PENCELUPAN POLIESTER

DENGAN ZAT WARNA

DISPERSI METODA KONTINYU
(PAD THERMOSOL)

oleh

Dede Karyana, S.Teks. M.Si.

KEUNGGULAN DAN KELEMAHAN
METODA CELUP PAD TERMOSOL

–Produktifitas dan Effisiensi

Tinggi
–Produksi Masal
–Kecerahan Hasil Celup Agak
rendah
 Perbedaan antara pencelupan metoda
perendaman dan kontinyu
Metoda Pencelupan Perendaman Kontinyu
Konsentrasi Zw. rendah dan tinggi dan
dalam larutan konstan
celup berubah
bertahap

Laju Pencelupan rendah tinggi

Kondisi pencelupan suhu berubah suhu konstan

Resiko belang rendah tinggi

Efek variasi bahan kecil besar

terhadap kerataan (tereliminasi) (sangat peka)
 (LANJUTAN)
Metoda Pencelupan Perendaman Kontinyu
Efek peralatan abn. kecil besar
terhadap kerataan (tereliminasi) (sangat peka)

Kualitas hasil celup sangat baik baik

Peralatan 1 mesin untuk 1 mesin untuk

seluruh proses tiap proses

Biaya Mesin rendah tinggi

Efisiensi dan pro-

duktitivitas rendah tinggi
 DIAGRAM ALIR :
PERSIAPAN
(Bahan, mesin, larutan celup)

PENCELUPAN

CUCI REDUKSI

PENGERINGAN
 SKEMA PROSES
Pre Drying,
90 0C

Pengeringan Termosol, 200 – 220 0C,

100 0C, 1 menit 1 menit
Pad Lar Zw
Dispersi

Pengeringan

Cuci Reduksi dan pembilasdan

 RESEP LARUTAN PAD :

– Zat Warna Dispersi x g/l

– Pendispersi 1-2 cc/l
– Asam Asetat 30 % 1-2 cc/l
– Zat Anti Migrasi 5-10 cc/l
– WPU 50 - 60 %
 KIAT-KIAT AGAR HASIL CELUP RATA

• Kondisi Kain
– Telah dilakukan pretreatment sehingga
rata secara fisika dan kimia.
– harus dingin dan bersih (lebih bersih
dari bahan untuk pencelupan cara
perendaman).
– tidak ada lipatan
 State of material to be dyed
(Material requirement)
1. Material should be dried uniformly and have
uniform water content across the width and
along the leng of fabric.
2. Material should be cooled to room
temperature in order to prevent the
temperature increase of padding liquor
3. The application of padding liquor is to be
completed in few seconds, so that material
should be those which have been uniform
pretreatment (desizing, scouring, bleaching
and heat setting)
 State of material to be dyed
(Material requirement)
4. In the pre treatments such as desizing,
scouring, bleaching and heat setting, material
should be uniformly treated
5. A formation of creases in the fabric results in
unlevel dyeing, so that it is necessary to pay
special attention tojoint of fabric wit an end
cloth.
6. The fabric should be pre treated in a
sufficiently relaxed state. Padding under strong
tension may lead to poor penetration.
KIAT-KIAT AGAR HASIL CELUP RATA
(lanjutan)
• Pemilihan jenis zat warna tepat
– Good dispersibility
– Good build up and high fixation in
thermosoling treatment
– Low dependence on thermosoling
temperature
– Good stability to oxidative decomposition
– Good fastness properties
– Minimal color change by resin finishing
 KIAT-KIAT AGAR HASIL CELUP RATA
(lanjutan)
• Suhu dan konsentrasi larutan zat warna di
bak padding harus konstan
• Pemilihan jenis dan konsentrasi zat
pembantu (pendispersi, zat anti migrasi
dan asam) harus tepat.
 KIAT-KIAT AGAR HASIL CELUP RATA
(lanjutan)
• Kondisi dan setting peralatan mesin harus
baik.
– Unit padding
• Volume bak padding sekecil mungkin
• Kekerasan rol pad rata dan tidak ada cacat
• Setting tekanan rol padding tepat dan rata
• Sistem penyuapan larutan zat warna ke
bak harus baik
 Sistem Pad :
a. 1 Dip 1 Nip b. 2 Dip 2 Nip
 Cara mengecilkan volume bak
padding
• Volume larutan sedikit, perendaman
singkat

diberi diberi rol-

spacer rol spacer
• Padding trough should be designed so
that a high degree of penetration can be
obtained by minimizing the volume of
padding liquor in order to achieve uniform
and rapid penetration of padding liquor
into the materials
• The squeezing of fabrics with rubber
rollers should be carried out at a proper
pick up that is uniform from side to side
and side to center
• Proper pick up is determined by hardness
and diameter of rubber rollers, the
structure of fabrics, the kind of fiber, the
form of subsequent treatment and the like.
• To prevent in variation in pick up from side
to center, uniformalize the pressure
distribution is employed by making a
different in diameter (crowning) between
the center and both the sides of one of the
two rollers (generally, non driven roller)
 Problem with dyes in padding
1. Tailing

Vat dyes on cotton

concentration of
pad liquors (%)
Relative dye

100

Disperse dyes on polyester

Padding time
 Effect of migration inhibitor to tailing
Relative dye concentration of pad liquors (%)
{% of ratio depth of shade 30 cm to 4 m after padding process)

Migration inhibitor No Sodium alginat Tamanori SA 25

Dyes addition 0,5 g/L 2,0 g/L 5 g/L 20 g/L

S. Orange SE-B 96,7 97,4 98,3 100,2 98,1

S. Turq. Blue S-GL 95,4 95,8 97, 3 95,3 98,9
• Factors with respect to dyes affecting such a change in
concentration of padding liquor include particle size and particle size
distribution of dyes and the stability of dispersion
• Also tailing is caused by deteriorated dispersibility due to the poor
compatibility with auxiliaries used together for padding and the
prolonged padding operation
 2. Speck (bintik noda)
• Large factor causing specks is
– Poor compatibility of dyes and auxiliaries
– Coarse dye particle more than 30 micron
– Dye aggregation
– Dye dispersion liquor used and stored for a
fairly long period
• So that in practical dyeing operation,
padding liquor should be prepared
carefully
 3. Listing
• Listing refers to a phenomenon in which variation
in depth ad shade occur on dyed fabric owing to
uneven dye uptake from side to side and side to
center
• As causes of listing are as follow :
1. Uneven drying before padding
2. Uneven squeezing
3. Uneven padding liquors temperature
4. Uneven padding liquors feeding
5. Uneven fabric temperature
6. Variation in dye migration due to air speed
7. Temperature dependence of disperse dyes
during thermosoling
KIAT-KIAT AGAR HASIL CELUP RATA
(lanjutan)
– Unit Drying
• Setelan kecepatan angin tidak terlalu
cepat
• Menggunakan rol khusus shg zat warna
tidak nempel ke rol –rol mesin pengering
• Setelan suhu tepat, tidak over dyring
sehingga tidak terjadi pengerakan zat
warna di permukaan kain
KIAT-KIAT AGAR HASIL CELUP RATA
(lanjutan)
– Unit Termosol
• Kondisi heater baik, suhu diatas dan
dibawah kain sama
• Setingan suhu tepat sesuai dengan
jenis zat warna dispersi yang
digunakan
• Kecepatan angin pemanas serendah
mungkin
 Arigato gozaimasu

Thank for your attentions