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 :
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.
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 Dye house automation system software provides fully automation of dye house department of the plant. It provides a complete automation solution. The Dye house automation system software cover all steps from batch planning automation to dyeing end automation needed in the process of dyeing. The Dye house automation system software has good graphical user interface and easy menu navigation. This software’s help users with a basic windows background to easily use the software system. Please contact us by submitting a comment below on Leave a Reply box, Cell# +880 17 92 52 53 54. For any queries, please Contact Us.
Plug and Play for Sedomat Module of Dye House Controller
Sedomat 2800 Module of Dye House Controller
Sedomat 5800 Module of Dye House Controllers
Dye House Controller
Textile Central Control Systems:
Batch dyeing machines Module of SedoMaster
Finishing machines Module of SedoMaster
Link host Module of SedoMaster
Link recipe system Module of SedoMaster
Link dispensing Module of SedoMaster
Weighing station Module of SedoMaster
Inventory dyestuff + chemicals Module of SedoMaster
EnergyMaster
Central System
Online Monitoring of Dye Machine Controller:
Program editor
Online status – Setex Module of OrgaTEX Basic
Process analyzer Module of Setex – OrgaTEX Basic
Configuration and setup Module of Setex – OrgaTEX Basic
Backup – Setex Module of OrgaTEX Basic
ControlPro
Micro Services Group – Dye Machine Control
SECOM X40 module of Controller
SECOM 535 module of Controller
SECOM 535 module of Controller
Machine management software OrgaTEX
Controllers for discontinuous processes
CPUs module of Compact PLC
I/O cards module of Compact PLC
Fieldbus modules
Seam detection module of Sensors
Online Monitoring
Dyeing ERP Software Solutions
SedoMaster Editor:
SedoMaster Editor is a tool to create and administer treatments and processes (programs). Processes are available at one place for all machine controllers and can be send ‘at a push of a button’ to the corresponding controller. The processes are used on the controller as ‘local’ programs. Programs, which are created on a controller can be loaded into SedoMaster Editor.Start the SedoMaster EDITOR. You can work with the left and right mouse button. All instructions are written for a right-hander mouse user. To access menus click on the menu bar and select the menu-item. Shortcut menus opens by a rightclick.
Elements
Menu
Toolbar (hide/unhide via the menu View, Toolbar)
Navigation pane
Contents pane
Status Bar (hide/unhide via the menu View, Statusbar)
To provide an optimal overview on the working environment the SedoMaster EDITOR is divided in panes.On the left, the Navigation pane is shown. This Navigation pane contains three property sheets with their tabs Process, Treatment and Function on the top. Within this property sheets there are lists with objects in a directory tree. Click on the corresponding tab and the property sheet comes to the forefront so you can use features.On the right, the Contents pane is shown. This Contents pane shows, depending on your selection, processes and/or treatments.
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.
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.
