Wet Processing

Reactive Wash-Off Dilution Series & Water Demand

Residual falls exponentially with the number of baths and only linearly with the water in each. Baths beat volume, every time.

After Dyeing What is left to remove
% owf

Total reactive dye on the recipe

%

Share covalently bound. The rest is hydrolysed and must come off

Rinse Geometry What each bath removes
%

Liquor the fabric carries out of a bath, on fabric weight

:1

Fresh water per kilogram in each rinse bath

nos

How many drain-and-fill cycles the sequence uses

% owf

Unfixed dye left on the fabric that the staining test will accept

Residual Unfixed Dye

— ppm

On fabric weight after the rinse sequence

Series & Water

Unfixed Dye to Remove
— % owf
Fraction Surviving Each Bath
— x
Residual After Sequence
— % owf
Baths Needed for Target
— nos
Water Used by Sequence
— L/kg
Water Needed for Target
— L/kg
Single Bath Ratio for Same Result
— :1
Water Penalty of the Single Bath
— L/kg

The series assumes each bath reaches equilibrium before it drains, which is a fair description of a batch machine given a few minutes of circulation and a poor one of a continuous washing range, where counter-current flow does better than this model predicts and the right comparison is stages rather than baths. It also assumes the dye is free in the liquor: hydrolysed dye that has back-stained onto cellulose or, worse, onto an elastane or polyamide component is not governed by dilution at all and needs temperature, a soaping agent or a reduction clear, none of which appear here. Pick-up is the single most sensitive input and the one most often guessed - the difference between an efficiently squeezed 60 percent and a lazily drained 120 percent is a factor of two on every bath in the series, compounding. Take it from the machine by weighing fabric in and out rather than from a handbook. The single-bath comparison is a rhetorical device rather than a proposal; it is there to show the shape of the mathematics, and the practical readings are the bath count and the water figure beside it.

Reactive Wash-Off Dilution Series & Water Demand — free, with the formula and a worked example, at Textile School.