25/3/2017 DifferentmethodofSpaceDyeingVariousmethodofSpaceDyeing

MethodsofSpaceDyeing
Writtenby:AshokAthalye

Therearevariousmethodsofspacedyeingondifferentformsofyarn.

Hank or Skein printing: The ready to dye yarn in hank or skein form is mounted on a stand or laid on a suitable
surface and then different colors are applied either by
brush or by spraying at fixed places to achieve the
desired multicolour effect. Depending on the type of
substrate and the dyestuffs used the hanks are then
processed for suitable dyefixation followed by
finishing. Though, this method imparts controlled yarn
coloration at specified points and desired length, the
process is cumbersome and time consuming and is
mainlysuitableforshortlengthfabric.

Space dyeing in package form: Depending on the machinery available and the effect desired, the yarn printing in
packageformisdonebytwomethods:

1.Manualoperation:Colorsareinjectedbyhandatdifferentplacesinthepackageusingasyringefilledwiththedye
solution. The skill set developed by the technicians enable them to insert the needle in the package horizontally,
verticallyoratvariousanglesandreleasethecolorwhiletakingtheneedleoutsothattherequiredamountofdyeis
appliedatthespecifiedplaceinthepackage.

Another variant of this method is dipstick process. In this case different places of the yarn package are dipped in
different dye solution so that multiple colors get applied at various places and with varying intensity which after
unwindingofyarnprovidesauniquefancydyedeffect.

2. Machine processing: The ready for dyeing yarn is pretreated as per the standard application process for the
specifiedsubstrateanddyedinasinglepackageforminamachinewhichcandyeupto8colors.Eachcolorhasa
different feed tank as well as injector pump. The color is injected at a fixed place at high pressure and the excess
coloriscollectedthroughvacuum.Thiscreatesbeautifulpatternsofdyedpatchesonpackagewithgoodsharpness.
Subsequently the colored yarn package is given adequate dye fixation treatment followed by washing off of unfixed
superficialdyeandfinishingwithayarnlubricant/softener.

http://www.fibre2fashion.com/industryarticle/printarticle/7462 1/3
25/3/2017 DifferentmethodofSpaceDyeingVariousmethodofSpaceDyeing

Knit de knit process: This process involves first knitting the yarn on a circular or flatbed knitting machine into a
tubularfabricfollowedbyprintingusingengravedrollersandthenunravelingtheknittoproduceaspacedyedyarn.As
theprintedcolordoesnotreadilypenetratetheareasoftheyarnwhereitcrossesitself,alternatelydyedandundyed
spacesappear.Inanothermethod,thepredyedknittedmaterialisoverprintedwithdifferentcolorsandsubsequently
deknittedtoproducecontrasteffectofoverprintedandbasedyedareas.

Thisimpartsaunique'microspaced'design,owingtothelimiteddyediffusionduringtheprintingstage.Theunraveled
printedyarnisrewoundontoconesandusedforsubsequentknittingorcarpetweaving.Since this process achieves
limited dye penetration into the yarn, as the pressure exerted by the printing rollers is insufficient to insure adequate
dye diffusion, incomplete and nonuniform coloration may result. Also, there is a characteristic curl to the unraveled
yarnduetopreknittingwhichaffectscutpileofcarpets.

Continuous or warp yarn printing: In this process multiple strands of yarn are continuously printed at spaced
intervalswithdifferentcolors.Theseyarnsusuallyhavelongspacesofeachcolorspacedatabout3to7inches.The
yarn is dyed as singles or piled form and the color is applied either by air jets or dye troughs. Given below are few
methodsofcontinuousyarnprintingforachievingspacedyeingeffectbasedontheinformationgleanedfromvarious
patentedprocesses.

One of the methods describes yarn dyeing at intervals along its length as it runs at very high speed through spaced
dye baths. Another method specifies systems where yarns are taken from wound packages on a creel and color is
applied,eitherbylickrollersorbyaspinningdiscapplicator.Suchwarpprintingimpartsa'longspacing'designwhich
isgenerallypreferredformanufacturingoftuftedcarpets.

Oneprocessindicatespassingofyarnsbetweenapairofcylindersaroundthesurfaceofwhicharemountedrowsof
smalldyeapplicatorpads.Thelowercylinderisdippedintoatroughofdyeliquorwhichgetspickeduponthesurface
ofthepadsandwhentheopposingpairsareintheraisedpositiontheyarnpassingbetweenthemgetsprinted.

http://www.fibre2fashion.com/industryarticle/printarticle/7462 2/3
25/3/2017 DifferentmethodofSpaceDyeingVariousmethodofSpaceDyeing

Another method proposes space dyeing by running yarn through the nip of printing rollers which have patterned
groovesontheouterperiphery.Inthisapparatus,theprintingrollersapplydyetotheyarnonlywhenthelandsofthe
tworollersarealignedacrossthenip.Anotherprocessincorporatesprintingrollerswithgroovesabouttheirperipheries
toprovideagearlikeappearance.Thus,whentheyarnisdeflectedintothenip,thatportionoftheyarnwhichpasses
through the nip gets intermittently printed to achieve closely spaced marks or dots and thus further vary the dye
patternappliedtotheyarn.

The advantage of space dyeing process over conventional solid dyeing is not only in terms of the intended special
effect but also in terms of reduced consumption of dyestuff and chemicals, avoidance of printing thickener and
considerablereductionineffluent.However,thechallengesassociatedwithspacedyeingprocessincludeprocessto
avoidmixingoroverlappingofcolorsalongthelengthofyarnandontheadjacentyarnswhichotherwisetendtoresult
invisiblestreaksonthefaceofthefabricaffectingitsappearance.

Anotherissuepertainstotendencyofdyemigrationduringthesubsequentheatsettingoperationresultinginblurring
of adjacent color bands affecting its appearance. Further, there is a chance of dye dripping or contact mark off
between different yarn layers resulting in unwanted patches. Moreover, the dye overspray from the various colors
beingappliedoftenmixtogetherinasinglecollectionsystem,whichresultinaddedcostsforreplacementofdyeas
wellasforwastehandlinganddisposal.Thishasnecessitatedfurtherdevelopmentofaninlineprocessforcontrolled,
efficientandrepeatablespacedyeingofyarn.

Conclusion:
Space dyeing is a technique used to give yarn a unique, multicolored effect. When woven or knitted together for
apparel, home furnishing and carpet making, beautiful patterns can emerge depending on the length and variation of
each color block. Adequate use of dyes and auxiliary chemical combined with specialized machines can create
finished product as some of the best in the world. Presently the 'Space Dyeing' segment occupies a miniscule (less
than1%)shareinthetextilecolorationspace.However,consideringitspotentialtoofferuniqueandcustomizedprint
designeffectsithasgreatpotentialtogrowbymanyfoldsinthenearfuture.

References:

1.WarrenS.Perkins,August1991,AReviewofTextileDyeingProcessesVol.23
2.ShangnanShuiandAlejandroPlastinaFAO/ICACWorldApparelFibreConsumptionSurveyICAC2013
3.Googleimages
4.Wisegeek.com
5.Wyspinners.com

http://www.fibre2fashion.com/industryarticle/printarticle/7462 3/3