Disperse Dyeing
Main Information
Description
Disperse Dyeing
Disperse dyeing is specifically designed for synthetic fabrics such as polyester and nylon, allowing the dye to penetrate deep into the fibers to maintain high colorfastness and durability. This method ensures that patterns remain vivid and bright even after extended use and washing. The technique is ideal for the production of sportswear, industrial clothing, and durable textiles, and enables the creation of precise designs and vibrant colors.
Product Technical Description
Disperse Dyeing | Long-lasting Brilliance on Synthetic Fibers
Disperse dyeing is one of the most important and specialized dyeing methods in the textile industry, used for coloring synthetic fibers such as polyester, nylon, and acetate. In this process, water-insoluble (disperse) dyes, with the help of special auxiliaries, penetrate deep into the fibers, creating a long-lasting, shiny, and resistant color. The result of this technique is fabrics with high luster, exceptional color durability, and a professional appearance that withstands even harsh environmental conditions.
Disperse Dyeing Process
The disperse dyeing process, due to the physical properties of synthetic fibers, requires precise control of temperature, pressure, and time. The main stages include:
- Fiber Preparation: Cleaning and removal of oils and impurities from the surface of the fabric or yarn to enhance dye uptake.
- Color Bath Preparation: Using disperse dyes as very fine particles in an aqueous medium with the help of dispersing agents.
- Dyeing Stage: Penetration of the dye at high temperatures (usually 130 to 135°C) into the structure of polyester or nylon fibers.
- Color Fixation: After full penetration of the dye, fixation is carried out to strengthen and stabilize the bond between dye and fiber.
- Washing and Finishing: Finally, the fabric is washed to remove unfixed dye and maintain surface softness.
Characteristics of Disperse Dyeing
- High Brilliance and Vibrant Colors: Producing clear, shiny, and durable colors resistant to washing and light.
- Exceptional Color Durability and Fastness: Excellent resistance to heat, friction, and detergents.
- Deep Penetration into Synthetic Fibers: The dye enters the molecular structure of the fibers and does not remain on the surface.
- Maintaining Fabric Softness: No negative effect on the softness, flexibility, or natural sheen of the fabric.
- Precise Printing Capability: Suitable for printing various patterns and special color combinations on polyester fabrics.
Applications of Disperse Dyeing
Due to its durability, brilliance, and high quality, disperse dyeing is widely used in the production of various apparel, industrial, and decorative products. This method is employed in the design and production of sportswear, workwear, durable tunics, upholstery, and curtain fabrics, in situations where resistance to light, heat, and frequent washing is especially important. In addition, in technical and engineering industries, fabrics dyed with this method are used for durable equipment and specialty applications.
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Tejaratdookht Bartar Sabalan Factory
- Factory: Iran, Ardabil, Industrial Town No. 2, next to the Service Square
- Head Office: Iran, Tehran, Elahiyeh, East Maryam St., No. 47, 5th floor, Unit 17
Sabalan: The Beating Heart of Iran’s Textile Industry
On the green slopes of Ardabil, where the cold of Mount Sabalan blends with the warm efforts of the workers, one of Iran’s largest and most modern industrial complexes stands tall: the Sabalan Textile and Garment Complex, a symbol of progress, self-sufficiency, and transformation in the nation’s apparel industry.
The construction of this massive complex began in early 1999. After years of relentless effort, the erection of warehouses, installation of machinery, and launch of production lines were accomplished from 2004 to 2007. Ultimately, with the president in attendance, the factory officially opened its doors in 2007, ushering in a new era for Iran’s textile industry. But this was only the beginning of the story—a journey that, through considerable investment, technical innovation, and managerial revitalization, has today become one of the nation’s proudest industrial achievements.
Capacity and Scale at a National Level
The Tejarat Dookht Bartar Sabalan Factory is built on a 200,000-square-meter plot, with 120,000 square meters of infrastructure, in Ardabil’s Industrial Town No. 2.
This immense complex includes seven specialized units, each playing a vital role in the production process:
- Spinning
- Indigo (Denim Dyeing)
- Weaving
- Circular Knitting
- Dyeing, Printing & Finishing
- Sewing
- Flat Knitting
The design of these units is “independent island-style,” enabling each section to operate self-sufficiently and with maximum efficiency. The result of this meticulous structure is the production of a wide range of products—from various yarns and denim/tricot fabrics to ready-made clothing under proprietary brands.
Employment and Social Role
Currently, over 919 people work three shifts in production halls, administrative sections, and support units. Upon full implementation of the overhaul plan and full activation of all production lines, the complex's employment capacity can rise to 5,000—a figure that positions this factory as one of the largest employers in Ardabil Province.
A Challenging Development Path
The initial investment for this complex, supported by multi-million-euro capital and bank facilities, was made in January 2011, and the factory began operations under the name Arta Tejarat Zarrin. However, along the way, financial and managerial hurdles created a rocky road. From 2015 to 2021, the complex was leased out to various companies and teetered on the brink of bankruptcy.
The turning point came in October 2022, when the factory came under the protection of the “Industrial Support Board,” breathing new life into the company. A year later, in October 2023, factory ownership was transferred to Tejarat Bank, enabling a phase of rejuvenation under fresh management and extensive financial backing.
Modernization and Industrial Leap
With Tejarat Bank’s support, over 7,000 billion IRR in funding was injected for the complete overhaul of machinery, warehouse renovation, and infrastructure upgrades.
The results were not just improved productivity but also a renewed sense of motivation among the staff. Timely payment of wages and benefits, better working conditions, and the establishment of a new rewards system fostered a dynamic and hopeful work environment.
The Birth of World-Class Iranian Brands
During its transformation, the complex decided to become not just a producer, but also a brand builder. To this end, three new proprietary brands were launched:
- Araz Jeans (for denim apparel)
- Araz Tex (for textile and fabric products)
- El-Savala (for modern and export garments)
These brands now stand as emblems of quality and authenticity in Iranian manufacturing. By entering both domestic and regional markets, they have opened a new chapter of profitability and competition.
Looking Ahead: Bright Horizons
Tejarat Dookht Bartar Sabalan Factory has developed a meticulous, forward-looking plan for the coming years. Key objectives include:
- Achieving an annual production of 35 million garments
- Expanding a high-quality supply chain from raw materials to final goods
- Increasing exports through collaborations with reputable global brands
- Moving towards a more innovative and competitive structure
- Expanding digital presence and media engagement to showcase capabilities
From Ardabil to the Global Market
The Sabalan Textile and Garment Complex is more than a factory; it’s a symbol of the revival of Iran’s textile industry, youth employment, and a testament to the power of domestic production.
Through the efforts of its managers, engineers, and workers, this complex has become a key industrial hub for the region and is steadily moving toward a brighter future—a future in which the “Made in Iran” label proudly shines on high-quality, modern apparel.
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