Rope Dyeing Machine

Rope Dyeing Machine forms an essential process in the denim plant. It works on the principle of the form of rope (from the ball warping m/c). In MIL, generally 32ropes are simultaneously fed to the rope dyeing machine through various guides and tensioning arrangement at the creel zone to introduce firstly into the scouring box. The level of this bath is controlled by a leveller which on lowering up to a certain level (manually present) along with liquid level opens a value for addition of the caustic liquor from the main tank. Then come the two wash boxes, hot wash box followed by the cold one.

The ropes now ready to dye enters the first dye bath. There are eight dye baths and number of them employed depends according to the type of dye to be done .The addition of dye liquor and other aux are carried out through different metering pumps like DYSTAR .The liquors circulated between the employed dyes baths to another circulated pumps, as they are inter connected .Formula use for estimating the feeding rate:

Feeding (lt/min)=(total no.of ends *machine speed*shade%)

(Count *length of yarn)

After coming out of the each dye box yarns are padded, the pressure being highest at the first and last dye box, which is 55psi and the intermediate 40-50psi.The ropes pass after padding around a no. of sky roller to provide adequate time of oxidation. After this the ropes passes through the five wash box, where hot wash, cold wash and neutralization is carried out.

Sometime softener treatment is also given in one of the wash box .The temperature of the entire wash box is controlled through the control panel by means of thermostat.

• Capacity of the scouring /mercerization and wash box=1300 litres
• Capacity of the dye box =2500 litres

There are three columns of the vertical drying cylinders range each having twelve cylinder following washing. Each column is providing  with the steam trap .The temperature is control from the electronic control panel .The ropes are guided out of the m/c the respective guides ,delivery rollers and the guide pipes which coils the ropes in the large can .

• The dimension of the can :height =64in &diameter =68in
• The capacity of the can is about 22000 m rope

Colours Processed In Plant

1. Pure 100% indigo dyed
2. Midnight indigo
3. Deep blue
4. Light blue
5. Sulphur black

Material Flow In Rope Dyeing Machine

 Ball/logs

↓

Creel

↓

Draw nip

↓

Scouring

↓

Washing -1

↓

Washing-2

↓

Dye boox-1

↓

Dye box-2

↓

Dye box-2

↓

Dye box-3

↓

Dye box-4

↓

Dye box-5

↓

Dye box-6

↓

Dye box-7

↓

Dye box -8

↓

Washing-1

↓

Washing -2

↓

Washing-3

↓

Softening

↓

Drying

↓

Coiler

↓

Can

Balls, Creel, Draw Nip:-There are 32 numbers of balls which are feeded continuously in the rope dyeing machine with the help of tensioner and draw nip.

Scouring Box:Scouring is done in scouring box with 4nip 4 dip passages .Then the yarn is passed through 2 wash boxes in which 1^st is hot wash and 2^nd is cold wash

Recipe For Scouring:-Caustic =1.5gpl

Dekol (wetting agent) =0.5gpl

Sandogen EH (mercerising agent) =0.5gpl

Temperature=90 c

Speed=23mpm

Capacity=1500lts

Washing Boxes:There are 2 washing boxes 1^st is hot wash and 2^nd is cold wash .The yarn is passed through 4-dip 4-nip sequence .capacity of first wash box is 1300 litres and of second wash box is 1400 litres.

Dye Boxes:There are 5 dye boxes used in which indigo dyeing is done .The dipping time is 24 sec. and oxidation time is 105 sec. Dye pickup is 70% and nip pressure is 0.5kgs per mt.

Drying:

There are 36 drying cylinders used for drying .drying is done with the help of dry steam which is fed in the steel cylinders .the temperature is maintained between 100-110.c

Long Chain Beaming

The dyed ropes in the cans coming from the rope dyeing machines are converted into pre beams. The no. of ends (around 360) in a rope is the same as set in ball warping machine.

The rope are withdrawn from the can by means of a pair of drawing rollers as it passes over a guide and through a trumpet guide to enter the nip of drawing rollers .After this it enters the tension stand, where it warps (usually 3) around the falling rollers on then passes with in a number of guides and around roller to enter the accumulator. The tension at the tension stand is kept between 20-40psi,depending on the count of the yarn .At the accumulator the tension is generally set 60-80psi and it is used to accumulate the length of rope that is reversed drying detection of any broken end .it works on the principle of gate type tensioning .one set tension .The path of yarn is somewhat different in the mill made machine  .There is no accumulator & thus an extra person is employed to pull the rope ,while the beam is being reversed to maintain the desired tension .After coming out of the accumulator of the rope passes around the beater bar on the tension stand. The pressure roll presses of 7-15psi on the package i.e. the pre beam.

The denting is made easier with the help of lease threads, which separates the adjacent end in two levels .These lease threads are taken out of the shed before the end crosses the dent.

Machine Data

Maker: Mc Coy Elision (U.S.A)

Year manufacture: 12/12/2002

Running speed: 250-300m/p

Pressure: 7-17 psi

Efficiency: 35-40%

Faults Of Lcb

1. Missing end
2. End piecing
3. Weak places
4. Reed cut
5. Weak piecing
6. Knotting
7. Fluff cut for Rope Dyeing Machine