Before dyeing, fabrics undergo a crucial preparation process called PFD.
This process removes the sizing from the yarns (which allows the dyes to better penetrate the fibers) and semi bleaches the fabric to create a white base for color to be applied.
All dye machines create 2 things:
Movement and heat.
Continuous movement prevents dye from settling unevenly, while heat opens up fibers for dye molecules to penetrate effectively.
Dye houses use specialized machines for different fibers. Polyester machines are long and filled with dye. Cotton machines have a doughnut shape to alternate immersion and air exposure. And all-purpose machines can handle various fibers and be sectioned off for smaller orders too.
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For startups needing small fabric quantities, sampling machines are a great option.
Though more expensive, they allow for lower minimum order quantities and are perfect for brands looking to get their foot in the door with a supplier.
After dyeing, fabrics are dried using a tenter frame in a drying range.
This process is the secret to your clothes not shrinking at home.
The color kitchen is where dyes are stored and mixed.
Modern dye houses use advanced systems of vacuum tubes to transport the mixed color receipes directly from the color kitchen to the dyeing machines.
Dye houses often provide additional services like fabric finishing. These include chemical treatments like waterproof coatings and mechanical finishes like sand-washed jeans.
These techniques can change the look and feel of the fabric.
Quality assurance involves checking for color consistency and fabric shrinkage.
This is one of the most important steps in the process because good fabric creates good garments.
Dye houses have environmental challenges like water and energy use. Efforts to reuse water and transition to greener energy sources are crucial.
It is also important for suppliers to choose eco -friendly, toxin free dyes whenever possible.
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