Reactive Dyeing – Prepare recipe according to same dyeing condition(temperature, time, process aaa
Check weigh the substrate sample to within +/- 2%
Accurately weigh the dye (+/- 2% of the required weight) and dissolve in an accurately volume of water using volumetric flask. The correct level being achieved after dye dissolution. Dye solutions should be stored in stoppered flasks at room temperature and discarded after 2 days (maximum). The solution should be appropriate for the depth of shade to avoid dispensing small volumes. For example
Add the required volume of dyestuff accurately (preferably via electronic dispensing pipette) Electronic Dispensing Pipettes (EDPs) have a capacity of 10mls. Where larger volumes are required multiple additions will be required.
Calculate the quantity of water required, allowing for dye and chemical additions, and add to the dyeing vessel.
Add the required amount of electrolyte and ensure it is thoroughly mixed/dissolved.
Add the rolled up substrate (avoid folding/creasing) , seal the dyeing vessel and vigorously shake the vessel to ensure even liquor uptake.
Place the dyeing vessel into the dyeing machine at the pre-set starting temperature.
Pre-program the dyeing machine to reproduce the bulk dyeing profile. Use Isothermal to represent standard, isothermal and rapid process. If using migration in bulk, the same migration profile should be used in the laboratory.
At the point of alkali addition, stop the machine and remove the dyeing vessels individually. Accurately add the dilute solution of alkali. Seal the vessel and shake vigorously before placing back in the dyeing machine.
Run at the set fixation temperature for the prescribed fixation time.
If recipe have caustic soda addition aside from soda ash, then the machine will just be set for soda ash fixation, and stop the machine for caustic addition. It will be accurately added as diluted solution also. The vessel will be sealed and shake vigorously before placing back in the dyeing machine. Run at the set fixation time mostly 40 minutes.
At the end of the dyeing stage remove the dyeing vessels from the machine and rinse the dyed samples individually in hot running water for 2 minutes. The dyed samples should then be acidified at 40 degrees for 10 minutes then cold rinse. Soaping with anionic detergent followed at a liquor ratio of 1 : 30 for 15 minutes at the boil. After soaping rinse in warm water for 2 minutes, then squeeze and dry in finishing dryer to have similar drying temperature as in production.
Deep dyeing machine Deep dyeing is the process by which the is dyed partially. In this process dyeing is completed by sinking the garments in the dye bath. This gives the garments a unique look. Influencing Factors for Dyeing During dyeing with reactive dyes, following important factors are to be considered
The pH of the bath Pretreatment Process
The temperature of bath
The concentration of the electrolyte
The time of dyeing
The liquor ratio
Process Requirements Equipment used Special type of machine is used for deep dyeing program. It consist hanger where the garment are hanged. Key Accessories Key accessories used in dyeing with reactive dyes are : • Mixing tank • Machine Tank • pH meter • Hanger Pretreatment Process • Eye protecting glass • Hand gloves • Hand lifter for carrying the batch, and • Gum boot. Materials / Chemicals used Following materials/chemicals are used in the dyeing with reactive dyes process: • Water • Steam • Compressed Air • Wetting agent • Sequestering agent • Acid • Anti-creasing agent • Glauber salt, • Soda ash, etc.
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. • Be cautious while handling caustic soda and use hand gloves, eye protecting glass for safety. • During production, after reaching at the optimum temperature (above 800C), operator must use hand gloves, eye-protecting glass etc. while performing such task for safety.
4 Operation Procedure
4.1 Operation Staff
Operation stuffs for Dyeing process include:
Factory Manager
Assistant Manager
Sr. Production Officer
Production Officer
Supervisor
Operator
Helper
4.2 Checklist before Operation
Following are the items to be checked before production:
a) Checking the programme in Beacon Controller
b) Machine set-up
c) Garment weight
d) Garment quality
e) Dyes availability
f) Chemical availability
g) Power availability
h) Steam availability
i) Water availability
j) Compressed air
k) Manpower availability
l) Garment stitch is done properly
4.3 Operation Procedure
The sequence for deep dyeing process with Starfix dyes is as follows:
Hot wash the garments
Hang the garments in the hanger
Take water bath in deep dye machine at required level
Add dyes solution in the water bath
Add G.salt and soda ash
Mix them well
Hang the garments in the machine in the machine hanger
Now gradually sink the garments by manual operated up down switch
The lower portion of the garments will be deeper then the upper portion
Check the shade with approved shade
Rinse and Drain
Unload
4.4 Machine /Area Cleaning
The daily cleaning for machines are described below:
a) Clean chemical chambers by water flow.
b) Clean the floor by water flow.
c) Machine Oiling by oil or greases done by the Mechanical Maintenance Department.
5 Applicable Forms & Documents
5.1 Forms & Documents Used
Following forms and reports are used for dyeing process:
Process Batch Card
Process Recipe Card
Production Report Format
Document Flow
Document flow for the pre-treatment process can be enumerated as below:
Dyeing Department receives the Process Batch Card attached to it from the Batch Preparation Section.
Based on the shade and other specification plans for the machines are prepared.
Print-out of the recipe is taken from the computer. The Recipe Card 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 Bacon Controller.
The recipe shit Card is used to keep track of the dyeing procedure 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 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’, then this garment is sent to the Finishing Department along with batch card.
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.
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.
