Yarn Dyeing
Main Information
Description
Yarn Dyeing | Achieving Clear and Beautiful Patterns
Yarn dyeing is performed before fabric weaving so that the color penetrates deep into the fibers and achieves high colorfastness. This method allows woven fabrics to have clear and harmonious patterns. It is ideal for patterned fabrics such as checks, stripes, and mélange, and enhances the quality, durability, and visual appeal of the final product.
Product Technical Description
Yarn Dyeing | Uniform Color from Base to Product
Yarn dyeing is one of the fundamental and specialized stages in the textile industry, in which yarns are dyed before the weaving stage. This method allows pigments to penetrate uniformly and deeply into the fiber structure and create a high level of colorfastness. Unlike fabric dyeing, which takes place after weaving, yarn dyeing ensures that the color remains consistent and lasting in all parts of the yarn, from the surface to the core.
Yarn Dyeing Process
The yarn dyeing process generally includes the following steps:
- Yarn preparation: First, the yarns are washed and cleaned to remove any oils, dirt, or excess materials.
- Dyeing stage: The yarns are immersed in a dye bath at a specific temperature and for a specific period. Depending on the type of fiber (cotton, wool, polyester, etc.), different dyes such as reactive, disperse, or acid dyes are used.
- Color fixation: After the dye is absorbed, the fixation process is carried out to lock the color into the fiber structure and increase its resistance to washing and light.
- Washing and drying: Finally, the yarns are washed, water is extracted, and they are dried to be ready for weaving.
Unique Features of Yarn Dyeing
- Deep color penetration: The dye penetrates the core of the fibers, creating extremely high durability against environmental factors.
- Uniformity and luster of color: The resulting fabric from dyed yarns has a vibrant, uniform appearance without undesirable shading and unevenness.
- Design flexibility: Allows for the creation of various patterns such as stripes, checks, mélange, and composite designs.
- High durability: Colorfastness to washing, abrasion, and sunlight are among the key advantages of this method.
Yarn dyeing has a wide range of applications and is used in the production of various apparel, home, and industrial fabrics. In apparel, dyed yarns are used to produce shirts, mantua, suits, and formal wear fabrics. In home textiles, this method is used to produce curtains, tablecloths, bed sheets, and upholstery fabrics, increasing their durability and beauty. In addition, in technical and industrial fields, dyed yarns are used to produce durable and functional fabrics such as filters and specialty bags.
Ultimately, yarn dyeing is a combination of science and art, resulting in fabrics with vibrant colors, precise patterns, and exceptional quality—a product that preserves its integrity and brilliance over time and provides a solid foundation for the creation of lasting and professional fabrics.
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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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