Characterization and dyeing performance of cold pad batch method using reactive dyes

The textile sector in Bangladesh, heavily reliant on resource-intensive exhaust dyeing, faces urgent sustainability challenges, including excessive water consumption, salt pollution, and high energy demand. This study evaluates the eco-efficient Cold Pad Batch (CPB) method as a scalable alternative to conventional exhaust dyeing for 100% cotton single jersey fabrics, benchmarking its performance. Results demonstrate the transformative potential of CPB: it achieved an average dye fixation of 82.5% without salt additives at ambient temperature. Calorimetrically, CPB matched exhaust dyeing in shade fidelity where ΔE < 1.0 across all colors, while enhancing color strength for red and blue dyes. 1–2 levels improve the light fastness of CPB compared to traditional methods, and 0.5-1 levels enhance its wet friction fastness. Material characterization revealed the gentler processing of CPB. SEM showed smoother fiber surfaces, EDS confirmed negligible sodium residues validating salt-free operation, and XRD indicated reduced crystallinity disruption. By eliminating salt and thermal energy use, CPB mitigates effluent pollution and aligns with the sustainability imperatives of the country.