1.1 Poly Cotton Fabric
The yarn produced by mixing Polyester fibre and Cotton fibre with each other during yarn preparation process is known as polyester-cotton blended yarn. Generally, two types of polyester-cotton blended yarn are produced. These are :
- 65% Polyester + 35% Cotton = PC or TC
- 40% Polyester + 60% Cotton = CVC (Cheap Value Cotton)
1.2 Pre-treatment Process for Blended Fabric
Pre-treatment process for Polyester-Cotton blended fabric is similar to the 100% Cotton pre-treatment process. Refer to Specification No. 51-301 for detailed pre-treatment process.
1.3 Dyeing Process for Blended Fabric
Two types of dyeing methods are used to dye blended fabric. These are :
- One-bath Dyeing Method
- Two-bath Dyeing Method
1.3.1 One-bath Dyeing Method
One-bath dyeing method is a dyeing process whereby, polyester part and cotton part are dyed together in one bath.
1.3.2 Two-bath Dyeing Method
Two-bath dyeing method is a dyeing process whereby, polyester part and cotton part are dyed separately in separate bath.
2.0 Process Requirements
2.1 Equipment used
Three types of Thies machines are used for dyeing process. These are :
- Mini-soft
- Eco-soft
- Luft-roto
2.2 Key Accessories
Key accessories used in dyeing process are :
- Mixing tank
- Machine Tank
- Bohme meter
- pH meter
- Eye protecting glass
- Hand gloves
- Sewing machine
- Hand lifter for carrying the batch, and
- Gum boot.
2.3 Materials / Chemicals used
Following materials/chemicals are used in the dyeing with reactive dyes process :
- Water
- Steam
- Compressed Air
- Wetting agent
- Detergent
- Sequestering agent
- Acid
- Anti-creasing agent
- Dispersing Agent
- Gluber salt, and
- Soda ash, etc.
3.0 Safety
In order to ensure floor and personnel safety, floor personnel are instructed to follow the safety guidelines given below :
- Smoking is strictly prohibited in the factory premises.
- Put on the safety masks while mixing or transferring alkali and acid.
- During production, after reaching at the optimum temperature (above 800C), in case the lid of machine needs to be opened, operator must depressurise the machine and use hand gloves, eye-protecting glass etc. while performing such task for safety.
4.0 Operation Procedure
4.1 Operation Staff
Operation stuffs for Dyeing Process includes :
- Manager
- Assistant Manager
- Production Executive
- Production Executive
- Operator
- Helper
4.2 Machine Set-up
4.2.1 Machine Set-up for Eco-Soft & Mini-Soft Machine
Machine set-up for Poly-Cotton Blended Fabric Dyeing in Eco-Soft & Mini-Soft Machines are as follows :
Machine Group | Fabric Type | G.S.M. | J.P.(Mb) | R.S. (MPM) |
ECO-SOFT
& MINI-SOFT | Single Jersey | Up to 140 | 0500 | 200 |
140 ~ 180 | 0600 | 190 | ||
180 & Above | 0800 | 180 | ||
Polo Pique | Up to 160 | 0600 | 200 | |
Black Pique | 160 ~ 200 | 0700 | 180 | |
Popcorn | 200 & Above | 0900 | 180 |
.
4.2.2 Machine Set-up for Luft-Roto Machine
Machine set-up for Poly-Cotton Blended Fabric Dyeing in Luft-Roto Machine is as follows :
Machine Group | Fabric Type | G.S.M. | J.P.(Mb) | R.S. (MPM) |
LUFT-ROTO | Single Jersey | Up to 140 | 0700 | 200 |
140 ~ 180 | 0800 | 200 | ||
180 & Above | 1000 | 190 | ||
Polo Pique | Up to 160 | 0800 | 190 | |
Black Pique | 160 ~ 200 | 0900 | 190 | |
Popcorn | 200 & Above | 1000 | 180 |
4.3 Checklist Before Operation
Following are the items to be checked before production :
- Checking the programme in Beacon Controller
- Machine set-up
- Fabric weight
- Fabric quality
- Yarn quality
- Collar design (Tipping / Solid)
- Rib designs (Normal / Lycra)
- Chemical availability
- Power availability
- Steam availability
- Water availability
- Compressed air
- Manpower availability
- Fabric stitch is done properly.
4.4 Operation Procedure
4.4.1 One-bath Dyeing Method
Steps of One-bath Dyeing Process
The sequence for one-bath dyeing process is as follows :
- Take water in bath at required level
- Add Detergent, Sequestering Agent, Anti-creasing Agent, Dispersing Agent
- Circulate the fabric for 5 minutes at 500C
- Add Acetic acid and circulate for 5 minutes at 500C
- Add Glauber salt and circulate for 5 minutes at 500C
- Check pH of the Dye bath
- Add Polyester Dye solution by linear dosing and circulate the fabric for 10 minutes at 500C
- Add Cotton Dye solution by linear dosing and circulate the fabric for 10 minutes at 500C
- Circulate the fabric and raise the temperature at 1300C
- Continue circulating the fabric for 30 ~ 40 minutes at constant temperature (1300C)
- Circulate the fabric and decrease the temperature at 700C
- Check the shade of Polyester part with approved shade
- Circulate the fabric and raise the temperature at 820C
- Continue circulating the fabric for 10 minutes at constant temperature (820C)
- Add Soda Ash by curve dosing and continue circulating the fabric for 30 ~ 50 minutes at 820C
- Circulate the fabric and decrease the temperature at 700C
- Check the shade of Cotton part with approved shade
- Rinse and Drain
- Add Acetic acid and circulate for 10 minutes at 600C
- Drain
- Add Soaping Chemical and circulate for 10 minutes at 950C
- Drain
- Circulate the fabric for 10 minutes at 700C
- Drain
- Unload
Graphical Representation of One-bath Dyeing Process
The one-bath dyeing process for poly-cotton blended fabric can be graphically represented as below :
4.4.2 Two-bath Dyeing Method
- Polyester Part Dyeing with Disperse Dye-stuff
Steps of Two-bath Dyeing Method
Steps involved in Two-bath Dyeing Process with Disperse dye-stuff for Polyester Part dyeing are enumerated below :
- Take water in bath at required level
- Add Detergent, Sequestering Agent, Anti-creasing Agent, Dispersing Agent
- Circulate the fabric for 5 minutes at 500C
- Add Acetic acid and circulate for 5 minutes at 500C
- Check pH of the Dye bath
- Add Dye solution by linear dosing and circulate the fabric for 10 minutes at 500C
- Circulate the fabric and raise the temperature at 1300C
- Continue circulating the fabric for 30 ~ 40 minutes at constant temperate (1300C)
- Circulate the fabric and decrease the temperature at 600C
- Check the shade with approved shade
- Rinse and Drain
- Add Caustic Soda and circulate for 3 minutes at 700C
- Add Hydross and raise the temperature at 800C
- Continue circulating the fabric for 15 minutes at constant temperate (800C)
- Drain
- Add Acetic Acid and circulate for 10 minutes at 600C
- Drain
- Unload
Graphical Presentation of Two-bath Dyeing Process with Disperse Dyes
The Two-bath Dyeing Process with Disperse dye-stuff for Polyester Part dyeing can be graphically represented as follows :
- Cotton Part Dyeing with Procion Dye-stuff at 820C
Chart
The chart of Electrolytic agent (Glauber Salt) and Fixing agent (Soda ash / Caustic Soda) is given below :
Shade % | G. Salt
(gm/l) | Soda Ash
(gm/l) | Caustic Soda
(gm/l) |
Up to 0.30% | 30 | 10 | ~ |
0.31% ~ 0.50% | 60 | 10 | ~ |
0.51% ~ 1.00% | 60 | 15 | ~ |
1.01% ~ 1.50% | 70 | 15 | ~ |
1.51% ~ 2.00% | 80 | 15 | ~ |
2.01% ~ 2.50% | 90 | 15 | ~ |
Above 2.50% | 90 | 20 | ~ |
Steps of Two-bath Dyeing Process with Procion Dye-stuff at 820C
The sequence of Two-bath dyeing process for Cotton part dyeing with Procion Dyes at 820C is given below :
- Take water in bath at required level
- Add Detergent, Sequestering Agent, Anti-creasing Agent
- Circulate the fabric for 5 minutes at 500C
- Add Electrolytic agent (G. Salt) and circulate for 5 minutes at 500C
- Check pH and S. G. of the Dye bath
- Add Dye solution by linear dosing and circulate the fabric for 15 minutes at 500C
- Circulate the fabric and raise the temperature at 820C
- Circulate the fabric for 25 minutes at 820C
- Add Soda Ash solution by curve dosing and circulate the fabric for 30 ~ 50 minutes at 820C
- Circulate the fabric and decrease the temperature at 600C
- Check the shade with approved shade
- Rinse and Drain
- Add Acetic acid and circulate for 10 minutes at 700C
- Drain
- Add Soaping Chemical and circulate for 10 minutes at 950C
- Drain
- Circulate the fabric for 10 minutes at 700C
- Drain
- Unload
4.5 Product Quality Check
To check the quality of production, following measures are taken :
- Check the pH of the bath.
- Absorbency of the fabric.
- Hardness of the water.
- Iron / Impurities contamination of the water.
- Heating and Cooling system of the machine.
- Check the shade with customer approved shade.
- Check the specific gravity of the bath.
4.6 Q.C. Sample Tests
Not applicable.
4.7 Response to Equipment Faults
Following are the response to be taken in case of equipment fault of dyeing machine :
Equipment Fault | Response |
Pump Fault | Call Mechanical Maintenance. |
Dosing Fault | Self / Call Mechanical / Electrical Maintenance. |
Pump Leakage | Call Mechanical Maintenance. |
Filling Problem | Call Mechanical / Electrical Maintenance. |
Valve Leakage | Call Mechanical Maintenance. |
Program Deleting | Call Electrical Maintenance. |
Pressure Fluctuation | Self / Call Mechanical / Electrical Maintenance. |
Motor Fault | Call Mechanical Maintenance. |
4.8 Machine /Area Cleaning
The daily cleaning for machines are described below :
- Clean chemical chambers by water flow.
- Clean the floor by water flow.
- Machine Oiling by oil or greases done by the Mechanical Maintenance Department.
The Maintenance Department performs the preventive maintenance task as per the PM schedule. Refer to Maintenance Specification for details.
5.0 Applicable Forms & Documents
Document Flow
Document flow for the poly-cotton blend fabric dyeing process can be enumerated as below :
Dyeing Department receives the Process Batch Card (F21-101-1) along with the Job Card (F21-101-2) attached to it from the Batch Preparation Section. Process Batch Card is used for fabrics while Job card is used for Collars & Cuffs.
Different specifications (e.g. Lab dip approval #, Fabric weight and quality, Collar quality, shade, etc.) mentioned in the Batch card and Job Card are checked.
Based on the shade and other specification plans for the machines are prepared.
Print-out of the recipe is taken from the DATA-COLOUR computer. The Recipe Card (F51-301-1) is used as an internal document to keep record of dyeing for a particular batch.
Availability of chemicals and dyestuff is checked and program is put in the Becon Controller.
The Shade Batch Card (F51-301-2) is used to keep track of the dyeing production continuity. Production Officer fills out different areas of the form. This is an internal document of the dyeing department.
The Operator fills out the Production Report (R51-301-1) and it is sent to the Planning department. This report contains information like the Quantity produced, Machine wise production, Amount of re-process, Machine utility percentage (%) and shift wise production.
Upon completion of dyeing for a particular batch, if the dyeing is ‘OK’, the Process Batch Card is stamped as “SHADE APPROVED TO FINISH” in Green, on the other hand, if dyeing is ‘NOT OK’, the card is marked as “SHADE APPROVED TO DRY ONLY” in Red. This Process Card is then sent to the Finishing Department.
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