Hydro extractor or centrifugal extractor use centrifuge technology for manufacturing laundering which is used in Textile Company. Hydro extracting m/c is mainly centrifuges for generating hydropower. The wet substantial is placed in the hydro extracting m/c or centrifugal extracting m/c which has a barrier of metal generally steel. The internal drum of centrifugal extracting m/c switches at high speed thus throwing out the water contained in it. The use of this extractor considerably decreases the energy required to dry any material. It is special types of washing machine. Through our technique apartment hardwork, exploit new the leading level, and the national patent. This extractor is used after dyeing machine and before tumble dryer machine.
Feature of Hydro Extractor:
According the brake way it can be stored: new style liquid pressure start series and whole converter controlling series
Stainless steel inner roller, anti-ersion, durable using
3-feet suspending holding frame, good for preventing vibration, safety and reliable
Simple operation, easy maintenance , economic
Specifications of Centrifugal Extractor:
[label type=”label” title=”Specifications Name”]
[label type=”label” title=”Specifications Value”]
Product Category
Hydro Extractor
Machine Category
Centrifugal Extractor Laundry Machine
Product Name
Washing hydro extractor for industrial laundering
Product Model
According to Manufacturer
Product Class
New
Origin
Scottish hydro
Brand/Manufacturer
Name of Manufacturer
Agent in Bangladesh
No/Yes
Power
380v
Temperature
Normal
Certification
SGS/Others
Production Capacity
500 Set/Sets per Month
Rated capacity
100 Kg
Drum speed
640 rpm
Drum size
1000*400mm
Motor power
7.5kw
Motor Speed
1400(r/m)
Motor Frequency(HZ)
50
Dimension
1670*1460*1000mm
Weight
350kg
Description
Hydro power of hydro extracting machine have 3 legs suspended instruction can avoid shock caused by unbalanced loaded
Types Of Other Dry Process:
Tagging
Hand brushing
Sand blasting
Whiskering
Grinding
Destroy
Scrapping
Crinkling/Wrinkle
PP spray
Tie
Painting
Dye spray
What Should Textile Industry Factories Do:
During receiving the bulk fabric garments factory should do the inventory.
By following roll no and fabric way garments factory have to make the blankets 02 sets from each colour way covering all rolls (100% rolls) and send to washing factory.
Shade blanket approval s/b taken before going for size set.
Shades s/b identified & made family card.
Advice to cutting section to avoid shading or mix shade issue.
For the major shade deviation:
Textile industry should make 5-6 pcs leg panels and send to washing to do the experiment to match with original.
Pls give all the information time to time to Asmara wash technician and QC.
Textile industry should assign a wash technician to handle all wash related matters.
Job Responsibilities Of Machine Operator:
Carry out production work as per given instruction.
Clean and maintain own machine before starting the days work.
In case there is any problem regarding machine, inform the supervisor.
Maintain the given work speed.
Do not waste time unnecessarily by talking and gossiping with others.
In case something goes wrong during work, inform the same to the operator.
Clean and maintain own machine before leaving for home.
Job Responsibilities Of Machine Helper:
Assist operator in carrying out duties.
Carry out own assigned job.
Try to learn as much about the machine as possible.
Clean own machine before starting and ending days work.
Should not waste time unnecessarily gossiping.
Should learn the use of PPEs.
Know the details of own pay and allowances.
Assist operators in their work.
Know the details of leave and other welfare details, the company offer to the workers.
Must know how time keeping is done and details of time card.
Kinds Of Garment Dyeing:
Direct dye
Reactive dye
Pigment dye
Florescent dye
Tie and dye
Dip dye
Sulfur dye
Web dye
What is pH and how it is Control ?
pH: Potential of Hydrogen.
In chemistry, pH is a measure of the activity of the (solvated) hydrogen ion. p(H), which measures the hydrogen ion conectration is closely related to, and is often written as, pH. Pure water has a pH very close to 7 at 25 degree C.
Washing factory should use Litmus paper/pH meter to check the pH value. pH control by acetic acid.
Pls remember: In a garment pH value acceptable level is at dry form 6 to 8 and at wet form 4 to 5.5
We do prefer to keep pH value level below 7 because of, during navigation pH level can be gain in garments.
Activities of Centrifuge Extractor for Industrial Laundering:
Centrifugal extractor machine is used for removing extra water from fabric by centrifugal method. Normally 75% water is passed away by this technique of hydropower.
Centrifuge Extractor for Industrial Laundering
Washing unit should have to maintain RSL standard as required for EU and US countries. Pls remember: Azo is worldwide banded item right now. Therefore it is advise to use Azo free dyes and chemicals. The extraction time of centrifugal extractor is about 7-10 minutes. After extraction of access water we can find out the productivity of the hydro extractor. It is used for industrial laundering business
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:
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.
A jet machine for acid dyes have cloth guide tube for each loop of fabric being processed.
A powerful pump circulates the liquor through a heat exchanger outside of the main vessel and back into the jet machine for reactive dyes
The fabric moves at high velocity of 200-800 meters per minute while it is in the cloth guide tube of dyeing factory.
The fabric leaving the cloth guide tube enters a larger capacity cloth chamber and gradually advances back toward the cloth guide tube.
This machine is also used for dyeing polyester
Advantages of Jet Dyeing Machine for Organic Dyes:
It is used for dyeing polyester in dyeing factory
Vigorous agitation of fabric and dyeformulation in the cloth tube increases the acid dyes rate and uniformity.
Rapid circulation of fabric through the machine minimizes creasing because the fabric is not held in any one configuration very long.
Lengthwise tension for disperse dyes on the fabric is low so the fabric develops bulk and fullness of handle.
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.
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-
Jet Dyeing Machines
Capital and maintenance costs are higher for this machine and for disperse dyes
Limited accessibility makes cleaning between dyeing and sampling for colorduring the dye cycle difficult.
The jet action tends to make formulations foam in partially flooded jet machines for organic dyes.
Printing conveyor dryer is a machine which is used after printing techniques to dry the fabric or garments quickly and to add the paint, varnish or ink smoothly into the material is called conveyor dryer. It widely used in textile printing industries to dryeing t-shir, garment, clothes printed by different printing ink except uv ink.[1]
Specifications of Printing Conveyor Dryer for Conveying Systems:
[label type=”label” title=”Specifications Name“]
[label type=”label” title=”Specifications Value“]
Product Category
Dryer
Machine Category
Printing Dryer
Product Name
Printing Conveyor Dryer
Product Model
Supplier Based
Product Class
New
Origin
China/Others
Brand/Manufacturer
Supplier Based
Agent in Bangladesh
No
Power
380V*4.8KW
Temperature
0-300 Centigrade
Certification
SGS/Others
Production Capacity
60 Set/Sets per Month
Output length
500mm
Input length
700mm
Heating area length
1250mm
Belt width
700mm
Max. Temputer
250 degree Celsius
Weight
300kg
Dimension
2450*1200*1000mm
Description
Motor can be set to any speed and provides a smooth and even motion. screen printing at home
Conveyor Dryer for Diy Screen Printing :
The list of feature of printing conveyor dryer for conveying systems is given below-
Conveyor
Drying box is equipped with inlet and outlet point and it has shelter door which can be adjusted up and down shield heating sources leak, as a result it can protect working environment of dryer that save energy and usefull for diy screen printing.
Total 8 infrared lamps working in the conveyor dryer during conveying and somebody may control infrared lamps according to their requirements in textile printing ,
Conveyor belt height which is used for textile printing can be adjustment according types of products’s dimension.
Very high powered multiple infrared curing elements to enhanced printing techniques
Require thick stainless plate conveyor
UV tube with reflector is used for diy screen printing
Machine have conveyor belt for conveying garments with quiet varying speed motor
Teflon coated fiber glass belt dryer of textile printing stand can be separeate freely and easy to move.
The air volume can adjust wind supply for textile printing in printing industry
It has different types of printing techniques. E.g. diy screen printing
Conveyor Components:
Some conveyor components are listed below-
Drying box
UV tube
Infrared lamps
Inlet point
Outlet point
Shelter door
Parts of Conveyor Belt:
Some parts of conveyor belt are listed below-
Parts of Conveyor Belt
Drive Unit
Drive Support
Conveyor belt
Hood
Wind guard
Training idler
Lateral Frame
Truss section
Screw
Foot Terminal
Loading hopper
Transition section
Return belt
Bent
Fixed foot terminal
Walk way and had rail
Belt wear
Head terminal
Discharte chute
[1] Sujan Shakhawat, B.Sc. in Textile Engineering, City University
Dyeing Machine for dye is used for dyeing fabric, dyeing polyester, dyeing clothe and others type of dyeing. This machine is also used for natural dyes, purple dye, tie dye instructions etc. Before the people used the fabric without dyeing, after the few years they was dyed fabric with the help of big pot. That time, no dyeing machine was invented when people dyed the fabric with vary short range most probably at home for their domestic use for dyeing wool. The dyeing or dyeing wool was not so good because of the poor chemical and dyes ratio. Day to day peoples are increasing and needs of cloth was also increased and also increase their decorative working for dyeing fabric. Every dye system has different features in terms of versatility use of carriers, weight limits, etc.
The machine is used for dyeing loose Fiber and dyeing wool,
Feature Fiber Dyeing Machine for Dyeing Clothe:
When huge amount of loose cotton fiber or dyeing wool is to be dyed in standard dyeing shade, continuous dyeing may be carried out.
The output of the can be as high as 2500lb per hour for natural dyes and purple dye
Owing to the cut off, the pump only sucks through the lower half of the cylinder.
Specification of Standard Dyeing Machine for Dyeing Clothe:
When we will buy dyeing machine we should check some specifications which are given below-
[label type=”label” title=”Specification Name”]
[label type=”label” title=”Specification Value”]
Product Category
Dyeing
Machine Category
Dyeing Machine
Product Name
HT-HP Dyeing Machine
Product Model
FUTURA HT2 (4 ropes)
Product Class
Used
Origine
EUROPE
Brand/Manufacturere
Alliance
Agent of Bangladesh
No
Power
NA
Temperature
NA
Description
2 coupled machines each 2 tubes each 1 electronic Programming COMEUREG Possibility to work independently
Certification
NA
Max. Cloth Capacity
800 kg
Cloth Capacity
800 kg
No of Tube
2
Fabric Linear Speed
NA
Max. Heating up Speed
5/min (steam pressure 0.50.7MPa
Liquor Ratio
1: 3 Polyester
Max. Working Temperature
140
Max. Working Pressure
0.4MPa
How to dyeing clothe and how to dye polyester:
In the machine of purple dye the dye liquor is kept stationary while the cotton is moved in the liquor Cotton fiber are feed in the form of laps, 2 inch thick and 36 inch wide, which are uniformly packed.
A perforated cast iron cylinder with closed end plates is made to rotate at the conveyor speed. Its axis is provided by a stationary hollow pipe which is connected to a suction pipe.
There are five units, wetting, dyeing clothe, cold wash, hot wash, drying with this type of cylinder and every nit has definite liquor.
Five such units may be connected in series, with one common conveyer as the lower conveyer and five individual upper conveyors for dyeing clothe
Different options are carried out in this those five units and finally the lap is fed to Creighton opener, where the lap is disintegrated into loose fiber.
Abnormalities seen in the dyeing processes
Lack of supervision: This is the main abnormality that is seen in the dyeing process. The supervisors and their superiors are not willing to keep in touch with the dyeing machines.
Time reduction tendencies of the operators: Operators are always interested in reducing the dyeing process time. For this sometimes they decrease the standard process time. It doesn’t give them any fruitful result as they have to redye some fabric often.
Improper handling of chemicals: operators are not careful in handling chemicals. Some chemicals are dangerous and some should be strictly isolated. But operators use the same mug for taking different agent. It may contaminate the chemicals. Safety equipments are not used by the workers.
Improper utilization through imperfect measurement of chemicals: The operators and helpers are not interested to use balance. They take chemicals from store by assumption. They have tendencies to use more chemicals. They believe by using more chemicals time can be reduced.
Mechanical problems in the dyeing machines: there are several types of turbulence in dyeing machines. they can be stated machine wise as follows~
Dyeing Machine 1-
Sealing problem in the non return valve of streamline.
Lack of insulation in the steam line.
Dyeing Machine 3-
Sealing problem in the steam line flange.
Sealing problem in the steam line valve.
Insulation problem.
Sample dyeing machine1-
Severe problem in the slip ring sealing of the pump
Leakage in the stem line
Sample dyeing machine2-
Sealing problem in the lid.
Problem in the control valve with actuator
Dyeing Machine 4-
Problem in the globe valve sealing in the steam line.
Display problem
Dyeing machine 5-
Problem in the steam line valve sealing.
Dyeing machine 6-
Steam line flange leakage
Sealing problem in the pump
Other common problems are
dosing line jam for not filtering soda & salt
problem in the winch real motor
steam line problem
improper pressure in the pneumatic line
Lack of willingness to find the cause of faulty dyeing~ there is lack of willingness to recover from dyeing faults in everyone’s mind. There lack of accountability. The work force only has to enquire for delay of production.
Maintenance Problem: maintenance department is solving the problem when the fault has been occurred. They are not proactive, that is they are not using preventive maintenance for the smooth running of the factory. Although preventive maintenance scheduling is so tough as the process is continuous. The dyeing fault may arise from the machine fault. Bad sealing system in the pump will require more chemicals and water. Faulty insulation will require more heat energy as
Some Aspect and Impact of Dye:
Aspect of Dye
Impact of Dye
As per recipe dyeing helper collect the chemicals from chemical store
Spillage of chemicals harmful for users and environment.
Pre-treatment greige fabric in the dyeing M/C and sample cutting
Steam emission from dyeing to air
After pre-bleaching dyeing machine drains the waste water
Chemicals drain out from the dyeing machine
As per recipe dyeing helper collect the dyes, chemicals and salt from chemical store & mix those at the side tank of the machine
Spillage of dyes, chemicals & salt harmful for users and environment
Dyeing and pre-treated fabric and sample cutting.
Steam emission from dyeing machine to air
After dyeing machine drains the wastewater
Dyes and chemicals drain out from the dyeing machine
During sample cutting and washing of dyed fabric to match with approve shed
Steam is emitted from dyeing M/C
After wash of dyed fabric from dyeing M/C to trolley
Steam emission from dyeing M/C to air
Unloading of dyed fabric from dyeing M/C to trolley
Water spray to the floor.
Transportation of trolley to the De-Water, Slitting M/C
Water spray to the floor and becoming wet.
Emission of dust to air when unrolling the greige fabric in the dyeing machine
Air pollution
Autoclave:
Various types of machines in textile are used for processing fibers in loose form. In conical pan machines in textile the fiber is packed into a removable fiber carrier, which is located onto a central spigot in the base of the vessel. Associated pipe work allows liquor to be circulated either from the base of the pack or from the top.
Schematic Layout of a conical pan loose fiber dyeing machine
Pear shapes machines have a removable perforated based plate through which liquor is circulated via an impeller, returning to the dyeing container via a weir in textile industry. Fiber is loaded directly for dyeing fabric into these machines and perforated plate is positioned on top. Liquor circulation packs the fiber into the base of the machine between the two plates. Radial flow machines are characterized by a fiber carrier, equipped with a central perforated column from which liquor flows across the pack to the perforated walls of the carrier for dyeing fabric. The low packing density in these machines allows liquor to circulate freely through the fiber pack at modest pressures, thus minimizing mechanical damage to the fiber while ensuring level dyeing fabric. The bath heats by closed steam the base of the machine. In other cases electro programmers or logic controllers is installed to regulate time / temperature and to control the direction of liquor flow. The liquor ratio for loose fiber can vary between 1:4 to 1:12, depending on the type of machine, level of loading, type of fiber, etc.
[1] Abu Zamil Mohammad Zakaria, B.Sc.in Textile Engineering, Daffodil International University
Dyeing Machine for Dye:
Dyeing Machine for dye is used for dyeing fabric, dyeing polyester, dyeing clothe and others type of dyeing. This machine is also used for natural dyes, purple dye, tie dye instructions etc. Before the people used the fabric without dyeing, after the few years they was dyed fabric with the help of big pot. That time, no dyeing machine was invented when people dyed the fabric with vary short range most probably at home for their domestic use for dyeing wool. The dyeing or dyeing wool was not so good because of the poor chemical and dyes ratio. Day to day peoples are increasing and needs of cloth was also increased and also increase their decorative working for dyeing fabric. Every dye system has different features in terms of versatility use of carriers, weight limits, etc.
