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Technology We Use
Colour matching with the GretagMacbeth Spectrophotometer
When you send us a sample of the colour you want (we refer to this as ‘the standard’), we use a GretagMacbeth spectrophotometer to read the colour and create an accurate colour recipe. Our colour-matching technology is also equipped to predict colour using the Pantone PMS and Pantone TP systems.
Once we have a recipe, Helen (our laboratory technician) takes a sample of your fabric and does a “lab dip” in a small sample dyeing machine. The dyes are accurately added by using a pipette. Dyeing conditions, such as water levels and temperatures, are carefully measured so that when we go to bulk there are no variances in the colour.
If we are unhappy with the colour, we will make adjustments. Once we are satisfied with the match, we will send you this lab dip on a specially designed header for your approval.
Colour Database
We have an extensive list of colour recipes in our computer database. Our database is generally used by regular customers who want to repeat a colour used three or four seasons ago.
New customers can select a colour swatch of a fabric with a composition close to their fabric, and we can produce a recipe to match. However, since fabrics differ in thickness, construction, and yarn types, the absorption of dyes can differ and result in different colours, even though the fibre is same. When this occurs, the lab dip is essential.
Laboratory
The primary role of the laboratory is to reconfirm the recipes generated by the computerised colour-matching system. In standardising the liquor ratios and auxiliary concentrations in the beaker dyeing machine, which can dye 11 colours in one go, we are able to produce laboratory dips which will replicate very closely when done in bulk.
Properties of the dyeing, such as wash-fastness and light-fastness, can also be tested. After dyeing the bulk in multiple lots, lot-to-lot colour differences are measured keeping a high standard of ∆ E ≤ 1.1. The role of the laboratory in the Color Factory dye house is invaluable; we encourage you to use this service.
Sea-Lion Dyeing Machines
We recently invested over $200,000 in new dyeing equipment, particularly a variety of Sea-Lion dyeing machines to cater for a variety of dyeing requirements. The greatest advantage of the newer machines is that they are all computerised. This means that after the input of specifics for each batch, the entire process is automatic; this includes adding the dyestuff, adding the water and steam, and the extraction or spin processes.
Gas Dryers
Careful drying is very important, as over-drying can spoil the handle and the look of the garments. We dry fabrics and garments at the optimum drying temperatures, dictated by the fabric itself. For example, we would never dry a fabric containing spandex above 70° C. Our dryers are gas-fired and temperature and time-controlled. All our drying programmes have a cool down cycle, to ensure that the garments come out fresh, soft, and supple.
Steam Generator
Last year we replaced our inefficient 4000 lb. boiler with a compact steam generator. The generator is far more efficient as it generates steam on demand. This is very helpful when we want to do some sampling. An added benefit is that our gas bills have dropped sharply!
Dyestuff
We use dyes which comply with the Ocko-Tex standard 100 for materials that come in direct contact with the skin. We also fulfil the environmental criteria specified by the European Ecolabel for Textiles. The amount of metal impurities present in the dyes is below the internationally recognised ETAD recommended limits. See http://www.etad.com for further information. The dyestuffs do not liberate — by reductive clearage — any one or more of the 22 carcinogenic amines listed in the EU Directive 2002/61/EC dated 19/07/2002 i.e. they comply with the azo dye ban. Our dyes are also approved by the Global Organic Textile Standard.
