Claims:We Claim:
1. A method for lowering total dissolved solids (TDS) in a dyeing process of a textile material with a reactive dye using a dyeing machine, comprising the steps of:
adding required quantity of water to respective dyebaths of the dyeing machine,
adding a dye stock solution as per required shade calculation, wherein the dye stock solution is prepared by mixing the reactive dye with water;
adding Greensalt in the respective dyebaths for exhausting the dye stock solution onto the textile material;
starting the dyeing machine by initiating a program to achieve desire dyeing conditions and maintaining the temperature of about 60°C for a time period of about 15 to 25 minutes;
removing the textile material from the dyebath and adding Greensoda 400 or Greensoda 1000 Powder in the respective dyebaths, and
adding the dyed textile material again into the respective dyebaths and resuming the dyeing process for a time period of about 45 to 55 minutes.

2. The method of claim 1, further comprising the steps of: reducing the temperature of the dyeing machine about 40° C and removing the dyebaths from the dyeing machine and further, washing the dyed textile material for a time period of about 20 to 30 minutes using a washing off agent after completion of normal washing with water and treating at the temperature of about 80° C.

3. The method of claim 2, wherein the washing off agent is used in an amount ranges from about 1-2 g/l.

4. The method of claim 1, wherein the reactive dye comprises at least any one of Rosazol Black VX Conc (6%)(Vinyl Sulphone class), Rosareact N Blue ME2GL (2%) (ME class), Rosareact Golden yellow MERL (2%) (ME class), Rosareact Red ME3BS (2%) (ME class), and Combination olive shade (2.8%) (Rect. N Blue ME2GL - 1.5 % (ME Class), React. Golden Yellow MERL - 1.0% (ME Class), and Rea. Orange M2R - 0.3% (M class).

5. The method of claim 1, wherein the textile material to the dye stock solution ratio is about 1: 10.

6. The method of claim 1, wherein the textile material comprising at least any one of cotton fabric, cotton poplin fabric, and other cotton blended fabrics.

7. The method of claim 1, wherein the Greensalt is used in an amount ranges from about 20 g/l to 50 g/l.

8. The method of claim 1, wherein the Greensoda 400 or Greensoda 1000 Powder is used in an amount of about 5 g/l.

9. A method for lowering total dissolved solids (TDS) in a dyeing process of a cotton fabric with a remazol dye using a dyeing machine, comprising the steps of:
adding required quantity of water to respective dyebaths of the dyeing machine,
adding a dye stock solution as per required shade calculation, wherein the dye stock solution is prepared by mixing the reactive dye with water;
adding Greensalt in the respective dyebaths for exhausting the dye stock solution onto the cotton fabric;
starting the dyeing machine and initiating a program to achieve desire dyeing conditions by maintaining the temperature at 60°C for a time period of about 15 to 25 minutes;
removing the cotton fabric from the dyebath and adding Greensoda 400 or Greensoda 1000 Powder in the respective dyebaths;
adding the dyed cotton fabric again into the respective dyebaths and resuming the dyeing process for a time period of about 45 to 55 minutes;
reducing the temperature of the dyeing machine about 40° C and removing the dyebaths from the dyeing machine, and
washing the dyed cotton fabric with water for a time period of about 10 to 20 minutes after completion of washing with running water.

10. The method of claim 9, further comprising the steps of: washing the dyed cotton fabric for a time period of about 20 to 30 minutes using a washing off agent after completion of washing with water and treating at the temperature of about 80° C.

11. The method of claim 10, wherein the washing off agent is used in an amount ranges from about 1-2 g/l.

12. The method of claim 9, wherein the cotton fabric is dyeing with a reactive dye includes at least any one of Rosazol Black VX Conc (6%)(Vinyl Sulphone class), Rosareact N Blue ME2GL (2%) (ME class), Rosareact Golden Yellow MERL (2%) (ME class), Rosareact Red ME3BS (2%) (ME class), and Combination olive shade (2.8%) (Rect. N Blue ME2GL - 1.5 % (ME Class), React. Golden Yellow MERL - 1.0% (ME Class), Rea. Orange M2R - 0.3% (M class).

13. The method of claim 9, wherein the fabric material to the dye stock solution ratio is about 1: 10.

14. The method of claim 9, wherein the cotton fabric is a cotton poplin fabric.

15. The method of claim 9, wherein the Greensalt is used in an amount ranges from about 20 g/l to 50 g/l.

16. The method of claim 9, wherein the Greensoda is used in an amount of about 5 g/l.
, Description:A. Technical field
[0001] The invention disclosed herein generally relates to a method for lowering total dissolved solids (TDS) in a dyeing process. More particularly, the present invention relates to a method for lowering total dissolved solids (TDS) in a dyeing process of a textile material comprising at least any one of cotton and other cotton blended fabrics on a dyeing machine by keeping the textile material to liquor ratio at a predetermined value and reducing the usage of salt in order to efficiently prevent the discharge of untreatable toxic wastewater from the textile plant into natural waterways.

B. Description of related art
[0002] Reactive dyes are commonly used for cotton and other cellulose fibers in virtue of their properties including brilliant color, excellent color fastness, wide range of hue, and convenient application. They are much brighter, longer-lasting, and easier to use than all-purpose dyes. Fiber reactive dye is the most permanent of all dye types. These dyes chemically react with cellulose or protein molecule to form a covalent bond between dye molecule and cellulose. The garment has been dyed in the bright fiber reactive colors with white clothing could safely wash a hundred times without endangering the whites in the least even if it is all different bright colors or even solid black.

[0003] Cellulose fibers produce a slightly negative charge due to the ionization of hydroxyl groups when they come in contact with water, whereas most of the dye classes suitable for cotton are anionic (such as reactive and direct dyes) in solution. The slightly negative charge on the cellulose fibers results in the repulsion of anionic dyestuffs and thus the exhaustion of the bath is limited. Therefore, a large number of electrolytes, such as common salt are required in the dyeing of cotton with anionic dyes in order to reduce the charge repulsion between the negatively charged cotton and the anionic dyes. However, normally not all the dye in the dye bath is exhausted, thus causing environmental problems due to the discharge of effluent that is colored as well as having a high salt concentration.

[0004] Salt not only facilitates the binding process of reactive dyes to cellulosic fiber, but it also prevents the large-scale bonding of water molecules to the negatively charged dyes, which produces inert “hydrolyzed dye”.

[0005] A higher amount of electrolyte concentration in the effluent causes different effects such as, but not limited to, the impairment of the delicate biochemistry of aquatic organism, a destructive attack on concrete pipes if sodium sulphate is used as the electrolyte as a result of the formation of alumino–sulphato complexes, which swell and crack concrete with a considerable aluminum content, the evolution of hydrogen sulphide gas under anaerobic conditions when sodium sulphate is used as the electrolyte, and the dissolution of such sulphides and subsequent bacterial oxidation to harmful sulphuric acid.

[0006] The low value of salts makes them a poor target for recovery and the small nature of the ions comprising salts makes them difficult to remove by standard effluent treatment methods. They are not removed by biological treatments and require physical or chemical separation techniques (reverse osmosis, evaporation, electrolysis). Salts may affect the application of effluent to land for irrigation purposes.

[0007] The large quantity of salt used in the dyeing of textile materials has resulted in increasing environmental concerns. The salt output from the textile industry could produce toxic effects on freshwater organisms due to increased salinity of the water. The salinated water could not be used for irrigation and human consumption. High salt concentration interferes with proper operation of the waste water treatment and also change in density of water causes trouble in flotation and sedimentation.

[0008] Few existing patent references attempted to address the aforementioned problems are cited in the background as prior art over the presently disclosed subject matter and are explained as follows:

[0009] A prior art US5984979 assigned to Bella Otto, entitled “Method of reactive dyeing of textile materials using carboxylate salt”. The method of dyeing textile material providing a textile material comprising at least one of cotton and regenerated cellulosic fibers, providing an aqueous dyebath in a weight ratio of dyebath textile material of 10:1 to 20:1, the dyebath comprising a reactive dye and a carboxylate salt for salting out the dye onto the textile material. All dyeings essentially followed the manufacture's recommended dyeing procedure for Remazol Dyes as fabric 100% bleached cotton knit, Liquor/fabric ratio: 10:1, Set the dyebath at 80° F. with water and fabric, add the dyes and 1.5 g/L of Calgon (40%) to the dyebath, and run the dyebath for 5 minutes add the salt components and run the dyebath for 15 minutes, add 5 g/L of Soda Ash and run the dyebath for 10 minutes, add 2 g/L of a 50% solution of NaOH and run the dyebath for 5 minutes, raise the temperature to 140° F. and run the dyebath for 45 minutes, drain the dyebath and then rinse the fabric with cold water, hot water, soap off, warm rinse, and then dry the fabric. The carboxylate salts used in combination with other salts in the dyeing process. For example, it is desirable to combine the use of a carboxylate salt with Na2 SO4 or NaCl to reduce the cost of the salt requirements or to reduce the biological oxygen demand (BOD) of the effluent from the dyebath that may occur with the use of carboxylale salts.

[0010] Another prior art US5720779 assigned to Ebiike Yoshimi, entitled “Anthraquinone reactive dye compositions and methods for dyeing or printing using the same” discloses about anthraquinone-type reactive dye compositions capable of dyeing or printing cellulose fibers or cellulose-containing fiber materials. A reactive dye composition comprising 1 part by weight of an anthraquinone compound. A cheese dyeing machine, was set 50 parts of a cheese type cotton yarn. The liquor ratio and water temperature were adjusted to 1:10 and 58° C. The dyes to be mixed with the reactive dye composition, reactive dye selected from sulfatoethylsulfonyl group, vinylsulfonyl group. monochlorotriazinyl group and monofluorotriazinyl group; and dyes on the market with the commercial name of Sum/fix, Sum/fix Supra, Remazol, Levafix and Procion. The reactive dye composition contains an inorganic salt such as anhydrous sodium sulfate and sodium chloride. Amount of the inorganic neutral salt or acid binding agent, or total amount of the inorganic neutral salt and acid binding agent when both are used, is 1 g/liter or more, they may be used in an amount of 100 g/liter or more a small amount of 40 g/liter or less in total of both may be enough to carry out the dyeing. Each of the anthraquinone compounds (l) or (II) may be in the form of a free acid or salt, they are in the form of alkali metal salt or alkaline earth metal salt. The cotton cloth was washed with water, washed with hot water, soaped, washed with hot water, washed with water and dried to obtain printed cotton broad cloth showing uniform blue color.

[0011] However, the discussed prior art references are useful to some extent for some purposes. These prior efforts sometimes yield a poor efficiency with poor experience and could not able to efficiently prevent the discharge of untreatable toxic wastewater from the textile plant into natural waterways.

[0012] Referring to FIG. 1, a graph 100 represents atraditional dyeing technology and process is disclosed. The conventional method of dyeing 100 % cotton poplin fabric includes different steps. At one step, the required quantity of water is added to the pots of the rota dyer dyeing machine (Rossarilabtech). At another step, the dye stock solution is added as per the required shade calculation and salt could be added in the respective baths followed by the specific weight of 100 % cotton poplin fabric (construction 40 × 40 132 × 72 1/1 RFD) piece in a bath solution containing 1:10 material to liquor ratio. A pot containing dyeing bath is inserted properly in the dyeing machine and starts the dyeing machine. At another step, a program is initiated to achieve desire dyeing conditions. Once the dyeing temperature is reached then the dyeing machine is maintained at the temperature of about 60° C for a time period of about 15 to 25 minutes. At another step, the dyed fabric is removed from the pots and alkali is added in the respective pots of the dyeing machine. At another step, the dyed fabric is added into the pots and dyeing process is resumed. After addition of alkali, the dyeing is continued for a time period of about, 45 to 55 minutes. Further, the dyeing machine is cooled down to 40° C temperature and the pots are removed from the dyeing machine. The dyed fabrics are removed and washed under running water.

[0013] All fabrics are now washed at normal temperature for a time period of about 10 to 20 minutes in the rota dyeing machine. Then fabrics are removed and subjected to washing off process for a time period of about 20 to 30 minutes using a washing off agent and treated at the temperature of about 80° C. At the end of the process, samples are removed from pots and again washed at normal temperature for 10-20 minutes in the rota dyeing machine.

[0014] The total dissolved solids (TDS) could be calculated in ppm (parts per million) based on the amount in milligrams of the gravimetric weight of the water-soluble chemical component per liter of water. For example, the conventional dyeing process uses 60 g/l salt in a dyebath and it will correspond to 60000 ppm. In conventional dyeing process, at least 20 g/l soda ash could be added for promoting chemical reaction between the dyes and the cellulose fiber. The TDS load is about 80000 ppm in the conventional dyeing process. Further, a soaping agent is about1 g/l could be used for washing out the residual dye, dyeing auxiliaries, oil, etc. after the dyeing process. Further, the fabric could be rinsed in cold water to remove excess dye from the fabric. However, the conventional dyeing technology and process could produce toxic wastewater from the textile plant and discharge into the natural waterways.

[0015] Therefore, there is a need for a method of lowering total dissolved solids (TDS) in a dyeing process of a textile material comprising at least any one of cotton and other cotton blended fabrics on a Rota dyeing machine by keeping the textile material to liquor ratio at a predetermined value. Further, there is also a need for a method of lowering total dissolved solids (TDS) in a dyeing process in order to reduce the load on effluent treatment and the usage of salt, thereby efficiently preventing the discharge of untreatable toxic wastewater from the textile plant into the natural waterways.

SUMMARY OF THE INNOVATION
[0016] The present invention discloses a method for lowering total dissolved solids (TDS) in a dyeing process of a textile material comprising at least any one of cotton and other cotton blended fabrics on a dyeing machine by keeping the textile material to liquor ratio is about 1:10and reducing the usage of salt in order to efficiently prevent the discharge of untreatable toxic wastewater from the textile plant into natural waterways.

[0017] In one embodiment, the method comprises different steps for efficiently dyeing the textile material, for example, a cotton fabric. At one step, the required quantity of water is added to respective dyebaths of the dyeing machine. At another step, a dye stock solution as per required shade calculation is added in the dyebaths. The dye stock solution is prepared by mixing the reactive dye with water. In one embodiment, the reactive dye comprises at least any one of, but not limited to, RosazolBlack VX Conc (6%) (Vinyl Sulphone class), Rosareact N Blue ME2GL (2%) (ME class), Rosareact Golden yellow MERL (2%) (ME class), Rosareact Red ME3BS (2%) (ME class), and Combination olive shade (2.8%) (Rect. N Blue ME2GL - 1.5 % (ME Class), React. Golden Yellow MERL - 1.0% (ME Class), and Rea. Orange M2R - 0.3% (M class).

[0018] . At another step, Greensalt is added in the respective dyebaths for exhausting the dye stock solution onto the textile material, for example, a cotton fabric. In one embodiment, the Greensalt is used in an amount ranges from about, but not limited to, 20 g/l to 50 g/l. In one embodiment, the Greensalt could be a synergistic blend of the inorganic component. In one embodiment, the textile material comprises at least any one of, but not limited to, cotton fabric, 100 % cotton poplin fabric, and other cotton blended fabrics. At another step, the dyeing machine is started by initiating a program to achieve desire dyeing conditions and maintaining the temperature of about 60°C for a time period of about 15 to 25 minutes. At another step, the textile material, for example, cotton fabric, is removed from the dyebath and Greensoda 400 or Greensoda 1000 Powder is added in the respective dyebaths. In one embodiment, the Greensoda is used in an amount of about, but not limited to, 5 g/l. In one embodiment, the Greensoda 1000 Powder or Greensoda 400 Powder could be sustainable Alkali buffer products. The Greensoda 1000 Powder could require the amount of, but not limited to, 1/3 of total soda ash whereas Greensoda 400 Powder could require the amount of, but not limited to, 1/4 to 1/5 of soda ash during reactive dyeing of cellulosic materials like cotton. At another step, the dyed textile material is again added into the respective dyebaths and resuming the dyeing process for a time period of about 45 to 55 minutes. Further, at another step, the temperature of the dyeing machine is reduced about 40° C and the dyebaths are removed from the dyeing machine. Further, the dyed textile material is removed from the dyebath and washed using at normal temperature for a time period of about 10 to 20 minutes in the rota dyeing machine. The dyed textile material is again washed for a time period of about 20 to 30 minutes using a washing off agent after completion of normal washing with water and treated at the temperature of about 80° C. The textile materials are removed from pots and again washed at normal temperature for 10-20 minutes in a Rota dyeing machine. In one embodiment, the washing off agent is used in an amount ranges from about, but not limited to, 1-2 g/l.

[0019] In one embodiment, the washing fastness of dye samples are carried out using ISO 3 method, where non-ionic soap in the amount of about, but not limited to, 5.0 gpl and soda ash in the amount of about, but not limited to, 2.0 gpl are used to prepare a bath by keeping material to liquid M:L ratio is about1:50 in a Laundrometer (Rossari Labtech). In one embodiment, the dyed sample and multifiber strip are used for testing and dyed conditions are maintained at the temperature of about 95°C for a time period of about 30 minutes. All samples were drained, cold washed, and dried. In one embodiment, a grey scale could be used for visually evaluating changes in shade and staining on multi-fabric strip. The method could reduce the TDS value in the ranges of about, but not limited to, 40-50 %, which is in turn reduces the load on effluent treatment. The TDS value is further reduced by using the Greensoda 400 or Greensoda 1000 powder in the amount of about 5 g/l instead of using 20 g/l soda ash in the dyeing process. Henceforth, the entire process could effectively reduce the TDS.

[0020] In one embodiment, the color strength (K/S), where “K” is referred to absorption coefficient and “S” is referred to scattering coefficient values is carried out using spectophotometrically using a Spectorphotometer (X-rite sphere benchtopCi7600 model). The color strength (K/S) values of the low salt dyeing samples were compared with the conventional dyeing sample.

[0021] In one embodiment, the total dissolved solids (TDS) are calculated using the following steps. In one embodiment, the known concentration of salt solution in water was prepared and added in to a pre-weighed glass petri dish. The dish was completely dried in an oven at the temperature of about 105o C for a time period of about 4 hours till water completely evaporated. Cooled and kept in desiccator and then re-weighed. The dissolved solid content of the sample is calculated from the difference in the two weights.

[0022] Other objects, features and advantages of the present innovation will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating specific embodiments of the innovation, are given by way of illustration only, since various changes and modifications within the spirit and scope of the innovation will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF DRAWINGS
[0023] The foregoing summary, as well as the following detailed description of the innovation, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the innovation, exemplary constructions of the innovation are shown in the drawings. However, the innovation is not limited to the specific methods and structures disclosed herein. The description of a method step or a structure referenced by a numeral in a drawing is applicable to the description of that method step or structure shown by that same numeral in any subsequent drawing herein.

[0024] FIG.1 exemplarily illustrates a graph represents a conventional dyeing method, according to the prior art of the present invention.

[0025] FIG.2 exemplarily illustrates a flowchart of a method for lowering total dissolved solids (TDS) in a dyeing process, according to an embodiment of the present invention.

[0026] FIG.3 exemplarily illustrates a graph represents the method for lowering total dissolved solids (TDS) in a dyeing process, according to one embodiment of the present invention.

[0027] FIG.4 exemplarily illustrates a table shows different reactive dyes with respective their color difference values, according to one embodiment of the present invention.

[0028] FIG.5 exemplarily illustrates a table shows different reactive dyes with respective their color differences values and TDS reduction values with respective to the amount of usage, according to one embodiment of the present invention.

[0029] FIG.6 exemplarily illustrates a table shows the Rosazol Black VX Conc (6 %) with respective their color differences values and theoretical TDS reduction valueswith respective to the amount of usage, according to one embodiment of the present invention.

[0030] FIG.7 exemplarily illustrates a graph represents a comparison of color strengths obtained from the conventional dyeing process and the low TDS dyeing method, according to one embodiment of the present invention.

[0031] FIG. 8exemplarily illustrates a table shows the results of fastness of all dyed samples related to conventional and low TDS reactive dying process, according to one embodiment of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS
[0032] A description of embodiments of the present innovation will now be given with reference to the Figures. It is expected that the present innovation may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive.

[0033] Referring to FIG.2, a flowchart 200 of a method for lowering total dissolved solids (TDS) in a dyeing process according to an embodiment of the present invention is disclosed. In one embodiment, the low TDS method is used for dyeing of a textile material, for example, cotton and other cotton blended fabrics on a Rota dyeing machine by keeping the textile material to liquor ratio is about 1:10 and reducing the usage of salt in order to efficiently prevent the discharge of untreatable toxic wastewater from the textile plant into natural waterways. The method could reduce the TDS value in the ranges of about, but not limited to, 40-50 %, which is in turn reduces the load on effluent treatment.

[0034] In one embodiment, the method comprises different steps for efficiently dyeing the textile material, for example, a cotton fabric. At step 202, the required quantity of water is added to respective dyebaths of the dyeing machine. At step 204, a dye stock solution as per required shade calculation is added in the dyebaths. The dye stock solution is prepared by mixing the reactive dye with water. In one embodiment, the reactive dye comprises at least any one of, but not limited to, Rosazol Black VX Conc (6%) (Vinyl Sulphone class), Rosareact N blue ME2GL (2%) (ME class), Rosareact Golden yellow MERL (2%) (ME class), Rosareact Red ME3BS (2%) (ME class), and Combination olive shade (2.8%) (Rect. N Blue ME2GL - 1.5 % (ME class), React. Golden Yellow MERL - 1.0% (ME Class), Rea. Orange M2R - 0.3% (M class). In some embodiments, the dye stock solution could be prepared using different type of dyes such as, but not limited to, reactive dyes, acid dyes, basic dyes, direct dyes, disperse dyes, sulfur dyes, pigment dyes, mordant dyes, vat dyes, reactive dyes, naphthol dyes, azo dyes, and etc. At step 206, Greensalt is added in the respective dyebaths for exhausting the dye stock solution onto the textile material, for example, a cotton fabric. In one embodiment, the Greensalt is used in an amount ranges from about, but not limited to, 20 g/l to 50 g/l. In one embodiment, the Greensalt could be a synergistic blend of the inorganic component. In one embodiment, the textile material comprises at least any one of, but not limited to, cotton fabric, 100 % cotton poplin fabric, and other cotton blended fabrics. At step 208, the dyeing machine is started by initiating a program to achieve desire dyeing conditions and maintaining the temperature of about 60°C for a time period of about 15 to 25 minutes. At step 210, the textile material, for example, cotton fabric, is removed from the dyebath and Greensoda 400 Powder or Greensoda 1000 powder is added in the respective dyebaths. In one embodiment, the Greensoda is used in an amount of about, but not limited to, 5 g/l. In one embodiment, the Greensoda 1000 Powder or Greensoda 400 Powder could be a concentrated alkali buffer (sustainable Alkali buffer products) to replace soda ash in the reactive dyeing for cost-effective, superior dyeing characteristics and reduced effluent load. The Greensoda 1000 Powder could require the amount of, but not limited to, 1/3 of total soda ash whereas Greensoda 400 Powder could require the amount of, but not limited to, 1/4 to 1/5 of soda ash during reactive dyeing of cellulosic materials like cotton. In one embodiment, the greensoda 400 Powder also in the process since both Greensoda 1000 Powder and Greensoda 400 Powder are same in composition and action, helps to make the dyeing process more sustainable too.

[0035] At step 212, the dyed textile material is again added into the respective dyebaths and resuming the dyeing process for a time period of about 45 to 55 minutes. Further, at step at 214, the temperature of the dyeing machine is reduced about 40° C and the dyebaths are removed from the dyeing machine. Further, the dyed textile material is removed from the dyebath and washed using at normal temperature for a time period of about 10 to 20 minutes in the rota dyeing machine. The dyed textile material is again washed for a time period of about 20 to 30 minutes using a washing off agent after completion of normal washing with water and treated at the temperature of about 80° C. The textile materials are removed from pots and again washed at normal temperature for 10-20 minutes in a Rota dyeing machine. In one embodiment, the washing off agent is used in an amount ranges from about, but not limited to, 1-2 g/l.

[0036] In one embodiment, the washing fastness of dye samples are carried out using ISO 3 method, where non-ionic soap in the amount of about, but not limited to, 5.0 gpl andsoda ash in the amount of about, but not limited to, 2.0 gpl are used to prepare a bath by keeping material to liquid M:L ratio is about1:50 in a Laundrometer (Rossari Labtech). In one embodiment, the dyed sample and multifiber strip are used for testing and dyed conditions are maintained at the temperature of about 95°C for a time period of about 30 minutes. All samples were drained, cold washed, and dried. In one embodiment, a grey scale could be used for visually evaluating changes in shade and staining on multi-fabric strip.

[0037] In one embodiment, the color strength (K/S), where “K” is referred to absorption coefficient and “S” is referred to scattering coefficient values is spectophotometrically carried out using a Spectophotometer (X-rite sphere bench top,Ci7600 model). The color strength (K/S) values of the low salt dyeing samples were compared with the conventional dyeing sample.

[0038] In one embodiment, the total dissolved solids (TDS) is calculated using the following steps. In one embodiment, the known concentration of salt solution in water was prepared and added in to a pre-weighed glass petri dish. The dish was completely dried in an oven at the temperature of about 105o C for a time period of about 4 hours till water completely evaporated, cooled, and kept in desiccator and then re-weighed. The dissolved solid content of the sample is calculated from the difference in the two weights.

[0039] Referring to FIG. 3, a graph 300 represents the low TDS dyeing process is disclosed. In one embodiment, the total dissolved solids (TDS) could be calculated in ppm (parts per million) based on the amount in milligrams of the gravimetric weight of the water-soluble chemical component per liter of water. For example, the low salt dyeing process uses Greensalt in the amount of about 30 g/l in a dyebath and it will correspond to 30000 ppm of TDS but in the conventional dyeing, common salt is used in the amount of about 60 g/l and it will correspond to 60000 ppm. Therefore, the TDS load value is reduced by 50 % by using Greensalt instead of common slat in the dyeing process.

[0040] The TDS value could also be reduced by using the Greensoda 400 or Greensoda 1000 powder in the amount of about 5 g/l instead of using 20 g/l soda ash in the dyeing process. Henceforth, the entire process will reduce the TDS load from 80000 ppm to 35000 ppm and it is greatly reduced by approximately 56 %.

[0041] Referring to FIG. 4, a table 400 shows different reactive dyes with respective their color difference values in one embodiment is disclosed. In an exemplary embodiment, each reactive dye comprises color differences values include, but not limited to, difference in lightness/darkness value (DL), difference on red/green axis (DA), difference on yellow/blue axis (DB), difference in chroma (DC), difference in hue (DH), total color difference value (DE), color shade difference (% STR-WSUM), and STR-SWL value in percentage. In one embodiment, the reactive dye comprises at least any one of, but not limited to, Rosazol Black VX Conc (6%) (VS class), Rosareact N blue ME2GL (2%) (ME class), Rosareact Golden yellow MERL (2%) (ME class), Rosareact Red ME3BS (2%) (ME class), and Combination olive shade (2.8%) (Rect. N Blue ME2GL - 1.5 % (ME Class), React. Golden Yellow MERL - 1.0% (ME Class), Rea. Orange M2R - 0.3% (M class).

[0042] Referring to FIG. 5, a table 500 shows different reactive dyes with respective their color differences values and TDS reduction values with respective to the amount of usage in one embodiment is disclosed. In an exemplary embodiment, for the usage of 30 g/l Rosareact Golden yellow MERL (2%) (ME class) shows the DL value of about, but not limited to, -0.42 D, the DA value of about, but not limited to, 0.46 R, the DB value of about, but not limited to, 0.26 Y, the DC value of about, but not limited to, 0.41 B, the DH value of about, but not limited to, -0.34 R, the DEcmc value of about, but not limited to, 0.31, the % STR WSUM value of about, but not limited to, 104.67, the DE value of about, but not limited to, 0.68, the % STR-SWL value of about, but not limited to, 104.37, and the reduced TDS value is about 56 %.

[0043] In an exemplary embodiment, for the usage of 30 g/l Rosareact N Blue ME2GL (2 %) (ME class) shows the DL value of about, but not limited to, -0.76 L, the DA value of about, but not limited to, -0.18 G, the DB value of about, but not limited to, -0.30 B, the DC value of about, but not limited to, 0.35 B, the DH value of about, but not limited to, -0.05 G, the DEcmc value of about, but not limited to, 0.51, the % STR WSUM value of about, but not limited to, 94.90, the DE value of about, but not limited to, 0.84, the % STR-SWL value of about, but not limited to, 95.60, and the reduced TDS value is about 56 %.

[0044] In an exemplary embodiment, for the usage of 30 g/l Combination olive shade (2.8%) shows the DL value of about, but not limited to, -1.22 D, the DA value of about, but not limited to, 0.97 R, the DB value of about, but not limited to, -0.29 B, the DC value of about, but not limited to, -1.01 D, the DH value of about, but not limited to, 0.09 B, the DEcmc value of about, but not limited to, 1.20, the % STR WSUM value of about, but not limited to, 108.35, the DE value of about, but not limited to, 1.59, the % STR-SWL value of about, but not limited to, 107.82, and the reduced TDS value is about 56 %.

[0045] In an exemplary embodiment, for the usage of 60 g/l Rosareact Red ME3BS (2 %) (ME Class) shows the DL value of about, but not limited to, -0.76 D, the DA value of about, but not limited to, -0.30 G, the DB value of about, but not limited to, 0.65 Y, the DC value of about, but not limited to, -0.25 D, the DH value of about, but not limited to, 0.67 Y, the DEcmc value of about, but not limited to, 0.53, the % STR WSUM value of about, but not limited to, 106.93, the DE value of about, but not limited to, 1.04, the % STR-SWL value of about, but not limited to, 106.12, and the reduced TDS value is about 18 %.

[0046] Referring to FIG. 6, a table 600 shows the Rosazol Black VX Conc (6 %) (Vinyl Sulphone class) with respective their color differences values and theoretical TDS reduction values with respective to the amount of usage in one embodiment is disclosed. In an exemplary embodiment, for the usage of 50 g/l Rosazol Black VX Conc (6 %) shows the DL value of about, but not limited to, 0.12 L, the DA value of about, but not limited to, -0.09 G, the DB value of about, but not limited to, -0.16 B, the DC value of about, but not limited to, 0.08 B, the DH value of about, but not limited to, -0.017 B, the DEcmc value of about, but not limited to, 0.28, the % STR WSUM value of about, but not limited to, 98.84, the DE value of about, but not limited to, 0.22, the % STR-SWL value of about, but not limited to, 100, and the reduced TDS value is about 56 %.

[0047] Referring to FIG. 7, a graph 700 represents a comparison of color strengths obtained from the conventional dyeing process and the low TDS dyeing method according to the present invention is disclosed. In one embodiment, the value of the color strength obtained from the Rosareact Golden yellow MERL (2 %) (ME class) is about 104.37 % and the color strength obtained from the Rosareact N blue ME2GL (2 %) (ME class) is about 108.54 %. In one embodiment, the color strength obtained from the olive (2.8 %) is about 50 % and the color strength obtained from the Rosazol Black VX Conc (6 %) (Vinyl Sulphone class) is about 100 %.

[0048] Referring to FIG. 8, a table 800 shows the results of fastness of all dyed samples related to conventional and low TDS dying process in one embodiment is disclosed. The results of fastness of all dyed samples related to conventional and low TDS dying process were evaluated using color strength (%) and washing fastness. All results are compiled in the table.

[0049] In the present invention, dye exhaustion in low salt dyeing process was similar to the values in conventional dyeing as well as dye fixations. Experimental results showed that dye exhaustion reached the maximum value when the concentration range of Greensalt was 50% less against common salt dosages. These parameters support the claimed low salt dyeing process and it could replace the conventional reactive dyeing process. The present low TDS dyeing has high exhaustion, fixation yield, and reproducibility resulting in terms of less requirement of salt for the same depth of shade and reducing the salt consumption to about, but not limited to,50 % of the conventional dyes. The results of the study revealed that, the salt consumption could be reduced to about 50 % by using the reactive dyes and Greensalt and also the TDS level of the effluent will be reduced by about 50%.

[0050] The advantages of the present invention include, but not limited to, the method substantially reduces the TDS by comparing to conventional soda ash fixation, produces brighter and cleaner shades. This method also could be considered as low-salt dyeing process. The method could also produce better reproducibility of shades and better yields. It is cost-effective and also produces stable alkalinity over the entire fixation period.

[0051] Preferred embodiments of this innovation are described herein, including the best mode known to the inventors for carrying out the innovation. It should be understood that the illustrated embodiments are exemplary only and should not be taken as limiting the scope of the innovation.

[0052] The foregoing description comprises illustrative embodiments of the present innovation. Having thus described exemplary embodiments of the present innovation, it should be noted by those skilled in the art that the within disclosures are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present innovation. Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments of the innovation will come to mind to one skilled in the art to which this innovation pertains having the benefit of the teachings in the foregoing descriptions. Although specific terms may be employed herein, they are used only in generic and descriptive sense and not for purposes of limitation. Accordingly, the present innovation is not limited to the specific embodiments illustrated herein.