For more than last 70 years, regular research and development is going on garment dyeing machine, process and technique. Different types of garments dyeing machines have been developed and all types of dyeing machines can be classified into the following two groups- (a)Overhead padel type (b)Side padel type. This type of garments dyeing machines are the first and oldest type of garments dyeing machine still used is European countries and also used in our country.
Features of Garment Dyeing Machine
Used for woolen knit wear type garments dyeing
Dyeing cost is higher due to-
Manual operation
Higher labour load
Manual loading and unloading of garments
Manual chemical feeding etc.
Garment Dyeing Machine Inside
Rotary Garment Dyeing Machine
Rotary garment dyeing machine is the modified version of padel dyeing machine. It is of two types-
Normal atmospheric pressure type (>100˚c)
High temperature type (<100˚c)
Normal Atmospheric Pressure Type Machine
This type of rotary garments dyeing machines are widely used in our country.
Capacity: capacity of this machine is 50 kg to 500 kg. but 300 kg capacity garments dyeing machine is mostly in garments dyeing industry.
Advantages of Garment Dyeing Machine
The main advantage of this machine is that same machine can be used for desizing, scouring, bleaching, dyeing and washing treatment of the garments.
High Temperature Rotary Garment Dyeing Machine
High temperature rotary garments dyeing machine is the modified and latest version of the normal atmospheric pressure type rotary garments dyeing machine. It is a microprocessor control high temperature dyeing machine. Garments dyeing can be carried out upto 140˚c in the machine.
Features of Rotary Garment Dyeing Machine
Very big central door facilities, material loading and unloading mechanically.
Light m/c structure facilities, high speed m/c running with safe balance.
Simple A/C drive and A/C converter facilities with 5-35 rpm of main cylinder.
Additional two chemical tanks facilities, auto dozing of dyes and chemicals during operation without any manual effort.
Separate chemical dozing tanks may be attached besides those two chemical dozing tanks for auto dozing of more number of items to the dye solution during operation.
Separate liquor circulating pump, heater and filter facilities. Hence better dyeing quality.
The m/c is available only built in form. Hence less risk of installation and running problem.
Zoo dyeing or pre-treatment program could be saved and reused easily.
The microprocessor can also be set for different questions and answers about product and production parameters.
Selection Of Interlining Before Garments Dyeing
Garments to be dyed after manufacturing. So needs careful selection of interlining. As because, during garments dyeing, the performance of interlining used in the garments may be destroyed due to effect of chemicals and temperature used in the dye bath. To avoid such problem, interlining for garments to be dyed should have the following properties-
Interlining used in garments should take up equal amount of dyes and chemicals as the garments fabric take up.
Due to garments dyeing, bond strength between interlining and garments fabric should be unaffected.
Handle property of the interlining attached areas of garments should be as per expectation.
During garments dyeing resin present in the interlining may be pick up dye molecules. Hence color depth problem should not arise in the interlining areas of the garments with remaining areas of the garments.
Fusible Interlining
In the ready-made garments manufacturing industries fusible interlining is mostly used for making garments. The fusible interlining is composed of the following types of materials-
Base fabric should be cotton
Base fabric finishing should be done with Di-methynol Urea derivatives.
Fusible resin coating temperature should be equal to 140˚c or more.
Basic Theory of Garments Dyeing
Depending on wet fastness requirement of fabric, garments made from cotton grey fabric are mainly dyed with direct dye and reactive dye.
For low color fastness direct dyes are used and for high color fastness reactive dyes are used for cotton garments.
If cotton garments are dyed with direct dyes then hand wash separately should be marked on the care lebel of the garments.
If reactive dyes are used for cotton garments dyeing then the following advantages may be gained-
Good level dyeing is achieved.
Dye migration and diffusion is better.
Color fastness is better.
Total color range is available.
If the cotton garments are dyed with reactive dyes, then two types of reactive dyes are available in the market, namely- Hot brand reactive dyes and Cold brand reactive dyes
Between these two brands of reactive dyes, hot brand reactive dyes are mostly used for garments dyeing. Because cotton garments dyeing with reactive dyes facilitates easier and quick dyeing process with reasonably good dyeing quality.
Cotton Garments Dyeing Process (dyed the garments in reactive dye)
Cotton garments made of grey fabric are dyed with reactive dyes. Before dyeing the garments need pre-treatment.
Pre-treatment process of 100 kg cotton garments are described below-
Desizing of Garment Dyeing :
Recipe : garment dyeing
sample weight : 100 kg.
M:L = 1:5 ( liquor = 100X5 =500 liter)
Desizing agent : 2 g/l i.e 1 kg.
Leonil SR : 1 g/l i.e 0.5 kg.
Steam supply to raise temp. : 90˚c
Processing time: 15 minutes.
Procedure:Rotery
Pigment Dyeing Process
Cationization Process:
Add 2-10% of STARCAT PD at room temperature
Adjust pH to 8.5 with soda ash and run for 10 minutes
Increase temperature to 50 oC at rate of 1 oC/minute and run for 15 minutes
Drain and re-fill at room temperature and rinse 5 minutes
Dyeing Process:
In new bath adjust pH to 9.0 by ammonia solution
Add pigment and binder and run for 10 minutes at room temperature then
increase temperature to 60 oC, run for 15 minutes then drain, rinse and dry
Drying and Curing:
After garment is dried, cure binder at 150 oC for 5 minutes
Prof. M Kenedy, London Metropolitan University, Dept of Textile Engineering.
The equipment of air blowing softening & drying machine is used for regular and open width woven or knitted fabric wash and dry and finishing of woven or knitted fabric weighing from 200 to 1 200g/m2 for the purpose of obtaining good hand features and low shrinkage. For towel woven or knitted fabrics, loops can be made very natural and a special hand property will be achieved with most general natural shrinkage .
Features of Air Flow Machine:
Transmission of woven or knitted fabric is understood by the alternative blowing air produced by the general drying system. The woven or knitted fabric is tumbled repetitively between the two woven or knitted fabric tanks and stricken regularly under the action of hot blowing air. The amount of woven or knitted fabric fed is equivalent to the amount of woven or knitted fabric discharged to ensure regular operation of the air flow machine.
The woven or knitted fabric inside the air flow machine is processed tensionless as a result soft and full hand features can be earned with a very general shrinkage. For towel or knitted fabrics, loops could be made natural to achieve a special hand property.
Dwell time of the woven or knitted fabric in the unit, the temperature for drying and the blowing pressure can be attuned according to the processing requirements.
Device Design for Best Fabric Softener:
A unique design is accepted for the internal structure of the unit to use better woven or knitted fabric softener, so that the woven or knitted fabricant be stricken repetitively between the two fabric tank under the action of very hot blowing air and the cleaning device inside unit can remove the cotton dust from the filtering screen to make sure high quality of the processed woven or knitted fabric. Better woven or knitted fabric softener is used before drying process.
Dyes use for dyeing fabric in Jig or Jigger dyeing machine which is suitable for woven fabric than knitted fabric because jigger exert considerable lengthwise tension on the fabric. This is also particularly suitable for cellulosic fibers because the natural dyes generally do not exhaust well and the jig works with an exceedingly low liquor ratio. It is one of the oldest dyeing machines for dyeing fabric. There are mainly two types of jigger dyeing m/c for dyeing woven fabrics with dyes. One is open jigger dyeing machine and other is closed jigger dyeing m/c. Normally after the process of dyeing machine dyed fabric is sent to stenter machine.
Types of Jigger Dyeing Machine:
Textile Jigger Machine for woven fabrics,
Hydraulic Jigger Machine for dyed fabric,
Semi Automatic Dyeing Jigger for dyeing fabric,
Automatic Jigger Textile Machine for woven fabrics,
Semi & Jumbo Jigger Machine show how to dye fabric,
Mannul Jigger for for natural dyes
Automatic Jigger Dyeing Machine
Parts of Jigger Machine:
Parts of Jigger Machine is specified below-
Parts of Jigger Dyeing Machine
Batch Roll
Hinged Cover
Fabric Unloaded
Dye liquor container
Guide roller
Steam Heating Coil
Main Roller
Fabric Winding
Adjustable Expander Bar
Fabric Expander Bar
Dye Vat
Drain
Advantages of Jigger Dyeing Machine:
The cloth is dyed in open width form in textile industry,
The material to liquor ratio is 1:3 is used for dyed fabric in textile industry,
Liquor ratio 1:4 saves huge amount of chemical cost and steam cost,
Less chemical lose for woven fabric in textile industry,
No need training to operate how to dye fabric,
Disadvantages of Jigger Dyeing Machine:
It exerts lot of tension in the warp direction and because of this normally knitted fabrics, woolen, silk etc cannot dyed in jigger dyeing m/c because it is only for woven fabric.
Feature of Rope Dyeing Machine:
Feature of rope dyeing machine is given below with diagram-
Rope Dyeing Machine
Double creel for 6-36 wrap with framework (one creel for working another for stanby )
2-roll, 10 ton nip for draw the rope
2-role, 10 ton nip for caustic box,
3-sky drum fo air timing
2-compartment 10 ton nip for pre-washing
Steamer (27 meters yarn capacity)
8-compartment 10 top nip for dyeing / washing
65 sky drum with Teflon coated
4-copartment 10 top nip for final wahing and softener
Three dry can stacks with 36 cans
36 wrapo coiler section
Main circulation system
Indigo auto feeding system
Color bottom auto feeding system
Color topping auto feeding system
Softener auto feeding system
Kitchen system
Autofeeding for indigo and dudro caustic sulger bottoming / topping and softener with flow display
Level temperature and flow processing control
Ac drive control system with automatic field control technology
Theory of Dyes and Dyeing Fabric:
The process consists of three stages are
Migration of dye molecule from liquor to fiber. This process is assisted by increasing
temperatures and using auxiliaries ñ substances that help the dyeing process.
Diffusion of dye from the fiber surface into the fiber. This process is assisted by agitation of the fiber, dye bath or both together with heat.
Fixation ensures the dye molecule is attached to the fiber either by physical forces or chemical bonding. These forces may be weak or strong.
Most dyeing processes need heat to provide the energy for the dyeing to take place. This is commonly supplied by direct or indirect steam.
Dyes used in textile processing:
Description
Composition
Functions
processing steps
Salts
Sodium Chloride
Sodium Sulfate
Exhaustion
Retarder
Dyeing
Acids
Acetic acid
Sulfuric acid
pH control
others
Preparation
Dyeing
Finishing
Alkali
Sodium Hydroxide
Sodium Carbonate
pH control
Others
Preparation
Dyeing
Finishing
Buffers
Phosphate
Magnesium sulfate
pH control
Dyeing
Preparation
Sequestering agents, chelates
EDTA
Complex hardness retarder
Preparation
Dyeing
Surface active agents
Anionic
Cationic
Nonionic
Softeners
Wetting agents
Emulsifiers
Antifoaming/ defoamer
Leveling agents
Preparation
Dyeing
Finishing
Dispersing agent
Distribute dye uniformly
Dyeing
Oxidizing agents
Hydrogen peroxide
Sodium Nitrite
Insolubilising dyes
bleaching
Preparation
Dyeing
Reducing agents
Sodium hydrosulfite
Sodium sulfide
Solubilise dyes
Remove unreacted dyes
Dyeing
Carriers
Phenyl phenols
Chlorinated benzene
Enhanced absorption
Dyeing
Stabilizer
Sodium Silicate
Phosphate
Stabilize bleach bath
Dyeing
How To Dye Fabric:
Woven Fabrics are dyed based of their quality and blending and to the buyers standard sample appearance. The dyeing processes used in ATL are:
Reactive dyeing Process: 100 % Cotton dyeing fabric is done in alkali medium (in accordance to existing dyes) and fixation at relatively high temperature (130 oC-160 oC).
Disperse dyeing Process: Polyester dyeing fabric is done in acid medium. There are different process for blended fabrics such as PC or CVC.
Two bath process: Process for dyeing fabric separately using disperse dye for the poly part and reactive dye for the cotton part.
One bath process: Process for dyeing fabric using a solution that is made by both disperse and reactive dyes together.
Pigment Process
Vat process
Maintenance:
No.
Item need to be checked & serviced
1.
Check the indirect heating line and any leakage
2.
Complier cleaning of machine
3.
Cleaning of drain valves, replace seals if required
4.
Check air supply filters, regulators, and auto drain seals
5.
Clean filters element and blow out
6.
Greasing of Unloading Roller Bearings
7.
Checking of Oil line and bolts of Unloading Roller Gearbox.
8.
Checking of unloading roller coupling and packing
9.
Checking and cleaning (if required) of Main Vessel Level Indicator
10.
Check the roller bed of the traversing unit.
11.
Check the function of heat and cool controlling valves
12.
Check all belts and belt tension
13.
Check all door seals
Objective of Jigger Dyeing Machine:
Dyeing (Exhaust) is a chemical process by which textile substrates are immersed in liquor containing dyestuffs & chemicals by which the dyestuffs are transferred to textile substrates in a proper manner. For every shade & batch Q.C goes shade check, wash fastness, rubbing fastness, water fastness and light fastness, tear test, tensile test, pick up test, shade listing & tailing.
A dye trough design ensuring minimum possible liquor ratio
Fabric rope monitoring control system for precise calculation and control of the fabric speed and tension.
3) Uniform dyeing conditions in the dye trough, independent of the batch size.
Water meter for controlled rinsing
Dosing of dyes and chemicals dependent on the fabric length passing through the dye bath
Key Accessories:
Wooden plate, Sewing m/c, A-frame/batcher, Eye protecting glass, Hand gloves, Rotation station, Bucket mixer, Filter cloth. Process can be done by this m/c:
Dyeing
Washing- Washing is done by using detergent and wetting agent.
Striping- Stripping is done by using Hydross(4g/l) and caustic(15g/l).
Mercerizing- Chemical strength is 30 Baume
De-finishing: Definishing is done by using soda(8g/l) and caustic(10g/l)
Bleaching
Standard Machine set up:
Machine set up parameters
Actual parameter range
Machine set Value
Temperature
58 – 60’C initially
88 – 90’C later
60’C, 90’C
Chemical level
(500 – 520)L
520 L
Fabric position
Face
Face
Speed
40 – 80 m/min
40 – 80 m/min
Ph-8
M:L- 1:10
Time: 4 hours
Fabric length: 500-1000yds
Route temperature: 57 degree centrigate
Flow chart of Jigger dyeing m/c:
Fabric inlet
↓
Dye + Chemical Padding
↓
Fabric outlet
Process Description of Jigger Dyeing Machine:
Fabric inlet: After mercerizing batcher is feed into the inlet of Jigger machine. Where the fabric is passed through dye bath.
Process Description of Jigger Dyeing Machine
Dye + Chemical padding: Both chemical & color is prepared in different tank according to required. For example —-
Washing:- Detergent / Wetting agent is used
Striping:- Hydrose + Caustic is used
De – Finishing:- Soda + Caustic
pH:- 8
Chemicals/ materials Used
Used in average
Wetting agent
(0.25 – 0.5 ) gm/l
Detergent
(0.5 – 1) gm/l
Dye stuff (Reactive, Sulpher etc.)
Differs depend on the shade of fabric
Caustic
1.323 gm/l
Soda ash
5 gm/l
Reducing agent
9 – 10%
Oxidizing agent
2 gm/l
Acid
2 gm/l
Compressed air
As required
Salt
20 gm/l
Steam, water
As required
Here fabric is directly pass through dye bath & then batching on another roller. And again this process is start in opposite direction. This system is continued for 3-4 times. If shade is match then fabric will be outlet. If not match, dyeing will be continuing.
Fabric Outlet: If shade is ok then fabric will be outlet. And it becomes ready for finishing.
Control Panel of Jigger Dyeing Machine: From control panel all types of instruction can be provide to the machinery. This machine has a full manual control panel.
Control Panel of Jigger Dyeing Machine
The operator controls every process by control switch of Jigger Dyeing Machine.
Tumble dryer is a household appliance and appliances online that is used to take away moisture from a load of clothing and other textiles generally shortly after they are cleaned in a washing machine. Tumble drier is washing machine for tumble drying may cause clothes to shrink for its functionality. Tumbler drier of washing machine nonstop draw in the cool, dry and ambient air heat it before passing it through the process. Programmable automatic dry cleaning machine with built in programs for sensitive and high sensitive textile fabrics and garments testing for durability and shrinkage testing. This dryer is used after Hydro Extractor Machine [1]
Parts of Tumble Dryers :
Some important parts of tumbuler is given here-
Parts of Tumble Dryer
Rating Plate
Filter
Condenser Cover
Water Container
Model and Serial Numbers
Condenser Cover Handle
Air Intake Gril
Specifications of Tumble Dryer for Household Appliance:
Specifications Name
Specifications Value
Product Category
Dryer
Machine Category
Tumble Dryer
Product Name
Tumbuler
Product Model
According to Manufacturer
Product Class
New
Origin
China/India/Others
Brand/ Manufacturer
Name of Manufacturer
Agent in Bangladesh
No/Yes
Power
380v
Temperature
Normal
Certification
SGS/Others
Production Capacity
15 Kg
Consumes of Steam
40-50 Kg
Steam Pressure
0.4-0.6 Mpa
Heating power
14 Kw
Motor power
0.55 Kw
Fan power
0.55 Kw
Rolling Container Dimension
Φ760x650mm
Dimension(L.W.H)
840x1200x1620 mm
Weight
320 Kg
Description
This is very good Machine is used for household appliance and hotpoint service
Cleaning Fluff Filter for Tumble Dry:
Fluff Filter
Step one open the door of your dryer
Step two put out the filter using the two finger grips
Washing machine clean any fluff deposit from the filter mesh.
Refit the filter. Make sure the arrows are facing you.
Never run the drier of washing machine without the filter in position
This is hotpoint service which have built in manual how to use a tumble dryer
[1] Bhavdip Paldiya, Assistant Manager at Dwarkadhish cotspin pvt. Ltd, Bachlor of Engineering in Textile Technology and Gujarat Technological University
Open width compactormachine for textile factory is a textile machine referred to the compactor machine for open width knitted fabrics. It is used for shrinkage control, gsm of fabric control, compact the fabric and increase smoothness of fabric. Here, slitting machine is used before open width compactor machine for open the fabric from the tubular form.This machine is used after the process of stanter machine.
Feature of Open Width Compactor Machine:
This machine is used as industrial machinerywith stenter machine
Open width machine control shrinkage in textile finishing,
This machine have A.C. Inverter drives,
Compacting machine applicable both for cotton knit
This machine machine have PLC with touch screen.
Compactor textile machine equipped with modem connectivity with interface
Compactor textile machine should have online troubleshooting system.
Metal detector exist in compactor textile machine
Compactor textile machine works with this technique
Gsm of fabric is controlled by this machine
Compaction Equipment :
Compaction equipment is suitable for open width knit fabrics to measure gsm of fabric for achieving exact dimensional stability as well as soft feel. The machine consists of a feeding frame by means of centering device and driven scroll rollers which is an equalizing stenter frame with overfeed roller and brush pinning arrangement.
Open Width Compactor
The unit of drying of compacting machine drying have infra-red emitters are placed on either side of the machine. Compacting machine have infra-red emitters are placed on either side of the machine. The delivery side section consists of selvedge trimmer, edge dryer and a suction device, Exit roller, Width Adjustment device and the drive to the chain are housed in a exit box. Shima seiki is good brand name of compaction equipment.
Open width Compactor Machine Maintenance:
Weekly Maintenance Criteria:
Check spreader belts, wheels & its bearings.
Check Teflon sheets.
Check Blanket’s tightness, condition &
Check & clean all electrical & electronics
Two Month Maintenance Criteria:
Clean & Check all motors, commentators & its Carbons.
Calibrate all parameters if required.
Lubricate all motors chain, bearings, gearbox,
Necessary with grease Points.
Yearly Maintenance Criteria:
Drain Gear oil & fill it with new oil & Check
All steam valve & cylinder condition.
Compactor for Sale:
Some compactor is manufactured for sale. This machine is sold for open width fabric. Tubular Compactor is sold for tubular fabric
Tubular compactor machine is referred for tubular knitted fabrics which is used as finishing machine. It is used for shrinkage control, GSM control, compact the fabric and increase smoothness of fabric. Tubular compacting device is industrial machinery used after hydro-extractor, de-watering and dryer. This machine is installed after industrial dryer machine.
Functions of Tubular Compactor:
Functions of a tubular is given below-
Tubuler Compactor
Tubular compacting m/c control shrinkage ,
Tubular compacting m/c control fabric width ,
Tubular compacting m/c control GSM ,
Fabric smoothness is achieved by the tubular compactor,
Heat setting of fabric for Lycra in quality machine,
Shade checking of cotton knit by tubular compactor in textile factory,
Width checking of cotton knit in textile factory,
Edge line checking of cotton knit in textile factory,
Design and slanting of textile finishing,
Find fabric fault of cotton knit in textile factory,
Shima seiki machine used for textile finishing
Specifications of Tubular Compactor:
Specifications Name
Specifications Value
Product Category
Dyer
Machine Category
Compactor
Product Name
Tubuler Compactor
Product Model
According to Manufacturer of textile finishing
Product Class
New
Origin
Made in China
Brand/ Manufacturer
Shima seiki cotton knit machine
Agent in Bangladesh
No/Yes
Power
16KW, 3 Phase, 415V AC, 50 Hz
Temperature
Normal
Certification
SGS/Others
Production Capacity
NA
Steam Consumption
350 LBS / Hour @ 70-100 PSIG
Speed
0-70 Meters per minute
Air
80 PSIG Air Pressure
Weight
2400 Kg
Width
50 inches
Dimensions
7000 * 2250 *2300 mm L*W*H
Description
Shima seiki cotton knit machine machine is used in textile factory for textile finishing works
