Two-bath Dyeing
Main Information
Description
Two-bath Dyeing
Two-bath dyeing is a method for coloring blended fabrics composed of different fibers so that the dye is evenly distributed across all surfaces and types of fibers. This process ensures a more coordinated and attractive final fabric. By using the two-bath dyeing method, the colors become stable and resistant to washing and light. This technique is especially useful for producing high-quality garments and blended textiles, giving a professional appearance to the finished product.
Product Technical Description
Two-Bath Dyeing: An Advanced Method for Blended Fabrics
Two-bath dyeing is one of the most advanced and precise techniques in the textile industry, specifically designed for dyeing blended fabrics. This technique is used when the fabric is made of two different types of fibers, such as cotton and polyester. In these fabrics, each type of fiber requires separate dyeing with a dye suitable for its composition so that the final result is a harmonious, uniform, and long-lasting color.
Two-Bath Dyeing Process
This method consists of two distinct stages, with each bath dedicated to specific fibers:
- First Bath: In this stage, the synthetic part of the fabric (such as polyester) is dyed using disperse dyes at a high temperature, ensuring deep penetration into the fibers.
- Second Bath: After completing the first stage, the fabric is placed into the second bath, which is designed for natural fibers such as cotton or viscose. Here, reactive dyes or direct dyes are used to fix the color within the natural fibers.
- Final Washing and Fixation: At the end, the fabric is washed and fixed so that both dyes are locked in their respective places, resulting in a harmonious appearance.
Features of Two-Bath Dyeing
- High Color Uniformity: All parts of the fabric, both natural and synthetic, are evenly and harmoniously colored.
- Color Durability and Fastness: Superior resistance to washing, light, and abrasion compared to conventional methods.
- Preservation of Fabric Softness: The fabric structure is maintained throughout the process, and its softness is preserved.
- Design Flexibility: Allows for combining a wide range of colors and creating modern, appealing patterns.
- Efficiency for Special Fabrics: Ideal for blended fabrics such as polyester/cotton, polyester/viscose, and nylon/cotton.
Applications of Two-Bath Dyeing
Due to its high precision and quality, two-bath dyeing is widely used in various textile industries, particularly in the production of garments, modern fabrics, and home textiles. This method is applied in making blended T-shirts, coats, uniforms, workwear, curtains, tablecloths, and decorative fabrics. It is also highly effective for producing industrial fabrics that require durability, color fastness, and harmony.
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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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