“Zero effect” on TC 65%Polyester and 35% Cotton

Normally, Kongkiat recommends our customers to do the zero effect on 100% cotton but we also presents that “Zero effect” can be treated on TC also. Now one of our customers in local market is working on TC “Zero yarn” and I would like to present it to you again here. Due to the fact that the “Zero effect” will show after dyeing with reactive dyestuff. I this case the “reactive dyestuff” is used for dyeing in piece dyeing process. Not only you can get the “stripe Zero effect” but you also get the melange-like effect because reactive dyestuff cannot absorb into polyester part as you can see in the picture shown below.

Using TC as the main material which compose of 65% polyester and 35% cotton can reduce the cost of fabric significantly if your market really rely on the price of course , it is not suitable on every market in your country. This composition of material with Zero effect is suggested for “Mass market” that you have to manipulate the large amount of yarn and fabric in the production and garment.However, it should worth the effort that you put into it. Moreover, the nature of working with “Zero yarn” , you can keep to stock as yarn or even the fabric so that you do not have to concern about the leftover on order to order that much. You can still use the yarn with other order as you like without fading of the effect at all.

What is “Zero yarn” and Why ?

What is “Zero yarn” ?

“Zero yarn” is one of our prepared-for-dyed effect yarn which seem like regular raw white cotton yarn.However, the yarn is pretreated in dyeing process with fancy effect manufacturing process to increase the absorptivity or affinity of reactive dyestuff. This partial pretreatment on cotton yarn causes some parts of yarn get much stronger color depth than the untreated parts when the “Zero fabric” is dyed in piece dyeing process.

How “Zero RW” works?

Zero yarn concept :

“Zero yarn” is one of the innovative products in textile industry which created by “Kongkiat Textile Company”. The yarn itself does not have the dye color on it; however, the color effect will show only on fabric after performing the “piece dyeing: process or even the garment dyeing process.

“Zero yarn” can be knitted or weaved and transformed to be the fabric without color at all. Then the fabric is run though the dyeing process as fabric at the dye house. During the piece dyeing process, the dye stuff is absorbed to the particular parts of fabric which is the main property of “Zero yarn”. At the end of the dyeing process, you will get the fabric with the two-shade colors (one is lighter and one is darker) on it by dyeing as the regular dyeing process for cotton at the dye house.

Zero yarn properties :
“Zero yarn” is 100% cotton so you can target the cotton market which is the biggest share on the textil market. With our process to produce the “Zero yarn”, it means that you can reduce the effect to the environment comparing to the regular package dyeing process. Moreover, there is no toxic to the end users. It works just like the regular cotton fabric but it has the color effect after dyeing process.

Value stream of benefits using “Zero yarn” :
- As the manufactures, “Zero yarn” works just like the raw white cotton yarn so that you can use in knitting , woven or sweater. Then proceed the piece-dye process at the dye house but still getting the unique coloring effect on the fabric after all.
- As the traders or importers, you can now order “Zero yarn” in large quantity then proceeding through the dyeing process with any color trend. As the result, the over all lead time of the products can be reduced significantly.
- As marketers, you can promote it as the “INNOVATIVE”, or “ECO FRIENDLY” product as it is really reduce the cost on environment comparing to the regular yarn dyeing process.
- As designers, you can create the new fashion design by using our concept and color effect on knitted fabric, woven fabric or even sweater. It just like the break though concept products that can really be produced to the mass market.

When knitting or weaving mill gets the “Zero yarn” , they will notice that it seems like normal raw white yarn.Then “Zero yarn” is knitted or woven to be fabrics. These knitted or woven fabrics have been dyed with reactive dyestuff. The stripe effect appears with more color strength than background color on the same fabric.

How to knit or weave “Zero yarn” ? and how to lower the total cost of fabric?

“Zero yarn” is suitable for knitting and weaving process to make the “Zero fabric”. “Zero yarn” can be knitted as 100% “Zero yarn” but you can lower the total cost of fabric by knitting with raw white cotton as stripe or knitting “Zero yarn” with raw white cotton yarn every other feeder which can reduce the cost of “Zero yarn” down to 50% can you still almost get the same amount of “Zero effect” along the fabric. This knitting method can reduce significant cost of fabric. Kongkiat also recommend this kind of method because it also expands the market from niche fashionable market into mass market in a very short time as our Thai customers enjoy the benefit from it.

Please see the following pictures comparing the “Zero effect” with different feeder in single jersey knitted fabric.

How to dye “Zero fabric”?

“Zero fabric” as you know now , is knitted or woven from “Zero yarn” and it must be dyed with reactive dyestuff ;however, there are some the restrictions for dyeing “Zero fabric”. The dyestuff should be not be exceed 2.5% (by weight of fabric) because it will sightly blur up the “Zero effect”. The background color and the “Zero effect” is not much different in depth so that you cannot see the effect clearly. Kongkiat suggests every dye house to do the lab dip (testing before dyeing) and confirm the color and the color effect to the customers or designers before the real production is proceeded. Moreover, the “Zero fabric” cannot resist the strip chemical or bio-washing chemical. In case of dyestuff overdose,the only way that the dye house can do to fix the problem is soaping out the dyestuff only; however, lab dip is need to be done before run the process.

Garment dyed process can be done with our “Zero fabric” also. The garment can be knitted as stripe or as 100% zero yarn.

For the pretreatment on fabric , the dye house can use the regular pretreatment chemical and process just like it uses with regular cotton dyeing; however, please refer to the strength of chemical that we also recommend to our customers . The pretreatment processes are included : “SCOURING” , “BLEACHING” , “BLEACHING with O.B.A.” pretreatment. the fabric pretreatment is depended on the color and the brightness of the color that the dye house would like to reach.

 A.) For the lighter shade, the “BLEACHING” pretreatment can be applied; however, the color effect may be reduced during the bleaching process.

“BLEACHING” PRETREATMENT :
Scouring Agent 1-2 g/l
Chelating Agent 1 g/l
Stabilizer 0.5 - 1 g/l
NaOH (50%) 3 g/l
H2O2 (Hydrogen concentration peroxide (50%) 5 g/l (at 98’c,Holding time 45 minutes)
After “PRETREATMENT” , you can dye the fabric as the regular process then proceed to
the “FINISHING” process.

B.) For the lighter shade, the “BLEACHING O.B.A” pretreatment can be applied; however, the color effect may be reduced during the bleaching process.
“BLEACHING AND O.B.A” PRETREATMENT :
Scouring Agent 1-2 g/l
Chelating Agent 1 g/l
Stabilizer 0.5 - 1 g/l
NaOH (50%) 3 g/l
H2O2 (Hydrogen concentration peroxide (50%) 5 g/l and O.B.A
(OPTICAL BRIGHTENING AGENT) DEPEND ON CUSTOMER’S ORIGINAL COLOR

IMPORTANT NOTE :
The color effect after dyeing might not contrast if the dye stuff exceeds 2.5% for dyeing on
“Zero yarn”.We strongly suggest that the dye house should test dyeing “Zero yarn” with their chemicals as the lab scale before dyeing in production every batch. The salesman sample order is also recommended. Remark : recommend to dye on light to medium shade rather than dark shade which over 2% of the dyeing formula.

For more advanced use of “Zero yarn”, instead of using raw white cotton yarn to make the stripe pattern, using cotton-blended fancy yarn is also very innovative to create very unique stripe pattern effect fabric. Please refer to our post about “Knitted fabric idea for combining Kongkiat products.”

Why use “Zero yarn” ? what is the benefit using “Zero yarn” (prepared-for-dyed effect yarn)?

- For knitting mill, it stocks “Zero yarn” as raw material or as the final product (knitted fabric) to reduce the lead time of the whole process. Knitting mill can manipulate the stock and work with “Zero yarn” just like regular raw white yarn. it means that there is nothing left after knitting process or if there is still some yarn left. the yarn can be stocked as raw material again not like dyed yarn.

- As described above, the “Zero yarn” can be knitted with other material as stripe and get the effect after dyeing. Knitting with other material or raw white cotton yarn can greatly reduced the cost of fabric as well.

- You can get the color effect fabric with “Zero yarn” with much lower cost compare with using the package dyed yarn.

- “Zero yarn” now can be produced on 100% cotton with any yarn count available.(NE7-NE100). But most of current customers develop final product with NE20,NE32 and NE40. Moreover, any type of cotton yarn can be add “Zero effect” such as ring cotton yarn, OE cotton yarn,semi-comb or comb yarn etc.

The T-shirt shown above is knitted with 1x 2 feeder ( Feeder1 = Zero yarn ,Feeder2 and Feeder 3 = raw white cotton yarn). Then the fabric proceeded to dyeing process. The effect is quite clear and can be obviously seen as the color effect on the final product. Adding some t-shirt printing on it just to make it looks more fashionable based on your market and ideas.

Please contact us if you still have some questions or interested in getting the sample to test with your local market . Kongkiat can support you with a very small quantity of “Zero yarn” as the salesman sample size. Email us : sales@kongkiat.com or Skype us by add “kongkiat.com” to your contact list.