DyStar and RotaSpray are announcing a saltless dyeing solution for the denim industry. This new technology is awarded important ECO certificates and offers high flexibility for dyeing small lot sizes, reduced water usage and effluent discharge lower impact on yarn in the dyeing process and simplified recipe changes.

The companies developed their indigo spray dyeing procedure for production on a bulk level, which allows denim producers to significantly reduce their environmental impact, according to the manufacturers.

The solution was first introduced at ITMA Milan in 2015. Since then, DyStar and RotaSpray have been working together to develop it further and make it available for bulk production in important denim markets like Turkey, India and Pakistan.

Spray dyeing technology

The new Spray dyeing technology combines DyStar Indigo Vat 40% Solution, Sera Con C-RDA organic reducing agent and the optimisation of spraying parameters of the EPO patented RotoDyer and the RotoCoater spraying technology. Although rotary atomisers have been established for several decades in the textiles industry, they were mainly used for rewetting textiles with moisture. But recent cost pressure and a global demand for more sustainable solutions were motivators for the R&D of the industry and led to the recent technology leap, DyStar explains.

On sheet dyeing ranges (slasher), with process and layout modifications, coatings including DyStar Indigo Coat, Cassulfon, Remazol/Levafix and Imperon dyes can be applied by spray dyeing as well. The spray application of fixing agents and oxidation chemicals can be integrated into sheet dyeing (slasher) as well as rope dyeing machines.

“DyStar Indigo Vat 40% Solution has always been a step ahead of the cleanest dyeing process on the market for the denim industry. This is another innovative step to offer best-available technology to the industry,” the company says.

Specialists

RotaSpray is manufacturing rotating atomisers for tailor-made conceptions in dyeing and finishing of warp yarn, fabrics and nonwovens as well. The company was founded in 2013.

The DyStar Group is a leading dyestuff and chemical manufacturer and solution provider, offering customers a broad portfolio of colourants, specialty chemicals, and services. DyStar also caters to multiple sectors including the paints, coatings, paper and packaging industries. Its expansion into the food and beverages and personal care sectors reinforces the company’s position as a specialty chemical manufacturer.

www.dystar.com