A sample jigger for dyeing up to
20 meters of fabric at atmospheric conditions.
WicItt,
Min. 20 inches
Fabric fp 1 e d
Variable Speed Control
Fabric tension
Adjustable
Temperature range
Room temperature to 95 C or above
Heating
Electrical heating with rate of
rise and top temperature control
APPLICATION TECHNIQUES
The quantities to use depend mainly on the type of dyes used and on the biggest or smaller. Read about Woven Fabric Jigger Machine
contact with the air of the dye bath that loses reduction potential.
with similar redox potential , provides a lower pH than ordinary sodium
sulphur.
This inferior alkalinity offers the following advantages:
Smaller degradation of sensitive fibers in goods containing weaker fibres (half wool, rayon
acetate, etc.).
Less cellulosic fibres swelling and consequently, easy dye penetration in machines with bath
circulation through the material.
Another advantage of the in front of the sodium sulphur it is the easy
removal of the remaining sulphur by means of a single cold rinsing after the dye.
is odourless and it doesn’t produce any scent, avoiding the troubles
working with conventional sulphur reducers.
Reduction state can be checked on the way, dropping the dye bath on a filter paper, the stain
should not present insoluble particles and the extended aureole , it should be coloured the same all
over from the central part where it has thrown the drop.
We can recommend:
Dye in Jet R/b 1:10 – 1:15
2 to 4 gr. / l
Dye in Jigger R/b 1:3 – 1:6
4 to 8 gr. / l
Dye in Autoclave R/b 1:10
2 to 3 g. / l.
Information about safety properties can be found in MSDS (Material Safety Data Sheet).The right of the product and to make change in its prospect is concealed by us MKS Devo R&D laboratories can provide more info on application techniques of the product
Bias Line-Definition and Causes
This condition which can easily be seen on the greige goods
also predominantly occurs in the single Jersey structures and, if finished
incorrectly, can cause angular hem line distortion.
The main cause for this condition is knitting machine’s
feeder numbers. As a general rule increasing the number of feeders increases
the Bias angle.
With the increase in demand for finer and lighter weight
fabrics and also increase in the number of feeders in knitting machines this problem
is becoming more evident.
Due to the nature of weft circular knitting process certain
Bias is inevitable and most fabric producers and garment manufacturers have
come to learn to effectively manage this problem.
With new and advanced knitting machines, in order to
increase the rate of production, the number of feeders has been increased, thus
accentuating this angular distortion.
Preventive Suggestions
To reduce the angular distortion and have a manageable
measure of Bias, the simple remedy is to reduce the number of feeders (lower
than 92, preferably down to 60). This is done by disengaging some of the
knitting zone’s needles. Correct finishing of the fabric as well as an
adjustment in the markers to compensate for the excessive Bias are other important
steps that need to be taken.
Corrective Measures
During the dyeing process, due to exposure to water and
temperature and the subsequent shrinkage that takes place, the fabric will
obtain a dimensionally relaxed state including its natural Bias.This is the exact state in which the fabric needs to be
dried at.Any attempt to correct the natural Bias (even severe Bias),
will create an unnatural condition.
The garment manufacturers can now use this fabric provided
that they make the necessary adjustments in their markers to compensate for the
Bias.
We know carpet is a colorful
thing. It is mainly used for floor coverings. It is increases the beauty of
home and official also.
Objective of Dyed yarn sorting:
To makes separate bundle of yarn according to
cloth.
To helpful for knotting.
Winch Dyeing MachineProcedure:
After dyeing and drying the yarn.
Then it is sorting into a beam.
It is sorting by hand.
Washing and Wash Rug Drying:
After knotting a full carpet
actually made. Then it is needs to be wash. After wash it will be ready for
next process.
Objective of Washing and Wash Rug Drying:
To remove impurities is from carpet.
To increase lusture of carpet.
To make soft handle.
Procedure:
First we haveto lay the carpet in the field.
Then it is have to fall water on the surface of carpet.
Then wash the carpet by brush.
Then have to dry the carpet by sunlight.
Dyeing Related Defects/Problems
Uneven Appearance and Blotchiness-
Definition and Causes:
There are many factors that could cause these conditions.
The following are the most common causes:
uneven exhaustion of dyes (disperse and acid dyes)
uneven absorption of dyes
(reactive and direct dyes)
incompatibility of dyes in the color formula
incorrect or incomplete preparation of the greige goods
prior to dyeing
left-over and un-removed preparation chemicals prior to
dyeing (Hydrogen Peroxide)
insufficient and improper use of Retarders/Leveling
chemicals (in direct dyes)
incorrect fabric dwell time in the dye machine
high dye bath water hardness
application of fixing chemicals in un-clean dye bath water
the use of high energy disperse dyes at low temperatures etc.
Preventive Suggestions:
Due to the complexity of the dyeing process, every technical
aspect of dyes, chemicals and type of machineries, must be studied and taken in
to consideration before any attempt is made to select a procedure to dye a
fabric.
Corrective Measures:
Generally, and in less severe cases, removal and stripping
the original color and re-dyeing the fabric may correct the problem. Although,
total removal of the original color may weaken the fabric and thus special care
is required.
In more severe cases, over-dyeing in to a darker shade or
black may be the only solution.
Non-Union Dyeing (Cross-Dyeing)-
Definition and Causes:
This is a common problem with fabrics that are made with
blended yarns where one component of the yarn appears to be of a different shade.
Preventive Suggestions:
In order to get an even and uniform (union) color, both
fibers need to be dyed to the same color according to their percentage content.
This could be done by dyeing one component first followed by
the other fiber. This is known as “2 bath dyeing “
The other way would be to dye both components
simultaneously, which is referred to as
“1 bath dyeing”. This process is difficult and can not be
performed for certain colors.
In either case care must be taken to ensure that complete dye
uniformity is achieved.
Corrective Measures:
In most cases the non-union color can be corrected by making
an appropriate dye addition.
Winch Dyeing Machine : It is, however, very important to make sure any softeners or other finishing chemicals that are on the fabric are thoroughly removed before the dye addition is made.
Softflow Dyeing Machine – Woven and knit goods of various kind
Processing capacity: Weaight:
Min. 1 Kg or above
Cloth Speed:
Variable Speed Control
Liquir Volume:
10 – 60 Liters or higher
Max-working Temperature:
130 C or higher
Material of Machine:
Stainless steel
Heating/ Cooling
Heating at Below 0.5 to above 4
°C/min and cooling below 3 °C/min
Liquor preparation bath
Min. 10 L
Liquor preparation bath
Min. 10 L
Dye Spots-
Definition and Causes:
This common problem and defect can be caused by one or a
combination of the following:
Undessolved dyes, especially if dye granules and powder instead of liquid dyes are used. Read about Woven Fabric Jigger Machine
Incorrect use of Defoamer chemicals. In certain dye
procedures due to the machine’s high pressure and temperature, the interaction
of some chemicals produces a large volume of foam which can inhibit the
fabric’s rotation and movement. To remove this, de-foaming chemicals are used.
Incomplete removal of these foams can sometimes cause a build-up of coagulated
small particles on the fabric.
Incorrect use of Carriers in Polyester dyeing. Generally
Carrier type chemicals are used to facilitate the Disperse dye exhaustion in to
the fibers. At certain low temperatures, due to the condensation, unwashed
droplets of these chemicals can cause spots on the fabric. (Normally lighter
than the ground color).
There are other causes that could create dye spots. The above
mentioned are the most common in the industry.
Softflow Dyeing Machine Preventive Suggestions:
The use of correct procedures and chemically compatible dyes
and chemicals is a critical part of the dyeing process.
Corrective Measures:
Depending on the type of fabric, in most cases, a high
temperature scouring using
Dispersing chemicals, Phosphoric acid, and soda ash will remove the spots.
Poor Crocking-
Definition and Causes:
The transfer of dyes from one fabric surface and causing the
staining of another fabric surface through rubbing action is referred to as
Crocking and is evaluated using a standard Grey Scale system.
This is often caused by the incomplete removal and cleaning
of the left-over dyes from the fabric surface in the after-treatment process.
In the majority of dyeing processes, most of the dyes are
either fully absorbed or exhausted by the fabric (with the exception of pigment
dyeing). The left-over dyes need to be removed thoroughly.
Preventive Suggestions:
A complete after-treatment in the form of Reduction Clear
(for Disperse dyes), Fixation (for Direct and Acid dyes), and Soaping (for
Reactive dyes) must be given to minimize the staining problem.
Corrective Measures:
In most cases, repeating this after-treatment will improve
the crocking properties of the fabric.
Poor Color Fastness-
Definition and Causes:
Generally, the ability of a dyed fabric to retain its color
is referred to as Color Fastness.
This ability is normally measured in terms of fading due to
exposure to washing, perspiration, light sources, etc.
Color Fastness properties of fabrics which are also
evaluated by the Grey Scale system are adversely affected by the following:
Incomplete color fixing in direct dyeing process, reducing
the wash fastness.
Incomplete fabric soaping in Reactive dyeing, reducing the
wash fastness.
The use of Alkali sensitive dyes, reducing the perspiration
fastness.
The use of UV sensitive dyes or incorrect PH values,
reducing light fastness.
The use of dyestuffs which have poor overall fastness
properties.
There are other factors which can adversely affect dyed
fabrics color fastness. The above mentioned are the most common causes.
Preventive Suggestions:
To ensure a higher level of color fastness is achieved, all
technical aspects of dye and procedure selection must be examined and considered.
Corrective Measures – Softflow Dyeing Machine:
Based on the type of dyes used, the use of an appropriate
rewash will improve the required fastness.
Pad Steam Dyeing Machine -Plato rage 60% to 100% FabrSTheed Variable Speed Control Dwelltime in steamer Dwell time Min. 20 Sec or lower – Max. 90 seconds or higher Pad Pneumatically-Controlled, Maximum pressure 1-6kg/cm or above, NBR rubber with 70o Shore Steami amber Insulated, Max. Temperature Max 100°C or higher., Pressure 0.5mPa or above Display Digital display temperature indicator Steam Generation External Steam Generator Included Display Digital display of parameters Width Min 500 mm or above
Washing compartments Min. 4, with direct steam heating and temperature regulator Fabric take up/ batching system included Parts to be included: IR pre dryer, Steaming chamber, Steam generator
Localized Holes-
Definition Pad Steam Dyeing Machine:
The chemical reaction between the knitting oils ( see section 2 I ), left on the fabric and the Hydrogen Peroxide which is used in the preparation stage of dyeing, at higher PH levels of 7 to 13, results in the weakening of the fibers in the oil stained areas. Read about Woven Fabric Jigger Machine
This weakening of the fibers will eventually, during the
course of the dyeing process, cause localized and sporadic holes to appear.
Preventive Suggestions:
The use of water soluble knitting oils is strongly
recommended.
Yarn lubricants, especially with open-end yarns, need to be
checked to make sure the non-silicone types are used.
Corrective Measures:
For this problem no corrective measures are available.
Spandex Decomposition-
Definition and Causes:
The use of strong alkali in the preparation stage of the
dyeing process and in Reactive dyeing systems where PH values of up to 13 are
required is the main cause of the weakening, loss of elasticity and eventual
breakage of Spandex yarns.
Preventive Suggestions:
When dealing with Spandex yarns, specifically the bare
(uncovered) types and at finer counts, the use of strong alkali solutions must,
to the extent possible, be avoided.
Corrective Measures:
For this problem no corrective measures are available.
Caustic Burns-
Definition and Causes:
This is caused by the sudden exposure of areas of the fabric
to undiluted Sodium Hydroxide (caustic soda) during the dye process.
Here, due to the process of the partial “caustisization”
that takes place, these areas, after dyeing, appear on the fabric as color
intensified blotches.
Preventive Suggestions:
using a “dosing” system of delivery. Using this system, regulated and small pre-determined amounts of chemicals, at pre-determined rates, can be delivered to the dye machine.
This will prevent any possibility of fabric damage.
Corrective Measures:
For this problem no corrective measures are available.
Crease and Rope Marks-
Definition and Causes:
With medium and heavy weight fabrics, dyed in Jiggers or
continuous dyeing range, the incomplete flattening and smoothing-out of greige
goods’ wrinkles are the main causes of these problems.
With knit and light weight woven fabrics, dyed in the Jet
dyeing systems, the main causes are as follows:
fabric tangle,
machine stoppage, especially at high temperatures,
over-loading the dye machine,
lack of correct lubricants (Fiber to Fiber and Fiber to
Metal types need to be used)
incorrect fabric rotation speed
There are other causes but these are the most common ones.
Preventive Suggestions:
The use of correct dyeing process, considering all the
technical aspects is essential.
Corrective Measures:
Generally, re-dyeing the fabric at higher temperatures and
additional use of lubricants can remove the crease and rope lines.
For severe cases no corrective measures are available.
Metamerism-
Definition and Causes:
Metamerism is basically where the intensity and cast of a
color appear to vary under different light sources.
This is, usually, due to the use of incompatible dyestuffs
in creating a dye formula.
It could also be due to the presence of small particles of
optical brighteners in the fibers.
Preventive Suggestions:
Correct dye selection is a critical factor in reducing this
effect.
Corrective Measures – Pad Steam Dyeing Machine:
For this problem no corrective measures are available.
Thermosole Variable Speed Control NBR rubber with 70o shore, 0.1 0.5mPa, 2 pressure gauges, Total trough capacity 500m1, vapour-pressure type Min. 500 mm
Maximum Temperature 250°C or above Infraredjeating system Min. 12 reflect-type IR heaters, Heating distance 800 – 900mm or above,Fabric distance 70-120 mrr (adjustable) Thermosoling 1500mm or above, 250°C or above, Precision ± 1%. Dryer Drying distance 1800mm or above, Temperature 100 180°C, Fabric take up/ batching system included Circulation air speed Min 4 m/s or lower — Max. 15 m/s or higher. Read also Woven Fabric Jigger Machine
Chafe Marks-
Definition and Causes:
This defect appears on the fabric as longitudinal crushed
and discolored areas.
It is normally caused by the sudden stoppage of the fabric’s
movement and rotation during the dye process.
Preventive Suggestions:
To the extent possible, the stoppage of fabric’s movement
and rotation must be kept to the minimum.
Corrective Measures:
For this problem no corrective measures are available.
Salt and Mineral Deposits-
Definition and Causes:
In certain dye procedures, particularly Reactive, a large
amount of Sodium sulfate and other types of salts are used to facilitate and
assist the dye absorption and exhaustion.
Insufficient washing and rinsing during the final stages of
the dyeing process will result in accumulation of white powdery residues on the
fabric.
Preventive Suggestions:
A thorough rinsing of the fabric in the last stage of dyeing
using a strong sequestering chemical is always recommended, particularly when
more than 6 grams/liter salts are used.
Corrective Measures:
With dyed fabrics that exhibit these types of contaminated
areas, a sequestering based rewash process will correct the problem.
Excessive Surface Shine (Luster) and Moiré (Water Mark)-
Definition and Causes:
Intensified, visible, and uniform reflection of light from
the surface of a fabric is referred to as Luster.
In a non uniform and random pattern this effect is known as
Moiré or Water mark.
This problem occurs mainly on fabrics made of synthetic
textured filament yarns and is mainly due to a very small displacement of
fibers within the loops and stitches.
This principle is sometimes used to create the water mark
effect on certain silk fabrics using Calendaring equipments.
Preventive Suggestions:
To the extent possible, synthetic fabrics that are more
susceptible to having this problem must be processed at a relaxed and tension
free environment.
Corrective Measures:
The excessive shiny surfaces and the Moiré can not be
totally removed. However, by reducing and inhibiting the light reflection this
effect can be minimized.
To achieve this, a microscopic layer of a dulling chemical,
(usually Titanium Dioxide), is padded on to the surface of the fabric in the
finishing stage.
This chemical, however, will affect the softness of the fabric and should be used in small quantities.
Color Change Due to Incorrect Drying Temperature-
Definition and Causes:
Uneven or excessive application of heat on to the surface of
the fabric during the drying process may cause one or a combination of the
following:
One side of the fabric to have a different shade. This is
due to the malfunction of the heating chambers circulation mechanism
Complete and overall change of shade and/or cast. This is
due to the fact that in making the dye formulation certain “heat-sensitive”
dyes are used
Partial removal of color. This is due to the process of
sublimation
Yellowing of white color due to scorching and the use of
incorrect softeners
Preventive Suggestions:
Prior to the start of the finishing process the following
need to be established:
The types of dyed used in the dyeing process with regards to
their temperature threshold
The fabric type and selecting the appropriate temperature
range
Side-center-side temperature variation using heat-sensitive
strips
Corrective Measures:
In most cases re-bleaching or re-dyeing will correct the
problem.
Sublimation-
Definition and Causes:
The separation of the surface dyes in a gaseous state off of
the fabric and their transfer or relocation on to another surface in a solid
form is referred to as dye sublimation.
During the drying process, if a light color is dried in the
same machine, after a darker color, the darker dyes (in a gaseous form) that
may have remained in the machine can get redeposited on to the lighter color
(in solid form) causing blotchiness or discoloration.
Preventive Suggestions Thermosole :
During the drying process care must be taken to ensure that,
to the extent possible, fabrics of same or similar shades are dried in
succession.
IR Dyeing Machine -Temperature range: 40.135 C or higher, accuracy +/-1t, gradient at 3t/min up to 135C ring or cooling speed: 0.5 — 3.5 *C / min . Control accuracy: 0.5 *C-1*C peed: 10— 50 rpm (adjustable) Dyeing eaker : 180-200m1, 450-500 ml, 1000-1200m1
Can test the length, strength, fineness, color and moisture, color characteristics and trash particle content in cotton ,able to determine fineness and maturity properties of fiber Determine fiber length and tensile properties Automatic Color Tray or increased sampling for higher throughput Dual Sampler for increased sampling for higher throughput Data acquistion system ust include Standard Calibration Materials Micronaire Measured by relating airflow resistance Maturity, Calculated using algorithm itl’I Length, Upper Halt Mean Length, Uniformity Index, Short Fiber Index Measured optically in a tapered fiber beard which is automatically prepared, Strength and elongation, measured physically by clamping a fiber bundle between 2 pairs of clamps at known distance Moisture content, using conductive moisture probe (Color, Rd (Whiteness), +b (Yellowness), color grade, measured optically by different color Trash, Particle count. % surface area covered by trash, measured optically by utilizing a digital camera ;Calculation of spinnability of cotton. Read about Pilot-scale Garment Dyeing Machine
Fabric Odor-
Definition and Causes – IR Dyeing Machine
This is a common problem and it is mainly due to one or a
combination of the following:
The use of certain chemicals in the dyeing process such as Carriers in the dyeing of Polyester fabrics at low temperatures The over-use of neutralizing chemicals such as Acetic Acid or Sodium Thiosulfate The use of incorrect softeners .The use of incorrect Anti-Odor and Wicking chemicals
Preventive Suggestions
The use of correct dyeing and finishing procedures and considering all technical aspects of the used chemicals are essential .The use of Carrier based chemicals needs to be avoided. This chemical not only creates offensive odors on the fabric but it is also known to adversely affect the environment. The neutralizing chemicals used during the dyeing process need to be thoroughly rinsed.
Corrective Measures
In most cases a prolonged exposure to air will remove the odor.
In more severe cases a high temperature scour will be necessary.
Yarn Related Defects /Problems:
Pilling-
Definition and Causes
This is the formation of tiny balls of fiber on the surface
of the fabric caused by frictional forces.It is normally attributed to the low twist factors in the
yarn. Low twist levels create protruding fibers from the yarn, particularly
when short staple fibers are used.Spinning methods also play a roll. Air jet spinning produces
less protruding fibers than open-end spinning.
Other factors can also be considered. Such as the use of
different fiber staple lengths in blended polyester cotton and nylon cotton
yarns(having different tensile strengths) where pilled cotton components that
are formed are held on to the surface by the stronger synthetic fiber and can
not easily and naturally be removed.
Preventive Suggestions
Based on the end-use, yarns with correct twist factor and
fiber lengths must be used.Attentions must also be paid to methods of dyeing and
finishing to ensure correct procedures are employed (fabric rotation speed,
water levels, dye load size, etc.).The use of fiber to fiber and fiber to metal lubricants is
strongly recommended.
Corrective Measures -IR Dyeing Machine
Most of the pills can be removed by washing the fabric with
a mild solution of Enzyme at high temperatures. Using excessive amounts of
enzyme, however, may result in changing the color or weakening of the spandex
yarns. In severe cases a light brushing
and/or sueding may be an alternative.
