Reactive Dyeing
Main Information
Description
Reactive Dyeing
Reactive dyeing creates long-lasting color and high brilliance by forming a chemical bond between the dye and cellulose fibers. This method is suitable for cotton and viscose fabrics, fully preserving the quality and beauty of the fabric. With reactive dyeing, colors become resistant to washing and light, while the texture remains soft and smooth. This technique is ideal for producing high-quality garments and home textiles.
Product Technical Description
Reactive Dyeing | Long-lasting Color and Natural Softness
Reactive dyeing is one of the most advanced dyeing methods in the textile industry, used especially for fixing color onto cellulose fibers such as cotton, viscose, and linen. This method, due to the strong chemical bond between dyestuff molecules and the fibers, creates vibrant, brilliant, and long-lasting colors. Fabrics resulting from reactive dyeing not only have high durability but also retain natural softness and smoothness, making them ideal for everyday and professional use.
Reactive Dyeing Process
The reactive dyeing process combines chemical science and precise temperature control techniques to stably bind the dye to the fibers. The main steps of this process include:
- Fiber preparation: Initial cleaning of the fabric or yarn to remove oils, sizing, and impurities.
- Immersion in the dye bath: Use of reactive dye solutions that form covalent bonds with cellulose fibers.
- Addition of alkalis (such as soda ash): To activate the dyestuff and facilitate the chemical reaction with the fibers.
- Fixing and washing: After the reaction is complete, the fabric is washed to remove unfixed dyes and achieve complete color fastness.
Features of Reactive Dyeing
- Very high durability: The color is fixed within the fiber structure, providing remarkable resistance to washing, light, and abrasion.
- Brightness and color clarity: Colors remain vibrant, natural, and do not shift spectrum after washing.
- Soft fabric surface: Maintains the softness and smoothness of the fibers without causing roughness or stiffness after dyeing.
- Wide color variety: Ability to produce precise, harmonious colors to suit the needs of fashion designers and the garment industry.
- Eco-friendly: Many reactive dyes comply with environmental standards and generate less wastewater.
Applications of Reactive Dyeing
Thanks to its high softness and stability, reactive dyeing is widely used in various sectors of the textile industry. This method is extensively applied in producing cotton fabrics for everyday wear, formal clothing, T-shirts, uniforms, bed linens, towels, and home textiles. It is also the first choice of manufacturers in interior decoration and hospital textiles, where frequent washing and durability are important.
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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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