As part of its vertically integrated manufacturing operations, Nirwana Group undertakes fabric dyeing and finishing services that are fully supported by its in-house colour laboratory and professional staff. The group’s laboratory plays an integral role in accurately producing the right colour dye through the creation of a chemical formula to meet the client’s requirements — staff at Nirwana Group undergo chemical management training on the best practices and assessment of handling chemical textiles.
The process of dyeing can be carried out at different stages of the fibre life cycle such as with staple, yarn, fabric, and garment pieces. Samples of the fabric are then dyed against the colour specifications approved by the clients; Nirwana group’s quality control staff then checks the accuracy of the coloured samples. Once approved, the fabric is placed inside a dyeing tank for a specific period of time and temperature which differs depending on the material used and therefore affects the colour intensity – Nirwana group possesses the capacity to dye up to 100 tonnes of textile daily and 1,200 kg per batch.
Furthermore, before the dyeing process is completed, the fabric is submitted to the mercerisation process — a procedure that only Nirwana Group undertakes in Indonesia — which involves immersing the material in cold sodium hydroxide solution causing the fibres to shrink and swell. If the fibres are placed under tension whilst in this state then a permanent shine will appear. Additionally, if the sodium hydroxide is rinsed when the fibre is in the shrunk state then it will result in providing better elasticity to the fabric. Aside from improving the physical property of the fabric, the mercerisation process will also enhance the chemical properties and increase the fabric’s affinity to the dye thus resulting in a richer colour.
The fabrics then undergo specialised finishes such as ‘calendering’; to produce smooth surfaces on the fabric, or ‘raising’; to produce raised or fuzzy surfaces, to achieve the final texture as per the requirements of the client. As an integral part of the manufacturing process, Nirwana Group’s fabric dyeing and finishing procedure operate in an efficient manner in order to achieve the timely production of quality products.