Dyed Acrylic Fibre Prospects in Asia

Size: px

Start display at page:

Download "Dyed Acrylic Fibre Prospects in Asia"

Sydney Myles Cook
5 years ago
Views:

1 Dyed Acrylic Fibre Prospects in Asia B. Chaudhuri Chief Marketing Office for Acrylic Fiber business of Aditya Birla Group, Thai Acrylic

2 Dyed Acrylic Fibre - Prospects in Asia Presented By: Biswajit Chaudhuri Ashwini Chotani Eklovya Bajaj Chief Marketing Officer Regional Manager Manager China Sales Acrylic Fiber business Aditya Birla Group 55

3 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 4 th largest producer Carbon Black - The 4 th largest producer Acrylic Fibre - The 5 th largest producer Cement The 9 th 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 1,300 Alexandria Fiber Co.SAE 36, Total 149,000 1,600 56

4 Japan Quality Medal Highest recognition for Quality Management in the World First company in South- East Asia to have received this honor in 35 years of Award history The National Quality Award of Thailand, The Highest Recognition in Thailand 57

5 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 ) Different Stages of Dyeing Acrylic Fibre Non Bulk Yarn Stage Dyeing High Bulk Hank Dyeing Fabric Stage Dyeing Garment Stage Dyeing 58

6 Advantages of different types of dyeing- Yarn stage Type of dyeing Advantages Remarks Yarn dyeing Soft feed, Batch to Batch variation Small lots Tow dyeing Medium size lots with Small lots uniform not possible Better uniformity in yarn Low Tow to top Shrinkable yarn performance Fiber dyeing Gel dyeing Uniform color in mixing of Medium size Very uniform color possible in very large size lot Uniform quality Easy processing 10-15% lower speed in spg. Compared to gel dyed Shade variation in each dyeing batch Minimum lot size in 3-5 mt/col or mt/col 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 59

Huge water consumption High Chemical consumption Water treatment plant required Yarn Dyeing High Bulk Hank Dyeing High -bulk yarn hanks are immersed into a

7 Yarn Dyeing Cone Dyeing Non-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 cone Only non-bulk yarn can be dyed with small lot size. Huge water consumption High Chemical consumption Water 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. 60

10 ~30 gm of cationic softener, acid & other chemicals. Additional power cost approx 1.5~2.0 KWH/ Kg of yarn.

8 Yarn dyeing Yarn dyeing n 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. 61

9 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 Dyeing 62

10 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. 63

11 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. 64

12 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. 65

13 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. 66

14 Gel Dyed : GREEN Fibre Less dyeing cost approx. 0.3USD /Kg over Ecru fibre No 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. Demand of Gel dyed 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. 67

15 Growth Potential for Gel dyed Acrylic India 20,000 China 50,000 Iran 15,000 Middle East 10,000 Africa 10,000 68

Amar A. Bhoyar 1, Shrikant M. Fulmali 2, Vishal D. Ramteke 3 1,2,3 Department of Mechanical Engineering (Shift-II), B.D.C.E.

Design and Experimentation of Automatic Cloth Dyeing Machine Amar A. Bhoyar 1, Shrikant M. Fulmali 2, Vishal D. Ramteke 3 1,2,3 Department of Mechanical Engineering (Shift-II), B.D.C.E., Sewagram Abstract