APPARATUS AND METHOD FOR INCREASING COLOURFASTNESS

Abstract

A method for improving the colourfastness of a dyed textile is provided. The method comprises the steps of: conveying a dyed textile along a processing line in a first direction; flowing a fluid from a reservoir through the dyed textile on the processing line in a second directly substantially opposite to the first direction; subsequently removing at least 50% of the applied fluid from the dyed textile; removing contaminants from the fluid; and returning the fluid to the reservoir.

Claims

1. A method for improving the colourfastness of a dyed textile, the method comprising: conveying a dyed textile along a processing line in a first direction; flowing a fluid from a reservoir through the dyed textile on the processing line in a second directly substantially opposite to the first direction; subsequently removing at least 50% of the applied fluid from the dyed textile; removing contaminants from the fluid; and returning the fluid to the reservoir.

2. The method according to claim 1, further comprising: mechanically agitating the textile.

3. The method according to any preceding claim, wherein the total mass of fluid applied to the dyed textile is up to 500% of the mass of the dyed textile.

4. The method according to any preceding claim, wherein the fluid applied to the dyed textile is applied at 1-50 litres per minute.

5. The method according to any preceding claim, further comprising: heating the fluid to above 40? C.

6. The method according to any preceding claim, further comprising: heating the fluid to above 50? C.

7. The method according to any preceding claim, further comprising: heating the fluid to above 60? C.

8. The method according to any preceding claim, further comprising: heating the fluid to above 70? C.

9. The method according to any one of claims 1 to 5, further comprising: heating the fluid to 40-80? C.

10. The method according to any one of claims 1 to 6, further comprising: heating the fluid to 50-70? C.

11. The method according to any preceding claim, further comprising: determining a range of acceptable flow rates for the fluid being applied; monitoring the flow rate of the fluid being applied; and adjusting the flow rate of the fluid being applied if the flow rate of fluid being applied is outside of the range of acceptable flow rates.

12. The method according to any preceding claim, wherein the fluid is sprayed onto the dyed textile.

13. The method according to any preceding claim, wherein the fluid comprises an additive configured to improve the colourfastness of the textile.

14. Apparatus for improving the colourfastness of a dyed textile, the apparatus comprising: a processing line for conveying a textile in a first direction; a reverse osmosis unit including a fluid reservoir for retaining a fluid and a filtration unit for removing contaminants from the fluid; a fluid applicator configured to apply the fluid to the textile in a second direction substantially opposite to the first direction; a fluid removal device configured to remove the fluid from the textile and return it to the reverse osmosis unit.

15. The apparatus according to claim 14, wherein the fluid applicator comprises a spray nozzle.

16. The apparatus according to claim 14 or claim 15, wherein the fluid removal device is configured to generate a partial vacuum, in use.

17. The apparatus according to any of claims 14 to 16, further comprising a mechanical agitator.

18. The apparatus according to claim 17, wherein the mechanical agitator comprises at least one axis relative to which it may move.

19. The apparatus according to claim 16 or claim 17, wherein the mechanical agitator is configured to agitate the textile between the application and the removal of the fluid.

20. The apparatus according to any of claims 17 to 19, wherein the mechanical agitator is a roller.

21. The apparatus according to any of claims 17 to 20, wherein the mechanical agitator is a pair of rollers.

22. The apparatus according to any of claims 17 to 21, wherein the roller has a textured surface.

23. The apparatus according to claim 22, wherein the textured surface is knurled.

24. The apparatus according to any of claims 14-19, wherein the textured surface has a spiral pattern.

Description

[0140] The invention will now be further and more particularly described, by way of example only, with reference to the accompanying drawings.

[0141] FIG. 1 shows a method for improving the colourfastness of a dyed textile according to some embodiments of the present invention;

[0142] FIG. 2 shows a method for improving the colourfastness of a dyed textile according to some embodiment of the present invention;

[0143] FIG. 3 shows a method for improving the colourfastness of a dyed textile according to some embodiment of the present invention;

[0144] FIG. 4 shows an apparatus for improving the colourfastness of a dyed textile according to some embodiment of the present invention;

[0145] FIG. 5 shows an apparatus for improving the colourfastness of a dyed textile according to some embodiment of the present invention;

[0146] FIG. 6 shows an apparatus for improving the colourfastness of a dyed textile according to some embodiment of the present invention;

[0147] FIG. 7 shows an apparatus for improving the colourfastness of a dyed textile according to some embodiment of the present invention;

[0148] FIG. 8A shows a mechanical agitator in the form of a spiral roller;

[0149] FIG. 8B shows a mechanical agitator in the form of a screw roller;

[0150] FIG. 8C shows a mechanical agitator in the form of a profiled roller;

[0151] FIG. 8D shows a mechanical agitator in the form of a knurled roller;

[0152] FIG. 9A shows a section through a mechanical agitator in the form of a brushed roller; and

[0153] FIG. 9B shows a section through a mechanical agitator in the form of a geared roller.

[0154] FIG. 1 shows a method for improving the colourfastness of a dyed textile. The method comprising: conveying a dyed textile along a processing line 110; applying a fluid onto the dyed textile at a first position on the processing line 120; and subsequently removing at least 50% of the applied fluid from the dyed textile at a second position on the processing line 130.

[0155] More specifically, the method comprises applying a predetermined volume of fluid to the dyed textile at a first position on the processing line 120. The predetermined volume is based on the desired water content of the textile. The predetermined volume of fluid to be applied to the textile is calculated based on the mass flow rate of the textile along the processing line.

[0156] The total mass of fluid applied to the dyed textile is 100%-300% of the mass of the dyed textile. The fluid applied to the dyed textile at the first position is typically applied at 1-20 litres per minute. However, the rate volume of fluid being applied varies depending on the textile and dyestuff used. Moreover, the textile is typically conveyed along the processing line at 1-100 meters per minute (m/min). However, again, the rate at which the textile is conveyed along the processing line varies depending on the textile and dyestuff used.

[0157] The fluid applied to the dyed textile at the first position on the processing line 120 is sprayed. The method comprises spraying a fluid to the dyed textile at a first position on the processing line 120. The fluid is sprayed onto the dyed textile via a plurality of spray nozzles. The plurality of spray nozzles is configured to spray fluid across the entire width of the conveyed textile.

[0158] The fluid is removed from the textile by a vacuum. More specifically, the method comprises removing at least 50% of the applied fluid from the dyed textile at a second position on the processing line 130 using a vacuum.

[0159] The method further comprises a fluid decontamination step 140. Accordingly, the method comprises conveying a dyed textile along a processing line 110; applying a fluid to the dyed textile at a first position on the processing line 120; subsequently removing at least 50% of the applied fluid from the dyed textile at a second position on the processing line 130; removing contaminants from the removed fluid 140; and re-applying the fluid to the dyed textile 150.

[0160] The fluid being re-applied is re-applied at the first position on the processing line 120. However, in other embodiments, not illustrated in the accompanying drawings, the fluid being re-applied may be re-applied at a third position on the processing line.

[0161] The method is continuous. Accordingly, the method comprises: continuously conveying a dyed textile along a processing line 110; continuously applying a fluid to the dyed textile at a first position on the processing line 120; and subsequently, continuously removing at least 50% of the applied fluid from the dyed textile at a second position on the processing line 130. Moreover, contaminates are continuously removed from the removed fluid 140 and the decontaminated fluid is continuously re-applying to the dyed textile 150. The continuously re-applied fluid 150 is applied to the dyed textile at the first position on the processing line. The decontaminated fluid is, at least in part, the fluid applied to the dyed textile at the first position on the processing line 120.

[0162] The method further comprises heating the fluid to above 40? C. Therefore, the fluid applied to the dyed textile at a first position on the processing line 120 is above 40? C. More specifically, the method comprises heating the fluid to above 55? C.

[0163] The method further comprises heating the first position on the processing line to 40-95? C. More specifically, the temperature of the environment at the first position on the processing line 120 is 40-95? C. Most specifically, the method comprises heating the first position on the processing line to 50-70? C. or approximately 60? C.

[0164] The method further comprises: determining a range of acceptable flow rates for the fluid being applied; monitoring the flow rate of the fluid being applied; and adjusting the flow rate of the fluid being applied if the flow rate of fluid being applied is outside of the range of acceptable flow rates. The fluid being applied is accurately monitored and can be adjusted, in use.

[0165] The method further comprises: mechanically agitating the dyed textile. Consequently, the method comprises: conveying a dyed textile along a processing line 110; applying a fluid to the dyed textile at a first position on the processing line 120; agitating the textile 125; subsequently removing at least 50% of the applied fluid from the dyed textile at a second position on the processing line 130; removing contaminants from the removed fluid 140; and re-applying the fluid to the dyed textile 150.

[0166] The mechanical agitation occurs between the fluid application step 120 and the fluid removal step 130. More specifically, the dyed textile is mechanically agitated via a pair of rollers configured to contact the textile being conveyed along the processing line. The rollers are nip rollers. The mechanical agitation occurs between the first and second position on the processing line.

[0167] FIG. 2 shows a method for improving the colourfastness of a dyed textile. The method comprising: conveying the dyed textile along a processing line 110 and into a first chamber having a first controllable environment 210; temporarily storing the dyed textile in the first chamber for a first time period 220; conveying the dyed textile into a second chamber having a second controllable environment 230; and temporarily storing the dyed textile in the second chamber for a second time period 240. The first controllable environment is different to the second controllable environment. More specifically, the second controllable environment comprises a temperature gradient.

[0168] The dyed textile is automatically conveyed into the first chamber. Conversely, the dyed textile is manually conveyed into the second chamber.

[0169] The method further comprises adjusting the first and/or second controllable environment based on a characteristic of a textile to be dyed; a dyestuff for use in dyeing the textile and/or the dyed textile 215. The characteristics of the dyestuff comprise the concentration, colour, shade, pantone, reflectivity, water content, colour index number and/or molecular weight of the dyestuff. Moreover, the characteristics of the dyed textile and/or the textile to be dyed comprise the basis weight, absorbance capacity, reflectivity, water content, thickness, diameter and/or batch code of the textile.

[0170] The first chamber is maintained at a first internal temperature and the second chamber is maintained at a second internal temperature. The second internal temperature is lower than the first internal temperature.

[0171] More specifically, the first internal temperature is between 140? C. and 240? C. and the second internal temperature is between 120? C. and 220? C. Most specifically, the first internal temperature is between 160? C. and 220? C. and the second internal temperature is between 140? C. and 200? C.

[0172] The second time period is greater than the first time period. More specifically, the first time period is at least 10 minutes and the second time period is at least 30 minutes. Most specifically, the first time period is at least 40 minutes and the second time period is at least 2 hours.

[0173] The method further comprises: determining a cool down rate for the dyed textile 250 and adjusting the controllable environment of the first and/or second chamber based on the cool down rate 260. The cool down rate is defined as the time taken for the textile to decrease by 1? C. Moreover, the cool down rate is determined based on the characteristics of the textile to be dyed, dyed textile and/or dyestuff. The cool down rate is calculated prior to the textile dyeing process.

[0174] More specifically, the method comprises: temporarily storing the dyed textile at a plurality of different temperatures in the second chamber for a second time period 240. Most specifically, the method comprises conveying the dyed textile through a plurality of different temperatures within the second chamber for a second time period 240. Accordingly, the second chamber comprises a temperature gradient.

[0175] The method further comprises consolidating the dyed textile into a roll within the first chamber 270. Moreover, the speed at which the dyed textile is conveyed into the first chamber is varied, in use. More specifically, the dyed textile is conveyed into the first chamber at a faster rate than it is conveyed into the second chamber. This creates an excess of dyed textile within the first chamber. The consolidated textile roll is then separated from the processing line and conveyed into the second chamber. Simultaneously, the excess dyed textile begins consolidating to generate a second roll within the first chamber. Additionally, the speed at which the dyed textile is conveyed into the first chamber is reduced until the excess dyed textile has been consolidated.

[0176] The consolidated textile roll comprises 50-3000m of dyed textile. More specifically, the roll comprises 500m-1500m or approximately 1000m of dyed textile. Moreover, each roll within the second chamber is rotated about its roll axis, wherein the roll axis is the axis about which the textile is wrapped in order to generate the roll.

[0177] More specifically, the method comprises temporarily storing a plurality of dyed textile rolls in the second chamber 240. Once a first dyed textile roll has been conveyed a predetermined distance through the second chamber, a subsequent dyed textile roll is added to the second chamber. As previously disclosed, the second chamber comprises a temperature gradient. Accordingly, each dyed textile roll cools as it is conveyed through the second chamber.

[0178] The method further comprises conveying the dyed textile through a fixation chamber having a third controllable environment 280. More specifically, the dyed textile is conveyed through the fixation chamber before being temporarily stored in the first and/or second chamber. The fixation chamber is configured to reduce the water content of a textile comprising a dyestuff and simultaneously initiate the fixation process between the dyestuff and the textile.

[0179] The third controllable environment is maintained at a third internal temperature. More specifically, the temperature within the fixation chamber is between 180? C. and 220? C. Moreover, the fixation chamber is configured to heat the dyed textile to the third temperature for between 1 minute and 15 minutes. More specifically, the fixation chamber is configured to heat the dyed textile to the third temperature for between 3 and 8 minutes.

[0180] FIG. 3 shows a method for improving the colourfastness of a dyed textile. The method comprises conveying a dyed textile along a processing line 110; applying a fluid to the dyed textile at a first position on the processing line 120; subsequently removing at least 50% of the applied fluid from the dyed textile at a second position on the processing line 130; conveying the dyed textile into a first chamber having a first controllable environment 210 and temporarily storing the dyed textile in the first chamber for a first time period 220; and conveying the dyed textile into a second chamber having a second controllable environment 230 and temporarily storing the dyed textile in the second chamber for a second time period 240.

[0181] The method further comprises removing contaminants from the removed fluid 140; and re-applying the fluid to the dyed textile 150. Moreover, the method comprises mechanically agitating the dyed textile 125, wherein the mechanical agitation occurs between the fluid application 120, 150 and the fluid removal 130.

[0182] In some embodiments, not illustrated in the accompanying drawings, the method may further comprise dispensing dyestuff onto the textile via an array of flow channel dispensers. The dyestuff may be dispensed onto the textile prior to the fluid application. Moreover, the dyestuff may comprise a colourless dispersant.

[0183] FIG. 4 shows an apparatus for improving the colourfastness of a dyed textile. The apparatus 400 comprises a processing line 410 for conveying a textile 420; a fluid applicator 430 configured to apply a fluid 435 to the textile 420 being conveyed, in use; and a fluid removal device 440 configured to remove the fluid from the textile 420 being conveyed, in use. The fluid removal device 440 is downstream of the fluid applicator 430. Moreover, the fluid removal device 440 is in fluid communication with the fluid applicator 430 via a reverse osmosis unit 445.

[0184] The fluid applicator 430 and fluid removal device 440 are located within a chamber 480. The internal environment of the chamber 480 is heated. More specifically, the internal environment of the chamber 480 is between 40? C. and 95? C. Most specifically, the internal environment of the chamber 480 is between 50? C. and 70? C. Moreover, the fluid 435 is heated. The fluid 435 is heated above 40? C. More specifically, the fluid is heated to 50? C.-70? C.

[0185] The apparatus 400 further comprising a reverse osmosis unit 445. The reverse osmosis unit 445 comprises a filtration unit 455 and a fluid reservoir 450. The filtration unit 455 is configured to receive fluid from the fluid removal device 440, remove contaminants from within the removed fluid 435 and supply decontaminated fluid to the fluid applicator 430. More specifically, the filtration unit 455 is in fluid communication with the fluid reservoir 450 and is located between the fluid removal device 440 and the fluid reservoir 455. The filtration unit 455 comprise a plurality of filters each having a different pore size.

[0186] The fluid applicator 430 comprises a spray nozzle. The fluid is sprayed onto the textile, in use. More specifically, the fluid applicator 430 comprises a first spray head 432 and a second spray head 434. Each spray head comprises a plurality of spray nozzles. Moreover, the fluid removal device 440 comprises a vacuum. The fluid removal device 440 is configured to generate a partial vacuum, in use.

[0187] The apparatus 400 further comprises a mechanical agitator 460. The mechanical agitator 460 comprises a roller 462. More specifically, the mechanical agitator 460 comprises a pair of rollers 462, 464. The rollers 462, 464 are reciprocating rollers. The rollers reciprocate ?10 mm away from a starting position. Each roller 462, 464 is configured to contact the textile 420 being conveying, in use. The mechanical agitator 460 is configured to move the textile fibres, in use. More specifically, the mechanical agitator 460 comprises a textured surface. Most specifically, each roller 462, 464 comprises a textured surface. Some examples of rollers have textured surfaces are shown in FIGS. 8A to 8D and 9A to 9B.

[0188] FIG. 5 shows an apparatus for improving the colourfastness of a dyed textile. The apparatus 500 comprises processing line 410 configured to convey dyed textile 420 into a first chamber 530 having a first controllable environment. The first chamber 530 is configured to temporarily store the dyed textile for a first time period. The apparatus 500 further comprises a second chamber 540 having a second controllable environment. The second chamber 540 is configured to temporarily store the dyed textile for a second time period.

[0189] The first chamber 530 comprises a cylindrical core 532 configured to receive the dyed textile 420 and form a dyed textile roll 534, in use. The first chamber 530 further comprises a cutting module 536 configured to cut the textile 420 and generate a discrete dyed textile roll 380. The cutting module 536 comprises a blade 538.

[0190] The second chamber 540 is upstream of the first chamber 530. Moreover, the second chamber 540 comprises wheels 542. The second chamber 549 is mobile. Additionally, the second chamber 540 is configured to receive a plurality of discrete dyed textile rolls 380.

[0191] The second chamber 540 comprises a temperature gradient. More specifically, the second chamber 540 comprises a proximal end 544 having a first opening. The first opening 545 is configured to receive the dyed textile 380. The second chamber 540 comprises a distal end 546 having a second opening 547. The second opening 547 is configured to output the dyed textile rolls 380. The first 545 and second 547 opening each comprises a door and/or seal. The proximal end 544 is at a higher temperature than the distal end 546. More specifically, the proximal end 544 is at approximately 180? C. and the distal end 547 is at approximately 140? C. There is a substantially linear temperature gradient between the proximal end and the distal end. The dyed textile rolls 380 are conveyed from the proximal end 544 of the second chamber 540 to the distal end 546 of the second chamber 530. More specifically, dyed textile rolls 380 are conveyed from the proximal end 544 of the second chamber 540 to the distal end 546 of the second chamber 530 via a conveyor belt 548.

[0192] FIG. 6 shows an apparatus for improving the colourfastness of a dyed textile. The apparatus 600 comprises: a processing line 410 for conveying a textile 420; a fluid applicator 430 configured to apply a fluid 435 to the textile 420 being conveyed; a fluid removal device 440 configured to remove the fluid from the textile 420 being conveyed; a first chamber 530 configured to receive the conveyed textile 420, wherein the first chamber 530 comprises a first controllable environment; and a second chamber 540 having a second controllable environment. The first chamber 530 is configured to temporarily store the dyed textile for a first time period and the second chamber 540 is configured to temporarily store the dyed textile for a second time period.

[0193] The apparatus 600 further comprising a reverse osmosis unit 445 configured to receive fluid from the fluid removal device 440. The reverse osmosis unit comprises a filtration unit 455 and fluid reservoir 450. The filtration device 455 is configured to remove contaminants from within the removed fluid 435 and supply decontaminated fluid to the fluid applicator 430. More specifically, the filtration unit 455 is in fluid communication with the fluid reservoir 450 and is located between the fluid removal device 440 and the fluid reservoir 450.

[0194] Moreover, the apparatus 600 comprises a processing line 410 for conveying a textile 420. The processing line 410 is defined by a plurality of rollers 410 configured to define the path along which the dyed textile is conveyed. Any number of rollers 410 may be used. Each of the plurality of rollers 410 is configured to move relative to each other in order to extend or reduce the length of the processing line. This may be used to control the mass flow rate of the textile at a given position on the processing line.

[0195] The apparatus 600 further comprises a fixation chamber 610 configured to receive the dyed textile 420. The fixation chamber 610 comprises a third controllable environment configured to heat the dyed textile 420 to a third temperature. More specifically, the fixation chamber is configured to heat the textile to between 150? C.-240? C. Moreover, the textile remains in the fixation chamber for 10-60 seconds.

[0196] The fixation chamber 610 is positioned downstream of the fluid applicator 430, the fluid removal device 440, the first chamber 530 and the second chamber 540. Moreover, the fixation chamber 610 is positioned upstream of a digital dyeing process, not shown in the accompanying drawings. The digital dyeing process is as described in WO 2020/208362.

[0197] The fixation chamber 610 comprises a drying unit 620 located above the dyed textile 420. The drying unit 620 is configured to discharge energy as electromagnetic waves. The drying unit emits between 20 kW and 200 kW of energy. For example, the drying unit is configured to transfer approximately 50 kW of energy to the dyed textile. A 90-150KW drying unit is used. The energy emitted is in the form of Infra-Red (IR), Near Infra-Red (NIR), Mid Infra-Red (MIR), microwave and/or Ultraviolet (UV). However, in some embodiments not shown in the accompanying drawings, a plasma heater may be used.

[0198] The drying unit 620 further comprises an airflow configured to remove any vapour and/or humidity away from the vicinity of the dyed textile 420. The airflow is configured to remove up to 5 litres of water vapour per minute from the vicinity of the textile. More specifically, the textile 420 enters the fixation chamber 610 with a water content of approximately 25%. The textile leaves the fixation chamber with a water content of 0%-10%.

[0199] The fixation chamber 610 further comprises a reflector 630 located beneath the dyed textile 420. The reflector 630 is configured to optimise the amount of discharged energy that is transferred to the dyed textile.

[0200] The fixation chamber 610 further comprises a temperature sensor 640 configured to measure the temperature of the dyed textile. The dyed textile enters the fixation chamber at approximately room temperature, which may be between 5? C. and 45? C. degrees, but more preferably may be between 10? C. and 35? C. degrees and most preferably may be between 15? C. and 30? C. The temperature of the dyed textile 420 within the fixation chamber 610 is increased by 5? C. to 240? C. For example, the textile may enter the fixation chamber 610 at approximately 25? C. and leave the fixation chamber 610 at approximately 240? C.

[0201] The fixation chamber 610 is configured to enable dispensed dyestuff to diffuse into the textile substrate, chemically react with the substrate; and/or thermally fuse with the substrate.

[0202] The internal environment of the fixation chamber 610 is between 100? C. and 300? C. More specifically, the internal environment of the fixation chamber 610 is between 140? C. and 240? C. However, the temperature may be controlled and/or adjusted, in use.

[0203] FIG. 7 shows an apparatus for improving the colourfastness of a dyed textile. The apparatus 700 comprises a processing line 410, 462, 464, 766 for conveying a textile 420; a fluid applicator 430 configured to apply a fluid 435 to the textile 420 being conveyed; and a fluid removal device 440 configured to remove the fluid from the textile 420 being conveyed. The processing line 410, 462, 464, 766 is driven via a belt drive 730 connected between two rollers 462, 464. The belt drive 730 is powered by a motor. The dyed textile 420 moves from left to right across FIG. 7.

[0204] The fluid applicator 430 is located within a chamber 480. The internal temperature of the chamber 480 is between 40-80? C., for example approximately 60? C. The fluid applicator 430 comprises twenty-four (24) nozzles configured to spray the fluid onto the dyed textile. The fluid is a liquid. The fluid is sprayed substantially vertically downwards (i.e. in the direction of gravity). The sprayed fluid fans out between the spray nozzle and the dyed textile such that the sprayed fluid generates a cone-shaped spray pattern. The dyed textile is conveyed at an angle of between 30? and 60? relative to a substantially vertical axis. Consequently, the fluid being sprayed contacts the dyed textile at an angle between 20? and 70?.

[0205] The fluid being sprayed is heated above 60? C. or, more specifically, to approximately 80? C.-90? C. via a heating element 705. The heating element 705 is a trace heater. The fluid is sprayed at approximately 45 l/min. Furthermore, the fluid is sprayed at a pressure of approximately 0.7 bar. The apparatus 700 comprises a pump 710 configured to generate the required fluid flow rate and pressure.

[0206] In some embodiments, the fluid applicator 430 is configured to rotate. More specifically, the fluid applicator 430 is configured to rotate up to 360 degrees so that the spray nozzles can be used to clean excess dyestuff from within the chamber 480.

[0207] The chamber 480 is partially filled with a fluid. The fluid is a liquid. The fluid comprises any excess fluid sprayed by the fluid applicator 430. More specifically, the fluid is predominantly water. However, any suitable fluid may be used. The fluid collects at the bottom of the chamber 480, as shown in FIG. 7. The chamber is configured to hold up to 28 litres of liquid. The chamber further comprises a drain 720 having an adjustable weir 722. The adjustable weir is configured to control the amount of liquid, thus the liquid level X, within the chamber 480. More specifically, the weir 722 is configured to control whether the dyed textile being conveyed along the processing line passes below the liquid level with the chamber 480. In FIG. 7, the liquid level within the chamber 480 is configured such that the dyed textile is submerged within the liquid at location Y. However, in some embodiments, the liquid level Y is reduced, by adjusting the weir 722, such that the dyed textile remains above the liquid level at location Y.

[0208] Excess liquid within the chamber 480 overflows the weir 722 and exits the chamber 480 via the drain 720. The drain 720 comprises a pump 724 configured to pump fluid from the drain back to the fluid reservoir 450. The pump 724 is configured to pump fluid at a rate of 12 l/min. The drain further comprises a filtration unit 455 located between the weir 722 and the fluid reservoir 450. The filtration unit 455 is configured to remove contaminants and particulates from within the fluid.

[0209] Moreover, the fluid reservoir 450 is in fluid communication with the chamber 480 via a conduit 736 having a pump 738. The pump 738 is configured to pump liquid from the fluid reservoir 450 into the chamber 480 in order to maintain a predetermined liquid level X. the pump 738 is configured to pump liquid at approximately 10 l/min.

[0210] In some embodiments, not shown in FIG. 7, the fluid reservoir 450 is operably connected to a reverse osmosis unit configured draw fluid from within the fluid reservoir 450, via a pump; force the fluid through a semi-permeable membrane to remove contaminants; and subsequently return the fluid to the fluid reservoir 450.

[0211] The fluid reservoir 450 is configured to contain up to 10 litres of liquid. The fluid reservoir 450 also comprises gas, such as air. The fluid reservoir 450 is in fluid communication with a bulk fluid source 726 via a pump 728. The pump 728 is a bi-directional pump configured to ensure the fluid reservoir continuously contains 10 litres of liquid. The pump 728 is configured to pump fluid at a rate of 10 l/min.

[0212] The chamber 480 comprises a mechanical agitator in the form of two rollers 462, 464. The first roller 462 is located upstream of the fluid applicator 430 and the second roller 464 is located downstream of the fluid applicator 430. The two rollers 462, 464 are configured to reciprocate along a first axis substantially parallel to the movement of the dyed textile between the first and second rollers 462, 464 such that the dyed textile is stretched. Furthermore, the two rollers 462, 464 are configured to reciprocate along a second axis transverse to the movement of the dyed textile between the first and second rollers 462, 464 such that the dyed textile is sheared. These two reciprocating movements agitate the fibres of the dyed textile. Moreover, the movement of the dyed textile is configured to massage applied chemistry, such as softeners or fragrance, into the dyed textile fibres. The reciprocation of the rollers 462, 464 is controlled via a rotating cam 732.

[0213] The chamber 480 further comprises a nip roller 766 configured to apply a pressure to the dyed textile as it passes between the nip roller 766 and a second roller, which in this instance, is roller 464. However, in other embodiments not illustrated in FIG. 7, another type of second roller may be used. For example, in some embodiments, a plurality of nip rollers 766 may be used. The pressure applied to the dyed textile by the nip roller 766 is between 1500-3500 Kg/cm.sup.2, 2000-3000 Kg/cm.sup.2 or approximately 2500 Kg/cm.sup.2. The applied pressure squeezes liquid out of the dyed textile. This reduces the liquid content within the dyed textile to less than 50%. More specifically, the pressure applied by the nip roller 766 reduces the liquid content in the dyed textile to less than 45%.

[0214] The fluid removal device 440 comprises a tube 770 configured to eject a gas onto the textile. The gas is air. However, any suitable gas may be used. In some embodiments, the gas may comprise a fragrance. The gas is also heated to between 40-100? C. More specifically, the gas is heated to between 60-95? C. or, most specifically, the gas is heated to between 80-90? C. The gas is heated via a plurality of finned heaters 772. The gas is expelled from the tube 770 at a speed between 50-160 m/s. More specifically, the gas is expelled from the tube 770 at a speed between 80-140 m/s or, most specifically, the gas is expelled from the tube 770 at a speed between 100-120 m/s.

[0215] The fluid removal device 440 further comprises a collection chamber 773 configured to collect the fluid, comprising liquid and gas, and any solids, including, but not limited to contaminants and excess dye particulates, that pass through or are expelled from the surface of the dyed textile 420 in the vicinity of the tube 770. The collection chamber 773 comprises a knife-edge roller 778 configured to contact the dyed textile 420 in the vicinity of the fluid removal device 440. More specifically, the collection chamber comprises a plurality of knife-edge rollers 778. The knife-edge rollers 778 support the dyed textile 420 in order to minimise the deflection of the dyed textile that is generated as a result of the fluid removal device 440.

[0216] The collection chamber 773 is in fluid communication with a separation unit 774 configured to separate gas from liquid and solids. The separation unit 774 comprises a vortex or cyclone configured to collect liquid and solid particles at a first end 775, such as the base, and expelled gas from a second end 776, such as the top. The first end 775 of the separation unit 774 is in fluid communication with the fluid reservoir 450 via a pump 715. The pump 715 is configured to pump the fluid collected at the first end 775 of the separation unit 774 back to the fluid reservoir 450 at a rate of 3 l/min. The second end 776 of the separation unit 774 is in fluid communication with the tube 770 via the plurality of finned heaters 772. The apparatus 700 further comprises a fan 781 configured to generate gas flow within a conduit 782 connecting the tube separation unit 774 to the tube 770.

[0217] The dyed textile downstream of the fluid removal device 440 comprises a liquid content of less than 15%, or more specifically, a liquid content between 5-10%.

[0218] The chamber 480 further comprises an ioniser 771 configured to ionise the air in the vicinity of the dyed textile adjacent to the fluid removal device 440. This reduces the charge, thus surface tension, of the dyed textile.

[0219] FIG. 8A shows a mechanical agitator in the form of a spiral roller. The mechanical agitator 460 comprises a roller 462. The roller 462 comprises a textured surface. More specifically, the roller 462 comprises at least one protrusion 466 on its outer surface. Most specifically, the roller 462 comprises two protrusions 466, 467 on its outer surface. Each protrusion is helical in shape, thus spiralling around the outer surface of the roller. Each helical protrusion comprises four turns around the roller, wherein one turn is defined by one complete loop (i.e. 360 degrees) around the perimeter of the roller. Each turn of the spiral is spaced apart. The gap between each turn is a groove 481. A first turn 471 and second turn 472 have been labelled as an example. Each helical protrusion extends over substantially half of the roller 462. The two helical spirals meet approximately in the middle of the roller.

[0220] FIG. 8B shows a mechanical agitator in the form of a screw roller. The screw roller is similar to the spiral roller, but each protrusion 466, 467 has a greater number of turns per unit length of the roller. A greater number of turns results in a greater spiral density around the roller. In fact, the spiral density is so great that each turn of the spiral remains in contact with the adjacent turn. Therefore, the protrusion entirely encloses the roller. Again, a first turn 471 and second turn 472 have been labelled as an example.

[0221] FIG. 8C shows a mechanical agitator in the form of a profiled roller. The roller 462 comprises a plurality of protrusions 468 on its outer surface. Sixteen protrusions are shown in FIG. 8C, but only three have been labelled. However, any number of protrusions may be present. Each protrusion encircles the roller such that it extends around the entire perimeter of the roller. In addition, each protrusion comprises a ridge or point that extends around the entire perimeter of the roller 462.

[0222] FIG. 8D shows a mechanical agitator in the form of a knurled roller. The roller 462 comprises a plurality of overlapping protrusions 473, 474. Consequently, the roller also comprises a plurality of overlapping grooves 481 located between the overlapping protrusions 473, 474.

[0223] FIG. 9A shows a section through a mechanical agitator in the form of a brushed roller. The roller 462 comprises a plurality of protrusions 476 in the form of bristles protruding from the outer surface of the roller. Each protrusion 476 is flexible. Each bristle may be made from nylon, for example.

[0224] FIG. 9B shows a section through a mechanical agitator in the form of a geared roller. More specifically, the mechanical agitator 460 comprises a pair of geared rollers 462, 464. Each roller 462, 464 is configured to contact the textile 420 being conveying, in use. More specifically, textile is conveyed between the rollers 462, 464. Each roller 462, 464 comprises a textured surface. More specifically, each roller comprises a plurality of protrusions 478. Each protrusion may be solid and/or rigid. Each roller also comprises a plurality of grooves, wherein each groove 479 is located between two adjacent protrusions 478. The pair of rollers 462, 464 is configured to rotate such that a protrusion 478A of one roller 462 lies within the groove 179B of the other roller. As such, the conveyed textile 420 is deformed as it passes between the rollers 462, 464.

[0225] This invention is further illustrated by the following examples, which are for illustrative purposes only, and are not intended to limit the invention, as described above. Modifications may be made to the provided examples without departing from the scope of the invention.

EXAMPLE 1

[0226] The use of a continuous digital dyeing process as described in WO 2020/208362 was employed for the roll-to-roll deposition step in this example. A commercially available dispersive dyestuff was applied to a 100% polyester textile with high precision and control over homogeneity and wet add-on. The digital approach ensures that all deposited dyestuff is required for the target shade, ensuring no wash steps are required to remove excess dyestuff to achieve good colourfastness. The resulting wet loaded textile was passed through an infra-red (IR) fixation chamber to remove carrier water used in the deposition process. The use of IR further enhances the homogeneity of dyestuff across the web width of the textile and ensures limited aggregate formation during whilst the textile is wet.

[0227] The resulting roll of dry dyed textile was then then conveyed into the first chamber having a set temperature of 200? C. The line speed was then set as to allow for a 5 minute dwell time for the textile in the first chamber. The heat-treated roll is held in the first chamber to ensure no heat is lost from the roll and cut to a set size of 100m length.

[0228] The discrete roll of 100 m was then moved into the second chamber for two hours for additional treatment. To enable the production rate of the fixation unit to be maintained, several rolls are cut and stored in the second chamber in sequence, ensuring each roll is exposed to the same thermal conditions. The roll was then removed and stored for cooling.

[0229] Additional diffusion occurs during the cooling step. As a consequence of the low thermal conductivity of the textile the substrate nearest the core will maintain a sufficient temperature to allow for further diffusion enhancement.

[0230] The resulting product was of an improved colourfastness whilst the hand feel of the textile was not affected.

EXAMPLE 2

[0231] The dyestuff deposition method is the same as applied in Example 1.

[0232] The resulting roll of dry dyed textile was then conveyed, in a roll-to-roll manner, into the first chamber having a set temperature of 170? C. Moreover, steam was added to the first chamber to create a high humidity environment. The line speed was then set as to allow for an 8 minute dwell time for the textile in the heated steam zone. The treated substrate was then folded loose into an insulated drum and cut to a specific length of 500m. The drum was then heated by an external heat source to 180? C. for 1 hour for additional thermal treatment. The resulting product is of an improved colourfastness whilst the hand feel of the textile is not affected.

[0233] The resulting drum of textile can be held in an insulated environment, such as the second chamber, to limit cool down of the textile. This extends the time at temperatures deemed sufficient for thermally enhanced diffusion. The insulated carrier will also be movable to ensure the dyed textile can be moved.

EXAMPLE 3

[0234] A commercially available dyestuff with high fastness properties and minimal or colourless formulation auxiliaries was applied in the described method using a digital dye method. The exact amount of dyestuff was applied to achieve the target shade and the loaded textile was dried using IR heat. The use of minimal or colourless auxiliaries, such as surfactants or levelling agents can further enhance the wash-less fastness performance with this method.

[0235] The dry dyed substrate was then processed for 3 minutes at 220? C. within the fixation chamber. The resultant hot substrate was re-rolled into a consolidated roll within the first chamber to ensure that the textile retains heat, minimising any requisite additional heating to maintain the target temperature. The resulting roll was then moved into the second chamber, where one or more rolls are also incubated and held at a range of temperature steps for varying amounts of time. The specific temperature profile is dyestuff and/or textile specific. However, it will typically take the form of 20? C. steps from 180? C. to 140? C. with typical step times of 20 min. This will be controlled by the second chamber.

EXAMPLE 4

[0236] The dyestuff deposition method is the same as applied in Example 1.

[0237] A commercially available dispersive dyestuff was applied with a high precision and control over homogeneity and wet add on. The digital approach ensures that almost all deposited dyestuff is required for the target shade, ensuring minimal excess unfixed dye remaining on the surface, following drying by IR heat and initial thermal processing of 5 minutes at 200? C. within the fixation chamber

[0238] The resultant source material was then processed by exposure to a recirculated fluid flow, a combination of water and silicone softener. The fluid was applied to the textile by spray nozzles at a flow rate of 15 L/min, providing a wet add-on of 150% of the initial source textile weight. The textile was then agitated by the use of textured rollers, as to provide movement between the fibres and expose all excess dye to the fluid. This mechanical agitation process also improved penetration of finishing chemistries. The wet add on was then reduced to 20% using vacuum removal. This process of application, agitation and removal was repeated, as to achieve the optimum results. The resultant high colourfastness textile was then dried to <10% wet add on and the fluid that was removed from the textile by vacuum was continually recovered by filtration and reverse osmosis to yield pure water throughout the duration of the process.

EXAMPLE 5

[0239] The dye deposition method is the same as applied in Example 1, 2 and 4.

[0240] The resulting dyed source material was then processed by exposure to a recirculated fluid bath. The textile was dipped through the fluid bath and a wet add on of 300% of the textile weight was achieved. The wet add on was then reduced to 100 by the use of nip rollers following the bath and mechanical agitation was applied by use of rotating brushes at 5? relative speed to the web line speed, creating agitation within the textile. The fluid was then removed by vacuum, yielding a wet add on of 40%, and the fluid was recovered by filtration and recycled within the fluid system. The resulting textile was dried to completion by heat application.

[0241] Various further aspects and embodiments of the present invention will be apparent to those skilled in the art in view of the present disclosure. and/or where used herein is to be taken as specific disclosure of each of the two specified features or components with or without the other. For example A and/or B is to be taken as specific disclosure of each of (i) A, (ii) B and (iii) A and B, just as if each is set out individually herein.

[0242] Unless context dictates otherwise, the descriptions and definitions of the features set out above are not limited to any particular aspect or embodiment of the invention and apply equally to all aspects and embodiments which are described. It will further be appreciated by those skilled in the art that although the invention has been described by way of example with reference to several embodiments. It is not limited to the disclosed embodiments and that alternative embodiments could be constructed without departing from the scope of the invention as defined in the appended claims.