
placed in a reaction chamber with any gas
and the plasma is then ignited, the
generated particles interact with the surface
of the textile. In this way the surface is
specifically structured, chemically
functionalised or even coated with nm-thin
film depending on the type of gas and
control of the process.

27. Various application of plasma in textile.
APPLICATION MATERIAL TREATMENT
Hydrophilic finish PP, PET, PE Oxygen plasma, Air plasma
Hydrophobic finish Cotton, P-C blend Siloxane plasma
Antistatic finish Rayon, PET
Plasma consisting of dimethyl
silane
Reduced felting Wool Oxygen plasma
Crease resistance Wool, cotton Nitrogen plasma
Improved capillarity Wool, cotton Oxygen plasma
Improved dyeing PET SiCl4 plasma
Improved depth of
shed
Polyamide Air plasma
Bleaching Wool Oxygen plasma
UV protection Cotton/PET HMDSO plasma
Flame retardancy
PAN, Cotton,
Rayon
Plasma containing phosphorus

28. There are many different ways to induce the ionization of gases.
i)Glow discharge
ii)Corona discharge
iii)Dielectric Barrier discharge
iv)Atmospheric pressure plasma technique.

29. # Products that can bring the desired effect using fewer
amount of chemical
# Solutions that increase the efficiency of a process resulting
in saving water and energy, as well as time and costs
What BASF offers

30. Eco-efficient Solutions
Cyclanon® XC-W New: After-soaping agent for reactive-
dyed cellulose fibers. Compared to the conventional
process, it considerably shortens the processing
time, saving both water and energy.
Helizarin® ECOSOFT Printing System:
Eco-efficient pigment printing solution that significantly
reduces the consumption of water and energy compared to
reactive printing due to its shorter processing time.

31. Water-friendly enzymes enter the fashion world
China is one of the world’s largest textile producing countries, contributing a sizable
portion of the estimated 9 million tons of knitwear manufactured globally every year.
With the production of 1 ton of cotton knitwear consuming what corresponds to the
daily water usage of 600–700 urban Chinese people, the Chinese government
recently intervened in an attempt to improve this use of resources. As of 2011, new
legislation caps the maximum water consumption by textile plants at 100 tons of
fresh water per ton of cotton knitwear. A life cycle assessment (LCA) reveals that
enzymes can help manufacturers to overcome this challenge.
Clear benefits of using
enzymesChinese manufacturer Esquel has performed several trials incorporating Novozymes’
enzyme-based solution known as elemental textiles. In the LCA, for the concept in use
Esquel reported savings of 30 m3 (or 30 tons) of water per ton of knitted fabric in just a
single bleaching process when substituting enzymes for chemicals.

32. Eco-efficient Solutions
Cyclanon® XC-W New: After-soaping agent for reactive-
dyed cellulose fibers. Compared to the conventional
process, it considerably shortens the processing
time, saving both water and energy.
Helizarin® ECOSOFT Printing System:
Eco-efficient pigment printing solution that significantly
reduces the consumption of water and energy compared to
reactive printing due to its shorter processing time.

33. As water is a viatl resources but it is poluued by different ways
day by day. As a textile related persion it is our concern to
minise the water consumption in textile sector to save the water
resources from being polluted. We have already discussed about
the some methods to reduce the use of water in textile sector

34. • Evolution or revolution?
– Right first time
– Best available technology
– Re-cycling
– Liquid carbon dioxide
– Marginalisation of cotton (Kyoto style targets)
– Product labelling based on facts not hype

35. • Water ‘use’ is not always an issue
• Pollution is the major issue
• Energy use associated with water use is a major issue
• Focus on industry not domestic
• Best practice could halve water consumption in dyeing

38. 1. Yarn Manufacturing Technology
Link : http://www.facebook.com/pages/Yarn-Manufacturing-
Technology/485014954866808
2. Fabric Manufacturing Technology
Link : http://www.facebook.com/pages/Fabric-Manufacturing-
Technology/459520217425605
3. Garments Manufacturing Technology
Link : http://www.facebook.com/pages/Garments-Manufacturing-
Technology/472364799463126
3. Wet processing Technology
Link : http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-
/468645219825404
4. Fashion-Design-and-Technology
Link : http://www.facebook.com/pages/Fashion-Design-and-
My Facebook Textile related Pages
http://www.textilelab.blogspot.com (Visit )