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Reactive Exhaust Dyeing Recipe & Cost Calculator
Estimate chemical and dye recipes for exhaust dyeing batches. Compute reactive dyestuff, salt, and soda ash requirements and formulate cost breakdowns based on fabric weight and liquor ratios. No account needed — numbers update as you type.
Exhaust dyeing requires precise chemistry. Salt acts as an electrolyte promoter for exhaust efficiency, while soda ash acts as a pH stabilizer to permanently fix reactive dyes to cotton fibers.
Step By Step
How to Use This Calculator
5 steps
- Select the preferred operating currency and input the Fabric Batch Weight in kilograms.
- Adjust the Liquor Ratio slider (representing the fabric-to-water weight ratio, e.g., 1:10).
- Provide the Dyestuff dosage in percentage on weight of fabric (% owf) and the unit cost of dyestuff per kilogram.
- Enter Glauber Salt and Soda Ash dosages (in g/L) along with their respective unit prices.
- Observe the detailed exhaust dyeing recipe table containing precise chemical weights and cost breakdowns.
Worked Example
Worked Example — 100 kg Cotton Knit Dyeing Batch
Use this sample to sanity-check your inputs and understand what the final result represents.
- 1Fabric weight: 100 kg · Liquor ratio: 1:10 (Total water: 1000 Liters)
- 2Dye dosage: 2.5% owf · Salt dosage: 50 g/L · Soda dosage: 15 g/L
- 3Dye quantity: 100 × (2.5 ÷ 100) = 2.5 kg
- 4Salt quantity: (1000 × 50) ÷ 1000 = 50 kg
- 5Soda Ash quantity: (1000 × 15) ÷ 1000 = 15 kg
Final Result
Exporters require 2.5 kg of dyestuff, 50 kg of Glauber salt, and 15 kg of soda ash for this exhaust dyeing batch.
Methodology
Dyehouse Chemical Formulation Formulas
This section explains the calculation logic, assumptions, and source material used to make the result more trustworthy and easier to verify.
Water Volume (L) = Fabric Batch Weight (kg) × Liquor Ratio. Dyestuff Quantity (kg) = Fabric Weight (kg) × (Dye % owf ÷ 100). Glauber Salt Quantity (kg) = [Water Volume (L) × Salt Dosage (g/L)] ÷ 1000. Soda Ash Quantity (kg) = [Water Volume (L) × Soda Dosage (g/L)] ÷ 1000. Batch Cost = (Dye Qty × Dye Price) + (Salt Qty × Salt Price) + (Soda Qty × Soda Price). Source: BKMEA Wet Processing Manual.
Practical Guidance
Wet processing best practices for exhaust dyeing
- 1Use Glauber salt (sodium sulfate) instead of common salt (sodium chloride) for higher color exhaustion yields.
- 2Verify wash water temperatures and pH curves throughout the dyeing cycle to ensure uniform color fixing.
- 3Conduct pre-treatments (scouring and bleaching) to remove natural cotton waxes before executing exhaust dyeing steps.
- 4Adopt low liquor ratio machines to minimize steam and water consumption, lowering utility cost burdens.
Frequently Asked Questions
Why is Glauber salt used in exhaust dyeing?+
Glauber salt increases the exhaustion rate by neutralizing negative charges on both cotton fibers and dyestuffs, allowing reactive dyes to migrate closer to cellulose molecular chains.
What role does soda ash play?+
Soda ash acts as an alkali to raise bath pH levels (typically to 10.8 - 11.2), triggering covalent bond linkages between reactive dyes and cotton fibers.