As helpful application programs, quick guides or simply as an occasional form of entertainment, apps play a major role in almost all areas of our modern society and it is hard to imagine everyday (working) life without them.
Most industries have long recognized the benefits and want to offer their customers excellent service when they are on the go, and the textile industry is no exception.
The CHT Group recognized the potential of apps at an early stage and already assumed a pioneering role more than 10 years ago by launching its own dye app on the market.
In addition to the extensive product information with practical application examples, several helpful calculation programs have also been created over the years which were developed with the aim of making textile dyeing more reproducible, economic and ecological. Four calculation programs are currently available to users free of charge:
- BEZAKTIV Soaping Advisor: For an economically optimal and at the same time very sustainable combination of rinsing processes when dyeing with reactive dyes to achieve a certain fastness level
- BEMACRON Advisor: For the best levelness when dyeing polyester with disperse dyes by calculating the optimum heating gradients and dye combinability
- BEZAKTIV GO Calculation Program: To determine the savings in resources when dyeing with more ecological CHT reactive dyes in comparison with conventional products on the market as well as traditional processes
- WellVAT: For calculating exactly the right and individual quantities of chemicals and dyeing auxiliaries for efficient and ecological dyeing with vat dyes
BEZAKTIV Soaping Advisor
When dyeing cotton with reactive dyes the rinsing and soaping process consumes by far the most water and energy and takes up the most process time. If the aim is to reduce consumption of resources and the process time, this is most effectively achieved during dye rinsing.
The BEZAKTIV Soaping Advisor enables calculation of the fastness rating in advance, taking the respective dye properties and process conditions into account. This makes it very easy to simulate and therefore optimize alternative soaping processes.
Figure no. 1 shows the calculation of a typical rinsing process with a liquor ratio of 1:8. To achieve a rating of 4-5, six rinsing baths are required, two of which at boiling point. If, on the other hand, as shown in figure no. 2, the liquor ratio during rinsing is increased to 1:12, then four rinsing baths are sufficient, of which only one at boiling point is necessary.
Although the water consumption increases slightly, the energy savings and in particular the reduction in the length of the process are considerable. In other simulations it can be seen that increasing the rinsing temperature, for example, can be sufficient to save one rinsing bath.
The process optimizations are particularly impressive when simultaneously switching from standard dyes to the very easily washable dyes from the BEZAKTIV GO / ZERO GO range. It can then be seen very clearly that the dye hydrolyzate can be removed with just a few rinsing baths at low temperatures, which at the same time reduces energy and water consumption tremendously and also significantly shortens the process time.
The big advantage of the BEZAKTIV Soaping Advisor is that alternatives to the rinsing process can be evaluated for individual dyeing recipes in seconds.
The program therefore offers all companies an extremely easy way of structuring its production processes to be more cost efficient and to conserve resources. Savings in water, energy and time can be tremendous without any need for investment. In terms of sustainability, there is hardly a more groundbreaking solution than a process that is perfectly tailored to the individual batches.
The heating gradient plays an important role in achieving good levelness during disperse dyeing. However, the question of which heating gradient provides the most optimum solution is extremely complex, especially because the dye is mainly supplied in the form of undissolved particles and is only gradually dissolved over the course of the dyeing process and can only diffuse into the PES fibers in this way.
For an optimum heating gradient, the dye supply and demand must be balanced at all times. With the aid of comprehensive measurements, the relevant parameters of all BEMACRON dyes were determined to define algorithms that make it possible to calculate the optimum heating rate for any temperature range and for any dye recipe.
Figure no. 3 shows the temperature interval and heating gradient which result in an optimum compromise between levelness and the shortest possible process time for a dye recipe. The temperature curve with the corresponding bath exhaustion can also be displayed as a graph (figure no. 4)
BEZAKTIV GO and BEZAKTIV ZERO GO are reactive dye ranges that can already be dyed and rinsed out at 40 °C or 60 °C. Due to their good washability, the number of rinsing baths can usually also be reduced in comparison with standard dyes.
In addition to the ecological and economic benefits from the energy and water savings, there is an additional tremendous economic advantage from the increase in productivity which is achieved by shortening the process time.
With the BEZAKTIV GO calculation program, the savings realized in comparison to dyeing with standard dyes can be calculated for each dye recipe, taking the individual company cost structure into account. Figure no. 5 shows an example of such a comparison.
WellVAT is a program that calculates the optimum quantities of chemicals and dyeing auxiliaries for each recipe with BEZATHREN dyes. As specific dye and process factors are taken into account, the actual requirements can be covered much more accurately than with the usual standardized recommendations, resulting in significant potential savings while maintaining a very high process reliability.
Figure no. 6 shows a typical recipe recommendation as calculated after previously entering all relevant process parameters. The requirements for dyes and chemicals are given both as concentration (left column) and a total weight (right column) for the calculated batch.
The CHT Textile Dyes App is continuously optimized and updated by the dye experts and regularly adapted to market and customer needs. The app can be downloaded from the Apple and Google Play stores and is available to users free of charge after one-time registration.