The Development of Eco-Friendly Dye Microcapsules for Wool Fabric Dyeing Application

There is an urgent need to reduce the environmental impacts of wool fabrics dyeing process while maintain its dyeing effects. Microcapsule technology is a potential option which could be used to move towards cleaner production process and to cope with ever-increasing demands for wool fiber dyeing efficiency. Reactive dyestuff microcapsules were prepared via reverse-phase evaporation methods and then auxiliary-free dye microcapsules were used to dye the wool fabrics. Transmission electron microscope images and fourier transform infrared showed that dye microcapsules possessed a spherical core–shell structure with a diameter of about 500 ± 5 nm. The processing factors were analyzed and optimized by using response surface methodology to improve the encapsulation rate. Higher fixation rate (80.13% vs. 72.03%) of dyed wool fabric, while lower absorbance of dyestuff (0.071 vs. 0.96), chemical oxygen demand (COD, 190 mg/L vs. 1395 mg/L) and biological oxygen demand (BOD₅, 83.5 mg/L vs. 649.3 mg/L) of residual wastewater were observed by using microcapsule dyeing, compared with conventional dyeing process. In addition, the results also demonstrated that the filtrated wastewater of microcapsule dyeing can be recycled as dyebath to replace distill water. Thus, we innovatively produced a novel dye microcapsule for wool fabric dyeing application, advancing greatly in reducing the discharge of contaminants to environment, but also in economizing water and energy resources.