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Optimization of dyeing polyester-cotton blends using disperse and direct dyes: a comparison of single-bath and two-bath processes


Journal of Textile Engineering & Fashion Technology
Mohammad Mahbubul Alam,1 Tamim Bin Rafiq,1 Md. Sharif Uddin Sakib,1 A K M Fazlul Nayem Chowdhury,1 Sahanur Alam,1 Sonia Hossain,1 Badhon C Mazumder2

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Abstract

The increasing need for environmentally friendly and resource-efficient textile processing has made optimizing dyeing processes for polyester-cotton blends a crucial component of modern textile production. Using direct and disperse dyes in both single-bath and traditional two-bath processes, this work investigates how to optimize the dyeing of polyester-cotton (TC) blended textiles. The purpose of the study was to assess the repeatability, color strength, fastness characteristics, and dyeing efficiency of several process configurations, including the inclusion and timing of the reduction clearing (RC) phase. Five distinct approaches were examined, and colorfastness was evaluated in accordance with ISO criteria for rubbing and washing, while color strength was measured using the Kubelka-Munk K/S value. The one-bath one-step approach with post-dyeing reduction cleaning performed the best out of all the investigated processes, exhibiting a K/S value of 9.4 and outstanding fastness ratings (5 for both dry and wet rubbing). Conversely, two-bath procedures produced more staining and shade change and lower K/S values (3.02 to 4.80), especially when RC was skipped or performed incorrectly. Color homogeneity and dye fixation were negatively impacted by the lack of RC, particularly for the polyester component. The consistency of the one-bath approach was validated by reproducibility evaluations, particularly when RC applied after dyeing showed a low coefficient of variation (0.589%). These findings establish the one-bath one-step approach with efficient RC as a sustainable and effective alternative to traditional dyeing processes for TC blends.

Keywords

dyeing, disperse, one-bath, reduction clearing, process

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