Jet Dyeing Machine

Jet dyeing Machine generally used for dyeing fabric, dyeing polyester, dyeing clothe and others type of dyeing. Jet m/c resemble becks in that a continuous loop of fabric is circulated through the machine. There are different types of dyeing technique applied in dyeing machine like disperse dyes, reactive dyes, vat dyes, acid dyes, organic dyes etc. After Jet m/c fabric goes for Slitting Machine. 

Features of Jet dyeing machine of Dyeing Factory:

1. A high speed jet of dyeing machine for vat dyes liquid created by transports the fabric through the cloth guide tube of the jet machine.
2. A jet machine for acid dyes have cloth guide tube for each loop of fabric being processed.
3. A powerful pump circulates the liquor through a heat exchanger outside of the main vessel and back into the jet machine for reactive dyes
4. The fabric moves at high velocity of 200-800 meters per minute while it is in the cloth guide tube of dyeing factory.
5. The fabric leaving the cloth guide tube enters a larger capacity cloth chamber and gradually advances back toward the cloth guide tube.
6. This machine is also used for dyeing polyester

Advantages of Jet Dyeing Machine for Organic Dyes:

1. It is used for dyeing polyester in dyeing factory
2. Vigorous agitation of fabric and dyeformulation in the cloth tube increases the acid dyes rate and uniformity.
3. Rapid circulation of fabric through the machine minimizes creasing because the fabric is not held in any one configuration very long.
4. Lengthwise tension for disperse dyes on the fabric is low so the fabric develops bulk and fullness of handle.
5. Dyeing at high temperature of about 130C gives rapid dyeing, improved dyeutilization, improved fastness properties and makes possible the elimination of carriers required when dyeing at lower temperatures.
6. The lower liquor ratio used in jetdyeing allows shorter dye cycles and saveschemicals and energy.

Standard Operating Procedure of Dyeing Factory:

Autogarment dyeing factory follows its own quality management system. Every department has a SOP (Standard operating procedure). According to SOP all function are being done. There are some essential forms and register for proper functioning each department. All function are documented in respective department.

We follow 4 point system for inspection of greige fabric and finished fabric. In this system AQL limit is 28. Our main customer is Autogarment dyeing factory. we purchased yarn, dyes & chemicals. There is a checking system of every raw material. If its quality is pass, then its goes for using in production. Our main production division is knitting, dyeing and finishing.

A standard production processes of dyeing factory follow:

Knitting

↓

Greige fabric inspection

↓

Batching

↓

Dyeing

↓

Finishing

↓

Inspection of Finished fabric

↓

RFD (Ready for Delivery)

A dyeing factory have a standard Organogram. According to Organogram all recruitments are being done.

DYEING M/C TEMPERATURE RECORD (BEFORE & AFTER INSULATION):

Before Insulation	After Insulation
Date	Time For Temp. Increasing (45-98)°C	Time For Temp. Decreasing (98-80)°C	Date	Time For Temp. Increasing (45-98)°C	Time For Temp. Decreasing (98-80)°C
18.12.2012	09m46s	06m02s	17.01.2013	08m17s	05m44s
20.12.2012	08m30s	05m48s	23.01.2013	07m20s	05m00s
22.12.2012	09m10s	04m50s	29.01.2013	08m25s	04m07s
06.01.2013	12m30s	06m34s	30.01.2013	08m22s	05m25s
07.01.2013	19m03s	10m40s	31.01.2013	09m07s	06m10s
18.12.2012	15m46s	08m02s	05.01.2013	11m30s	07m13s
20.12.2012	15m17s	08m26s	06.01.2013	14m42s	07m36s
22.12.2012	16m20s	09m10s	07.01.2013	11m11s	07m24s
09.01.2013	14m50s	13m35s	05.05.2013	14m10s	10m15s
10.01.2013	14m53s	08m02s	06.052013	12m12s	07m20s
12.01.2013	18m03s	09m33s	07.05.2013	11m51s	08m15s
13.01.2013	14m53s	08m34s	08.05.2013	10m09s	07m02s
16.06.2013	08m40s	07m00s	01.08.2013	05m22s	05m59s
17.06.2013	08m20s	07m20s	02.08.2013	05m10s	06m30s
18.06.2013	09m10s	05m30s	03.08.2013	06m00s	05m00s
19.06.2013	10m25s	07m10s	04.08.2013	06m52s	O6m22s
24.05.2013	12m55s	07m45s	01.07.2013	10m03s	05m19s
25.05.2013	14m40s	05m20s	02.07,2013	09m08s	04m10s
26.05.2013	13m45s	09m15s	03.07.2013	10m01s	04m50s
27.05.2013	15m20s	05m19s	04.07.2013	10m20s	04m45s
24.05.2013	19m20s	09m10s	27.07.2013	10m03s	06m10s
25.05.2013	18m16s	05m55s	28.07.2013	10m15s	05m01s
26.05.2013	16m54s	08m15s	29.07.2013	11m25s	07m10s
27.05.2013	18m37s	07m45s	30.07.2013	11m20s	06m04s

STEAM VALVE TEMPERATURE RECORD (BEFORE & AFTER INSULATION):

Before Insulation
Date	Temp. of 01´´ Valve	Temp. of 02´´ Valve	Temp. of 04´´ Valve	Temp. of 06´´ Valve
19.12.2012	98°C	95°C	100°C	98°C
20.12.2012	95°C	98°C	97°C	96°C
22.12.2012	98°C	97°C	95°C	95°C
23.12.2012	95°C	98°C	98°C	98°C

After Insulation
Date	Temp. of 01´´ Valve	Temp. of 02´´ Valve	Temp. of 04´´ Valve	Temp. of 06´´ Valve
03.03.2013	42°C	38°C	36°C	42°C
04.03.2013	40°C	38°C	34°C	40°C
05.03.2013	36°C	37°C	35°C	36°C
07.03.2013	32°C	39°C	40°C	41°C

DYEING M/C HEAT EXCHANGER TEMPERATURE RECORD (BEFORE & AFTER INSULATION):

Before Insulation
Date	Heat Exchanger Temp. When M/C Temp. Inside Temp. is 100°C
18.12.2012	128°C
19.12.2012	130°C
20.12.2012	130°C
22.12.2012	132°C

After Insulation
Date	Heat Exchanger Temp. When M/C Temp. Inside Temp. is 100°C
09.01.2013	68°C
10.01.2013	70°C
15.01.2013	65°C
20.01.2013	72°C

Findings for Disperse Dyes and Other Dyes in Dyeing Area

• Need to clean & waterless beside of Overflow machine area
• Passage marking for all dyeing section
• Need to clean color room (Found poly, west water, empty dram)
• Electric cables & Electric board should be transfer in old color room. It’s found open & coverless.
• Danger sign for SDP board
• Need to create separate area for empty chemical dram or container & it’s also designated.
• Jute bag should be transfer from dyeing area for free passage
• Some electric cables found coverless in finishing area. It is looking danger
• Need to area marking for keeping trolley
• Need to clean in thread store
• Ensure all worker should use their PPE, in this act need to collect a list of PPE

Limitation of Jet Dyeing Machines:

Some limitation of jet m/c is described below-

1. Capital and maintenance costs are higher for this machine and for disperse dyes
2. Limited accessibility makes cleaning between dyeing and sampling for colorduring the dye cycle difficult.
3. The jet action tends to make formulations foam in partially flooded jet machines for organic dyes.

[1] Md. Ferdus Alam, B.Sc. in Textile Engineering, Southeast University, Cell # 1723300700, Email- ferdus.j@gmail.com