DYEING METHOD OF DENIM YARNS AND FABRICS

Abstract

In the production method according to the present invention, the binding speed and efficiency of vegetable dyes to cotton and other fibers is increased using an REM technique, such that organic denim and gabardine fabrics (or yarns) can be industrially manufactured in mass production. The method according to the present invention makes it possible to react vegetable dyes with cotton, vegetable or synthetic yarns under low heat, low solution concentration and reduced time parameters.

Claims

1. A production method of dyeing denim yarns and denim fabrics with vegetable dyes, the method comprising: subjecting natural or synthetic fibers to a REM process (R), after which selecting at least one of the vegetable dye dyes from a group consisting of madder (KK), acorn hull (MP), black cumin (BS), walnut hull (CV) black tea (BT), cochineal (CR), and tannin (TN), feeding the vegetable dyes into a system, process 1, dyeing denim warp yarn and rope-shaped cotton yarn in single colors and light color tones with an organic vegetable dye, process 2, dyeing denim warp yarn and rope-shaped cotton yarn in double colors and dark color tones with the vegetable dyes, wherein 2-3 basins (passages) or 2 vegetable dyes are used to give dark and intermediate colors, process 3, applying the vegetable dyes to the bottom as a base color on a warp yarn under an indigo dye, process 4, using the vegetable dyes as a topping hue dye on indigo dye in dyeing denim fabric and yarns, process 5, desizing raw denim, process 6, dyeing fiat cotton and mixed fiber denim and gabardine fabrics in a single color with a top dye in continuous fabric dyeing machines, process 7, desizing raw denim, process 8, dying flat cotton and mixed fiber denim and gabardine fabrics with the vegetable dyes by means of foaming, knife-, press- and other covering techniques in continuous fabric dyeing machines.

2. The method according to claim 1 further comprising: carrying out the REM process (R) in a beginning of the process 1 which is the dyeing denim warp yarn and rope-shaped cotton yarn in single colors and light color tones with an organic vegetable dye, the process 2 which is the dyeing denim warp yarn and rope-shaped cotton yarn in double colors and dark color tones with the vegetable dyes, wherein 2-3 basins (passages) or 2 vegetable dyes are used to give dark and intermediate colors, the process 3 which is the applying the vegetable dyes to the bottom as a base color on a warp yarn under an indigo dye, the process 4 which is the using the vegetable dyes as a topping hue dye on indigo dye in dyeing denim fabric and yarns, the process 5 which is the desizing raw denim, the process 6 which is the dyeing flat cotton and mixed fiber denim and gabardine fabrics in a single color with a top dye in continuous fabric dyeing machines, the process 7 which is the desizing raw denim, and the process 8 which is the dying fiat cotton and mixed fiber denim and gabardine fabrics with the vegetable dyes by means of foaming, knife-, press- and other covering techniques in continuous fabric dyeing machines, which serve to dye natural or synthetic fibers with the vegetable dyes, conducting the REM technique (R) using natural soap agents, textile softening agents and natural enzymes (wheat enzyme and honey glucose enzyme etc.) such that wetting and softening are achieved, using the natural soap agents, textile softening agents and natural enzymes singly or in mixture in a concentration of 1-1000 g/L, at 0-100 C. under steeping and air passage applications for 20-120 second.

3. The method according to claim 1, further comprising: in the process 1 which is the dyeing denim warp yarn and rope-shaped cotton yarn in single colors and light color tones with an organic vegetable dye, dying a denim warp yarn and a rope-shaped cotton yarn dyed in a single color and light color tones with organic the vegetable dyes, firstly subjecting the denim warp yarn and the rope-shaped cotton yarn to the REM process (R), supplying at least one of the vegetable dyes selected from madder (KK), acorn hull (MP), black tea (BT), black cumin (BS), walnut hull (CV), cochineal (CR), and tannin (TN) to the respective process step(s), wherein the process 1 further comprises the steps of aeration passage (SK), overflowing wash basin (Y), overflowing wash basin (Y), first vegetable dye basin (W1), skipped (X), aeration passage (SK), skipped (X), overflowing wash basin (Y), overflowing wash basin (Y), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), overflowing wash basin (Y) overflowing wash basin (Y), overflowing wash basin (Y), and overflowing wash basin (Y), in this given order.

4. The method according to claim 1, further comprising: in the process 2 which is the dyeing denim warp yarn and rope-shaped cotton yarn in double colors and dark color tones with the vegetable dyes, wherein 2-3 basins (passages) or 2 vegetable dyes are used to give dark and intermediate colors, dying a denim warp yarn and a rope-shaped cotton yarn in double colors or dark color tones (intermediate color) with the vegetable dyes, using the 2-3 basins (passages) or the 2 vegetable dyes to give dark and intermediate colors, firstly subjecting the dentin warp yarn and the rope-shaped cotton yarn to the REM process (R), supplying at least one of the vegetable dyes selected from madder (K), acorn hull (MP), black tea (BT), walnut hull (CV), cochineal (CR), and tannin (TN) to the respective process step(s), wherein the process 2 further comprises the steps of aeration passage (SK), overflowing wash basin (Y), overflowing wash basin (Y), first vegetable dye basin (W1), second vegetable dye basin (W2), aeration passage (SK), steaming (ST) and/or high heat treatment (HT), overflowing wash basin (Y), overflowing wash basin (Y), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), overflowing wash basin (Y), overflowing wash basin (V), overflowing wash basin (Y), and overflowing wash basin (Y), in this given order.

5. The method according to claim 1, further comprising: in the process 3 which is the applying the vegetable dyes to the bottom as a base color on a warp yarn under an indigo dye, applying the vegetable dyes to the bottom as a base color on a warp yarn and a under indigo dye, firstly subjecting the warp yarn to the REM process (R), supplying at least one of the vegetable dyes selected from acorn hull (MP), black tea (BT), cochineal (CR), and tannin (TN) to the respective process step(s), wherein the process 3 further comprises the steps of aeration passage (SK) and/or high heat treatment (HT), overflowing wash basin (V), overflowing wash basin (Y), first vegetable dye basin (W1), skipped (X), aeration passage (SK), steaming (ST), overflowing wash basin (Y), overflowing wash basin (Y), indigo dye unit (G), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), in this given order.

6. The method according to claim 1, further comprising: in the process 4 which is the using the vegetable dyes as a topping huge dye on indigo dye in dyeing denim fabric and yarns, using the vegetable dyes as a topping hue dye on a indigo dye in dyeing denim fabric and yarns, supplying at least one of the vegetable dyes selected from walnut hull (CV), black tea (BT), acorn hull (MP), (CR), and tannin (TN) to the respective process step(s), wherein the process 4 further comprises the steps of skipped (X), skipped (X), overflowing wash basin (Y), overflowing wash basin (Y), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), indigo dye unit (G), overflowing wash basin (Y), overflowing wash basin (Y) Rein process (R), overflowing wash basin (Y), overflowing wash basin (Y), third vegetable dye basin (W3), aeration passage (SK), steaming (ST), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y) and overflowing wash basin (Y), in this given order.

7. The method according to claim 1, further comprising: in the processes 5 which is the desizing raw denim, the process 6 which is the dyeing flat cotton and mixed fiber denim and gabardine fabrics in a single color with a top dye in continuous fabric dyeing machines, and the process 7 which is the desizing raw denim, dying raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics in a single color with a top dye (overdyed by covering, foaming covering methods) in continuous fabric dyeing machines, firstly subjecting raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics to the REM process (R), supplying at least one of the vegetable dyes selected from walnut hull (CV), black tea (BT), acorn hull (MP), madder (KK), (CR), and tannin (TN) to the respective process step(s), wherein the processes 5, 6, and 7 further comprise the steps of the overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), intermediary drying (AK), vegetable dye padder (WF), steaming (ST), overflowing wash basin (Y), overflowing wash basin (V), overflowing wash basin (Y) and drying unit (KR), in this given order.

8. The method according to claim 1, further comprising: in the process 8 which is the dying flat cotton and mixed fiber denim and gabardine fabrics with the vegetable dyes by means of foaming, knife-, press- and other covering techniques in continuous fabric dyeing machines, dying raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics with the vegetable dyes by means of foaming, knife-, press- and other covering techniques in continuous fabric dyeing machines, firstly subjecting raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics to the REM process (R), supplying at least one of the vegetable dyes being selected from walnut hull (CV), black tea (BT), acorn hull (MP), madder (KK), (CR), and tannin (TN) to the respective process step(s), wherein the process 8 further comprises the steps of overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), intermediary drying (AK), vegetable dye covering (WCO), steaming (ST), overflowing wash basin (V), overflowing wash basin (Y), overflowing wash basin (Y), and drying unit (KR), in this given order.

9. The method according to claim 2, further comprising: in the process 1 which is the dyeing denim warp yarn and rope-shaped cotton yarn in single colors and light color tones with an organic vegetable dye, dying a denim warp yarn and a rope-shaped cotton yarn in a single color and light color tones with organic the vegetable dyes, firstly subjecting the denim warp yarn and the rope-shaped cotton yarn to the REM process (R), supplying at least one of the vegetable dyes selected from madder (KK), acorn hull (MP), black tea (BT), black cumin (BS), walnut hull (CV), cochineal (CR), and tannin (TN) to the respective process step(s), wherein the process 1 further comprises the steps of aeration passage (SK), overflowing wash basin (Y), overflowing wash basin (Y), first vegetable dye basin (W1), skipped (X), aeration passage (SK), skipped (X), overflowing wash basin (Y), overflowing wash basin (Y), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), overflowing wash basin (Y), overflowing wash basin (Y) overflowing wash basin (Y), and overflowing wash basin (Y), in this given order.

10. The method according to claim 2, further comprising: in the process 2 which is the dyeing denim warp yarn and rope-shaped cotton yarn in double colors and dark color tones with the vegetable dyes, wherein 2-3 basins (passages) or 2 vegetable dyes are used to give dark and intermediate colors, dying a denim warp yarn and a rope-shaped cotton yarn in double colors or dark color tones (intermediate color) with the vegetable dyes, using the 2-3 basins (passages) or the 2 vegetable dyes to give dark and intermediate colors, firstly subjecting the denim warp yarn and the rope-shaped cotton yarn to the REM process (R), supplying at least one of the vegetable dyes selected from madder (KK), acorn hull (MP), black tea (BT), walnut hull (CV), cochineal (CR), and tannin (TN) to the respective process step(s), wherein the process 2 further comprises the steps of aeration passage (SK), overflowing wash basin (Y), overflowing wash basin (Y), first vegetable dye basin (W1), second vegetable dye basin (W2), aeration passage (SK), steaming (ST) and or high heat treatment (HT), overflowing wash basin (Y), overflowing wash basin (Y), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), overflowing wash basin (Y), overflowing wash basin (Y). overflowing wash basin (Y), and overflowing wash basin (Y), in this given order.

11. The method according to claim 2, further comprising: in the process 3 which is the applying the vegetable dyes to the bottom as a base color on a warp yarn under an indigo dye, applying the vegetable dyes to the bottom as a base color on a warp yarn and a under indigo dye, firstly subjecting the warp yarn to the REM process (R), supplying at least one of the vegetable dyes selected from acorn hull (MP), black tea (BT), cochineal (CR), and tannin (TN) to the respective process step(s), wherein the process 3 further comprises the steps of aeration passage (SK) and/or high heat treatment (HT), overflowing wash basin (Y), overflowing wash basin (Y), first vegetable dye basin (W1), skipped (X), aeration passage (SK), steaming (ST), overflowing wash basin (Y), overflowing wash basin (Y), indigo dye unit (G), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), in this given order.

12. The method according to claim 2, further comprising: in the process 4 which is the using the vegetable dyes as a topping hue dye on indigo dye in dyeing denim fabric and yarns, using the vegetable dyes as a topping hue dye on a indigo dye in dyeing denim fabric and yarns, supplying at least one of the vegetable dyes selected from walnut hull (CV), black tea (BT), acorn hull (MP), (CR), and tannin (TN) to the respective process step(s), wherein the process 4 further comprises the steps of skipped (X), skipped (X), overflowing wash basin (Y), overflowing wash basin (Y), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), indigo dye unit (G), overflowing wash basin (Y), overflowing wash basin (Y), Rem process (R), overflowing wash basin (Y), overflowing wash basin (Y), third vegetable dye basin (W3), aeration passage (SK), steaming (ST), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y) and overflowing wash basin (Y), in this given order.

13. The method according to claim 2, further comprising: in the processes 5 which is the desizing raw denim, the process 6 which is the dyeing flat cotton and mixed fiber denim and gabardine fabrics in a single color with a top dye in continuous fabric dyeing machines, and the process 7 which is the desizing raw denim, dying raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics in a single color with a top dye (overdyed by covering, foaming covering methods) in continuous fabric dyeing machines, firstly subjecting raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics to the REM process (R), supplying at least one of the vegetable dyes selected from walnut hull (CV), black tea (BT), acorn hull (MP), madder (KK), (CR), and tannin (TN) to the respective process step(s), wherein the processes 5, 6, and 7 further comprise the steps of the overflowing wash basin overflowing wash basin (Y), overflowing wash basin (Y), intermediary drying (AK), vegetable dye padder (WF), steaming (ST), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y) and drying unit (KR), in this given order.

14. The method according to claim 2, further comprising: in the process 8 which is the dying flat cotton and mixed fiber denim and gabardine fabrics with the vegetable dyes by means of foaming, knife-, press- and other covering techniques in continuous fabric dyeing machines, dying raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics with the vegetable dyes by means of foaming, knife-, press- and other covering techniques in continuous fabric dyeing machines, firstly subjecting raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics to the REM process (R), supplying at least one of the vegetable dyes being selected from walnut hull (CV), black tea (BT), acorn hull (MP), madder (KK), (CR), and tannin (TN) to the respective process step(s), wherein the process 8 further comprises the steps of overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), intermediary drying (AK), vegetable dye covering (WCO), steaming (ST), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), and drying unit (KR), in this given order.

15. The method according to claim 1, further comprising: carrying out the REM process (R) in a beginning of the process 1 which is the dyeing denim warp yarn and rope-shaped cotton yarn in single colors and light color tones with an organic vegetable dye, the process 2 which is the dyeing denim warp yarn and rope-shaped cotton yarn in double colors and dark color tones with the vegetable dyes, wherein 2-3 basins (passages) or 2 vegetable dyes are used to give dark and intermediate colors, the process 3 which is the applying the vegetable dyes to the bottom as a base color on a warp yarn under an indigo dye, the process 4 which is the using the vegetable dyes as a topping hue dye on indigo dye in dyeing denim fabric and yarns, the process 5 which is the desizing raw denim, the process 6 which is the dyeing flat cotton and mixed fiber denim and gabardine fabrics in a single color with a top dye in continuous fabric dyeing machines, the process 7 which is the desizing raw denim, and the process 8 which is the dying flat cotton and mixed fiber denim and gabardine fabrics with the vegetable dyes by means of foaming, knife-, press- and other covering techniques in continuous fabric dyeing machines, which serve to dye natural or synthetic fibers with the vegetable dyes, conducting the REM technique (R) using natural soap agents, textile softening agents and natural enzymes (wheat enzyme and honey glucose enzyme etc.) such that wetting and softening are achieved, using the natural soap agents, textile softening agents and natural enzymes singly or in mixture in a concentration of 50-350 g/L, at 0-100 C. under steeping and air passage applications for 20-120 second.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0025] The figures to provide a better understanding of the present invention are described below.

[0026] FIG. 1 provides a table showing the steps of a vegetable pre-dyeing and dyeing process of yarns and denim fabrics made of cotton, vegetable and synthetic fibers in the form of beam and rope warp.

[0027] FIG. 2 provides a table showing the process and dyeing standards by which vegetable natural organic dyes are applied to denim and gabardine fabric by means of a REM technique in a continuous dyeing machinery line.

[0028] FIG. 3, is an exemplary flowchart of process 1 to facilitate the understanding of the respective processes.

REFERENCE LIST

[0029] RREM technique, or simply REM [0030] SKAeration passage (AirSky) [0031] STSteaming (steamer) [0032] HTHigh heat treatment (high temperature) [0033] GIndigo dye unit [0034] BBVegetable dye nomenclature [0035] CVWalnut hull [0036] MPAcorn hull [0037] KKMadder [0038] BSBlack cumin [0039] BTBlack tea [0040] CRCochineal [0041] TNTannins [0042] YOverflowing wash basin, i.e. overflowing water wash [0043] AKIntermediate drying [0044] W1First vegetable bath basin [0045] W2Second vegetable bath basin [0046] W3Third vegetable bath basin, i.e. topping vegetable dye basin [0047] WFVegetable dye padder [0048] WCOVegetable dye coating [0049] KRDrying unit [0050] XSkipped process step or basin.

Description of Reference Lists

Rem Technique (R):

[0051] Rem basin: A basin or bath where a REM process is carried out. [0052] Concentration of the Rein application basin: 20-200 g/L [0053] Application basic temperature: 30-80 C. [0054] Rem feed rate: 20-70% of the weight of the yarn fabric [0055] Object of Rem use: Extending fiber gaps to provide swelling (volume increase).

[0056] Rem content: Wheat enzyme, honey enzyme, wetter and softener providing volume increase, tannic acid, stearic acid, citric acid and similar organic acid components. These organic and chemical substances are used singly or jointly in amounts determined according to the type and concentration of dye-plant pigments (tannins, juglone) to be added in subsequent steps.

Aeration Passage (Air Sky) (SK):

[0057] Provided to carry out aeration-oxidation for 20-100 seconds.

Steaming (Steamer) (ST):

[0058] Provided for steam fixation at 95-105 C. for 30-180 seconds.

High Heat Treatment (High Temperature) (HT):

[0059] Provided for steam-free heating in cabinet at 100-160 C. for 30-180 seconds.

Indigo Dye Basins and Unit (G):

[0060] Number of bath or treatment basin: 1-6 (basil)

[0061] Feature: It is a bath or baths (basin or basins) of vegetable natural indigo or chemically-derived liquid or powder indigo used in denims.

Overflowing Wash Basin (Y):

[0062] Provided to remove any dyes and chemicals not bond to yarns and fabrics by means of this overflowing water wash performed at 60-80 C.

Intermediary Drying (AK):

[0063] It is a step required to provide entrance into solution from dry state (DRY IN WET).

First Vegetable Dye Basin (WI):

[0064] Concentration factor of basin: 1/10-1/100=1 kg plant/10 L water-1 kg plant/100 L water [0065] Feed factor: 1/20-1/3 [0066] Feed rate: It is calculated so that 50-1000 g of dry color plant is used for 1 kg yarn/fabric. [0067] When plant extracts are used, it is calculated so that 30-300 g of plant extract is used for 1 kg yarn/fabric. [0068] Basin temperature: 60-95 C. [0069] Basin bath volume: 200-500 L

Second Vegetable Dye Basin (W2):

[0070] Concentration factor of basin: 1/10-1/100=1 kg plant/10 L water-1 kg plant/100 L water [0071] Feed factor: 1/20-1/3 [0072] Feed rate: It is calculated so that 50-1000 g of dry color plant is used for 1 kg yarn/fabric. [0073] When plant extracts are used, it is calculated so that 30-300 g of plant extract is used for 1 kg yarn/fabric. [0074] Basin temperature: 60-95 C. [0075] Basin bath volume: 200-400 L
Third Vegetable Dye Basin, le. Topping Vegetable Dye Basin (W3): [0076] Concentration factor of basin: 1/10-1/100=1 kg plant/10 L water-1 kg plant/100 L water [0077] Feed factor: 1/20-1/3 [0078] Feed rate: It is calculated so that 50-1000 g of dry color plant is used for 1 kg yarn/fabric. [0079] When plant extracts are used, it is calculated so that 30-300 g of plant extract is used for 1 kg yarn/fabric. [0080] Basin temperature: 60-95 C. [0081] Basin bath volume: 200-500 L

Vegetable Dye Padder (WF):

[0082] Concentration factor of basin: 1/20-50=1 kg plant/20-50 L water [0083] Feed factor: 1/7-20 [0084] Feed rate: It is calculated so that 100-500 g of dry color plant is used for 1 kg yarn/fabric. [0085] When plant extracts are used, it is calculated so that 20-200 g of plant extract is used for 1 kg yarn/fabric. [0086] Basin temperature: 20-85 C. [0087] Basin bath volume: 70-200 L

Vegetable Dye Covering (WCO):

[0088] In vegetable dye covering (WCO), the vegetable dye has the same factors with the padder, but the process is carried out using foams and pastes. [0089] Namely; [0090] Concentration factor of basin: 1/20-50=1 kg plant/20-50 L water [0091] Feed factor: 1/7-20 [0092] Feed rate: It is calculated so that 100-500 g of dry color plant is used for 1 kg yarn/fabric. [0093] When plant extracts are used, it is calculated so that 20-200 g of plant extract is used for 1 kg yarn/fabric. [0094] Basin temperature: 20-85 C. [0095] Basin bath volume: 70-200 L

Drying Unit (KR):

[0096] Here, a fixation function is provided at the same time.

Skipped Process Step or Basin (X):

[0097] This may be absent according to the state of the respective plant.

DETAILED DESCRIPTION OF INVENTION

[0098] In order to provide a better understanding of the production process according to the present invention, it will be referred to the prior art. According to the prior art, cotton fiber is a vegetable natural fiber and cannot form stable bonds by reacting with vegetable dyes. In order to eliminate this drawback, the so-called REM technique is carried out prior to vegetable dyeing process. The process step designated as REM or R, allows to increase the distance (gap) between the fibers and to provide a catalyst effect in the binding reaction between the dye molecules and the cotton molecules so that the dyeing efficiency is increased at least three fold. The development of this technique, in turn, paved the way to use vegetable dyes in mass production with competitive costs and qualities. Here below, both the process steps, and the raw materials (or materials) used in the process will be referred to with abbreviations.

[0099] Using this REM technique (R), it is now possible to carry out industrial production in a continuous system in reduced time intervals and at lower temperatures. Thus, it is further possible to provide textile products in original natural plant colors and luster, as desired, without using any auxiliary chemicals.

[0100] The REM technique (R) is characterized in that natural and synthetic fibers are treated with wetting agents, natural soaps, textile softening agents and natural enzymes (comprising wheat and honey-glucose enzyme) individually or jointly, so that the binding efficiency of the dyes to the fibers is increased at least three fold (geometric or multiplier effect). Thus, using the REM technique (R), the binding rate of vegetable dyes to cotton fibers are increased so that continuous systems or semi-continuous systems can be used. What is meant here with the terms continuous or semi-continuous is a system flow composed of integrated machines. Here, the REM technique is the foremost among all processes and process steps. Here, wetting and softening are achieved using enzyme catalysts together with natural soap agents which are applied singly and/or in mixture in the form of steeping, along with air passage, preferably in a concentration of 50-350 g/L at 0-100 C for 20-120 seconds, so that relatively larger vegetable dye pigment molecules are penetrated into the fiber gaps more easily and rapidly. Here, the use of 50-350 g mixture per liter is a preference in the implemented process. In this technique, the target effect is enhanced with an increase in the amount of added mixture. The effect is linear Therefore, this interval may be 1-1000 g/L.

[0101] The REM technique (R), which is a totally new approach implemented prior to dyeing using hot and concentrated softening soap and wetter, organic enzymes (wheat enzyme and glucose enzyme) provides at least a three fold increase in the affinity (dye binding, binding rate) of vegetable dyes to cotton and other fibrous products so that stable and strong chemical bonds are formed between them.

[0102] Wheat enzyme and honey glucose enzyme are produced by means of fermenting wholly organic and natural dough and honey which are left standing for a long period of time (10 to 100 days). Thus, the main agent is reproduced in wheat products. In addition, single or joint treatment with organic acids such as citric acid, tannin acid, stearic acid will increase the dyeing efficiency.

[0103] The vegetable dyeing method according to the present invention comprises different versions according to the vegetable dyes used, the products to be treated, and to the target results. These versions are divided into eight main groups. It is required to implement the REM technique (R) before each process. However in process 4, it is implemented not at the beginning, but within the process (between the steps of the process). In order to carry out the present invention on industrial continuous machines, seven basic separate processes are designed and developed upon standardization.

Processes

[0104] Process 1: It is a process (mono deep) in which denim warp yarn and rope-shaped cotton yarn are dyed in single colors and light color tones with an organic vegetable dye.

[0105] Process 2: It is a process (double deep) in which denim warp yarn and rope-shaped cotton yarn are dyed in double colors and dark color tones (intermediate color) with vegetable dyes, wherein 2-3 basins (passages) or 2 vegetable dyes are used to give dark and intermediate colors. Here, the term intermediary color means a color which is obtained by mixing two colors. For instance, an intermediate orange color is obtained as a result of applying red and yellow colors one after the other.

[0106] Process 3: It is a process in which vegetable dyes are applied to the bottom as a base color on a warp yarn under an indigo dye. Here, the dye is applied to the bottom of a material to be dyed. Here, e.g. natural indigo dye or blue indigo bye may be used. Namely, it is used under the natural dye or synthetic indigo dye to obtain different color hues of a normal blue denim jean dye, thereby giving 3 colors and the tones thereof These three colors are grayish blue (grey cast), greenish blue (green cast, turquoise), and reddish blue (red cast). It is used with natural vegetable dyes (walnut, tannin, etc.) for natural indigo dye or blue indigo dye.

[0107] Process 4: It is a process in which vegetable dyes are used as a topping hue dye on indigo dye in dyeing denim fabric and yarns. Here, the dye is applied to the top of a material to be dyed.

[0108] Processes 5-6-7: These are processes in which raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics are dyed in a single color with a top dye (over-dyed by covering, foaming covering methods) in continuous fabric dyeing machines.

[0109] Process 8: It is a processes in which raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics are dyed with vegetable dyes by means of foaming, knife-, press- and other covering techniques in continuous fabric dyeing machines. These covering methods are foaming covering, knife covering, press covering etc.

[0110] The aforesaid processes are briefly described in the tables in FIGS. 1 and 2. In order to understand these tables, however, it will also be referred to an exemplary flowchart of process 1 given in FIG. 3. Accordingly, the tables in FIG. 1 and FIG. 2 show the process types and the flow type of the process. The process tables may define the flow of the process from left to the right. Each cell resembles a process step. For instance, in describing a process, the beginning of the table (in FIG. 1 and FIG. 2) (i.e. the processes column) shows the type of the process, the next column shows the codes of the vegetable dyes used, and the following columns show the following steps.

[0111] In order to understand these tables, however, it will also be referred to an exemplary flowchart of process 1 given in FIG. 3.

[0112] In process 1, the REM technique (R) is applied to denim yarns with at least one vegetable dye selected from madder (KK), acorn hull (MP), black tea (BT), black cumin (BS), cochineal (Carmen, CR), walnut hull (CV) and tannins (TN). Then, it is passed through an aeration passage (SK) for 20-100 seconds. Thereafter, it is subjected to overflow washing in a overflowing, wash basin (Y) at 30-60 C. This step (Y) is repeated twice. Then, it is put into a first vegetable dye basin (WI) with a basin concentration factor from 1/10 to 1/100 and a bath volume of 200-500 L at 60-95 C. The feed rate here is 1/8 to 1/15 such that 300-1.000 g of dry plant extract is used for 1 kg of yarn, Then, it is passed again through the aeration passage (SK) for 20-100 seconds, after which one process step is skipped, and it is then subjected again to overflowing water wash (Y) at 30-60 C. at least three times.

[0113] Describing process 1 as above will facilitate the understanding of other processes. A person skilled in the art or a person generally familiar with vegetable dyes and textile dyeing will understand the invention better from this standard description of process 1. Accordingly, the type of material to be treated (e.g. denim, gabardine fabrics, yarns and similar materials), the conditions under which the treatment is carried out, the amount and type of the natural vegetable dyestuffs to be used, and the duration of the treatment in process 2, process 3, process 4, process 5, process 6, process 7, and process 8 are indicated in the tables in FIG. 1 and FIG. 2. The general characteristics of these tables will be as follows:

[0114] Accordingly, the present invention provides a production method for dyeing denim yarns and denim fabrics with vegetable dyes, the method having the following characterizing features.

[0115] Natural or synthetic fibers are subjected to the REM technique (R) in a continuous manner so that they are dyed with at least one vegetable dye selected from madder (KK), acorn hull (MP), black cumin (BS), walnut hull (CV) black tea (BT), cochineal (Carmen, CR), and tannins (TN) in process 1, process 2, process 3. process 4, process 5, process 6, process 7 or process 8.

[0116] The REM technique or process (R) is carried out in the beginning of process 1 process 2, process 3, process 5, process 6, process 7 and process 8, and during process 4, so that natural or synthetic fibers are dyed with vegetable dyes in these steps; the REM process (R) is conducted using natural soap agents, textile softening agents and natural enzymes (wheat enzyme and honey glucose enzyme etc.) such that wetting and softening are achieved, wherein said natural soap agents, textile softening agents and natural enzymes are used singly or in mixtures in a concentration of 1-1000 g/l, preferably 50-350 g/L at 0-100 C. in the form of steeping, along with an air passage application for 20-120 second.

[0117] The process 1 is a process in which denim warp yarn and rope-shaped cotton yarn are dyed in a single color and light color tones with organic vegetable dyes, wherein denim warp yarn and rope-shaped cotton yarn are first subjected to the REM process (R), after which at least one vegetable dye selected from madder (KK), acorn hull (MP), black tea (BT), black cumin (BS), walnut hull (CV), cochineal (CR), and tannin (TN) is supplied to the respective process step(s) comprised by process 1 as follows: aeration passage (SK), overflowing wash basin (Y), overflowing wash basin (Y), first vegetable dye basin (W1), skipped (X), aeration passage (SK), skipped (X), overflowing wash basin (Y), overflowing wash basin (Y), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), and overflowing wash basin (Y), in this given order.

[0118] The process 2 is a process (double deep) in which denim warp yarn and rope-shaped cotton yarn are dyed in double colors or dark color tones (intermediate color) with vegetable dyes, wherein 2-3 basins (passages) or 2 vegetable dyes are used to give dark and intermediate colors, wherein denim warp yarn and rope-shaped cotton yarn are first subjected to the REM process (R), after which at least one vegetable dye selected from madder (KK), acorn hull (MP), black tea (BT), walnut hull (CV), cochineal (CR), and tannin (TN) is supplied to the respective process step(s) comprised by process 2 as follows: aeration passage (SK), overflowing wash basin (Y), overflowing wash basin (Y), first vegetable dye basin (W1), second vegetable dye basin (W2), aeration passage (SK), steaming (ST) and/or high heat treatment (NT), overflowing wash basin (Y), overflowing wash basin (Y), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), and overflowing wash basin (Y), in this given order.

[0119] The process 3 is a process in which vegetable dyes are applied to the bottom as a base color on a warp yarn under an indigo dye, wherein the warp yarn is first subjected to the REM process (R), after which at least one vegetable dye selected from acorn hull (MP), black tea (BT), cochineal (CR), and tannin (TN) is supplied to the respective process step(s) comprised by process 3 as follows: aeration passage (SK) and/or high heat treatment (HT), overflowing wash basin (Y), overflowing wash basin (Y), first vegetable dye basin (W1), skipped (X), aeration passage (SK), steaming (ST), overflowing wash basin (Y), overflowing wash basin (Y), indigo dye unit (G), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), in this given order.

[0120] The process 4 is a process in which vegetable dyes are used as a topping hue dye on an indigo dye in dyeing denim fabric, and yarns, wherein at least one vegetable dye selected from walnut hull (CV), black tea (BT), acorn hull (MP), (CR), and tannin (TN) is supplied to the process step(s) comprised by process 4 as follows: skipped (X), skipped (X), overflowing wash basin (Y), overflowing wash basin (y), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), skipped (X), indigo dye unit (G), overflowing wash basin (Y), overflowing wash basin (Y), Rem process (R), overflowing wash basin (Y), overflowing wash basin (Y), third vegetable dye basin (W3), aeration passage (SK), steaming (ST), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y) and overflowing wash basin (Y), in this given order.

[0121] The processes 5, 6, and 7 are processes in which raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics are dyed in a single color with a top dye (overdyed by covering, foaming covering methods) in continuous fabric dyeing machines, wherein raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics are first subjected to the REM process (R), after which at least one vegetable dye selected from walnut hull (CV), black tea (BT) acorn hull (MP), madder (KK), (CR), and tannin (TN) is supplied to the respective processes step(s) comprised by processes 5, 6, and 7 as follows: overflowing wash basin (Y), overflowing wash basin (V), overflowing wash basin (Y), intermediary drying (AK), vegetable dye padder (WF), steaming (ST), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y) and drying unit (KR), in this given order.

[0122] The process 8 is a process in which raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics are dyed with vegetable dyes by means of foaming, knife-, press- and other covering techniques in continuous fabric dyeing machines, wherein raw denim, desized, flat cotton and mixed fiber denim and gabardine fabrics are first subjected to the REM process (R), after which at least one vegetable dye selected from walnut hull (CV), black tea (BT), acorn hull (MP), madder (KK), (CR), and tannin (TN) is supplied to the respective process step(s) comprised by process 8 as follows: overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), intermediary drying (AK), vegetable dye covering (WCO), steaming (ST), overflowing wash basin (Y), overflowing wash basin (Y), overflowing wash basin (Y), and drying unit (KR), in this given order.

[0123] Denim yarns and fabrics dyed with vegetable dyes based on the methods described above provides the achievement of the aforesaid results which cannot be provided according to the prior art. These methods can be applied both to all denim yarns and fabrics and other textile materials used together with denim, as well as to composite, nonwoven, knitting and similar weaving techniques.