Dye Quantity Calculator
Formula: Dye Quantity (grams) = Fabric Weight (grams) x Dye Concentration (% depth of shade). Light shade (2% depth): 1,000g fabric x 2% = 20g dye. Medium (5% depth): 50g dye. Dark (10% depth): 100g dye. Reactive dyes cost ₹300-500/kg (so 50g = ₹15-25 material cost). 1kg fabric batch: light shade ₹15, dark shade ₹30 dye cost. Dyeing services charge ₹80-150/kg (labor + utilities). So 1kg fabric dyeing = ₹20 (dye) + ₹100 (service) = ₹120/kg. Industrial dyeing: batch 500kg, cost ₹60,000 = ₹120/kg (same per-unit cost). Small batches are not cheaper per-unit, but more flexible.
Dye Types (Reactive, Acid, Natural)
Reactive Dyes (cotton, linen): most common in India. ₹300-500/kg, 2-10% depth typical. Usage: 50g dye + 950g fixative (salt + soda) per 5kg fabric. Acid Dyes (silk, wool): ₹400-800/kg, 1-5% depth typical (saturates quickly). Usage: 20g dye + acid per 5kg fabric. Natural Dyes (indigo, madder, turmeric): ₹1,000-3,000/kg (premium). 5-20% depth needed (less efficient). Usage: 100-200g dye per 5kg fabric (expensive). Synthetic reactive is most economical (high yield, predictable color). Natural dyes trending for eco-premium brands (charge 20-30% more). Industrial: mostly reactive. Boutique: mix reactive + natural for unique shades.
Shade Depth Guide
Light Shade (2% depth): pale pastels, uses minimal dye. Fabric ₹200/kg, dye ₹15, total cost ₹215/kg. Sell at ₹600-800/kg (light shades cheaper raw material but same retail price = better margin). Medium Shade (5% depth): standard colors (red, blue, green). Fabric ₹200 + dye ₹35 = ₹235/kg. Sell at ₹600-800 (same price, harder to sell in bulk). Dark Shade (10% depth): deep colors, maximum dye usage. Fabric ₹200 + dye ₹50 = ₹250/kg. Sell at ₹600 (same price, expensive to produce = lower margin). Price strategy: light/medium shades (better margin), avoid very dark shades unless premium (khadi, designer brands). Most commercial: 4-6% depth (balance cost + aesthetics).
Water Ratio Calculator
Dyeing liquor ratio (water:fabric weight): 1:40 (40 liters water per 1kg fabric) for bath dyeing. Example: 50kg fabric = 2,000 liters water (2 cubic meters). Industrial tanks: 5,000-50,000 liters. Home dyeing: 1kg fabric = 40 liters water (large bucket or tub). Higher water ratios (1:60, 1:100) = lighter, more even shade. Lower ratios (1:20, 1:30) = darker shade, uneven color. Pressure dyeing (closed system) needs lower water, higher temperature (80-130degC). Atmospheric dyeing (open vat) = max 100degC, needs higher water. Temperature affects dye absorption: 60degC for acid dyes, 60-95degC for reactive (hotter = deeper, faster). Cost per kg dyeing = (dye + water utilities + energy) / total kg. Industrial averages: ₹100-150/kg all-in.
FAQ
Can I dye different fabrics together? Only if compatible: cotton + linen (both reactive), silk + wool (both acid). Mixed fabrics take different colors (not recommended). Does water quality matter? Yes, hard water (calcium) prevents dye absorption. Use soft/filtered water for best results. Can I re-dye already dyed fabric? Yes, if going darker. Light dye over dark will not work. Can I mix dye colors? Yes, blend reactive dyes before adding to water. Creates custom shades (needs testing). How do I ensure even color? Stir frequently, maintain temperature, use proper water ratio. Uneven dye = poor machine agitation or low water. How long does dyeing take? 45-90 minutes active time + drying (natural = 2-3 days, mechanical = 4-8 hours). Cost of dyeing per kg? Total = (dye + utilities + labor + overhead) / kg = ₹80-150/kg. Can small batches use less dye? No, percentage-based (5% = 5% regardless of batch size). Small = less efficient (more overhead per kg).