Different Parts Of Computer Color Matching System | CCMS Utilities

Computer color matching system (CCMS) is the latest system to predict and analyze the color of the sample. It is mostly used for wet processing section. I have mentioned about the functions of CCMS in one of my blog. Now I like to present an idea about the different parts of a CCMS or how a CCMS is arranged and functions of different parts.



Computer color matching system was first established in 1963 by ICI dye stuff division for color matching prediction in their lab only for their customers. But CCMS was commercially introduced by International Color System (ICS) in 1973. Now CCMS is developing by different CCMS manufacturing companies. Among all of them DATA COLOR is best in this regards.

Following basic things are considered for CCMS:

• Spectrophotometer is the main color measurement instrument.


• Reflectance from a mixture of dyes or pigments applied in a specific way.


• To judge the closeness of the color matching, optical model of color (CIE Lab/ Hunter Lab/ XYZ Model) is used.

Different parts of computer color matching system: CCMS has different parts by which it runs. Followings are the main parts of CCMS.

1. Computer: Computer is needed for CCMS. In this system special software is installed in the computer before run the CCMS. Spectrophotometer and printer is joined with the computer. When spectrophotometer analyzes the color the results show in the monitor and if needed results could be print out by the printer. All the information is send from the hard disk of the computer.


2. Spectrophotometer: Spectrophotometer is the main instrument of CCMS. Spectrophotometer has a sample holder in the middle of the front side. The sample holds on there. Then it takes the reflection of the light and analyzes the depth of the color and shows the results on the computer monitor. It also makes decision about the fastness properties of the sample.


3. Printer: Printer is joined with the computer for printing the results.

So, computer color matching system is the best way to find out the solution about a sample color. Try to use it in your practical life. If you have better idea let me know.

Working Procedure Of Computer Color Matching System | Color Prediction

Do you hear about the compute color matching system (CCMS)? If you do so then it will be very easy to understand the working procedure of computer color matching system. In modern time man wants to save time and gets the result quickly. For this reason the popularity of computer color matching system is increasing rapidly. In most of the wet processing industry are trying to use CCMS. It has various advantages which attract people to use it.



Now, I like to explain the working procedure of CCMS which is used for dyeing lab to match the shade of the products. Generally buyer gives a fabric sample swatch or Panton number of a specific shade to the producer. Producer gives the fabric sample to lab dip development department to match the shade of the fabric. After getting the sample they analyze the color of the sample manually. In the other hand they can take help from the computer color matching system.

At first it needs to fit the sample to the spectrophotometer which analyzes the depth of the shade and it shows the results of the color depth. At the same time it needs to determine the color combination by which you want to dye the fabric. Then it will generate some dyeing recipe which is nearly same. Here it needs to determine the amount of chemicals which you want to use during dyeing.

After formation of dyeing recipe it needs to dye the sample with stock solution. I think you are also familiar with stock solution. Then sample should dye according to the dyeing procedure. After finishing the sample dyeing it needs to compare the dyed sample with the buyer sample. For this reason dyed sample are entered to the spectrophotometer to compare the sample with the buyer sample.

Then CCMS gives the pass fail results. If the dyed sample match with the buyer sample than CCMS gives pass results. After that, dyed samples send to the customer or buyer. After getting the approval from the buyer producer goes for the bulk production.

If the dyed sample does not match with the buyer sample than the CCMS analyses the color difference and correct the recipe. Then another sample dyeing is carried out for matching the shade of the sample.

So, it’s not so easy task to operate the CCMS. For operating the computer color matching system, expert is needed. Different companies are manufactured CCMS; you can collect your favorite one from there. But I have some experience to work with a computer color matching system which is developed by DATA COLOR.

Process Flow Chart Of Polyester Dyeing | Disperse Dyes Dyeing Process

Polyester is the most used synthetic fiber of the world. Polyester fiber is dyed with disperse dyes. If we want, we can dye the fiber during yarn preparation. Also we can dye the yarn after yarn preparation and in fabric form. The fastness properties of polyester dyed yarn are excellent. Day by day the use of synthetic fiber increases rapidly.

Dyeing sequence of polyester is given below:

Carrier and vessel washed by hydrose and caustic at 100⁰ C for 20 min

↓

Load the package in the carrier and feed in the vessel

↓

Add washing agent and run at 80⁰ C for 20 min

↓

Dyeing period

↓

Add leveling agent and acid, run at 60⁰ C for 10 min

↓

P^H check

↓

Color mixing at 70⁰ C for 40 min

↓

Color dosing at 60⁰ C for 20 min

↓

Polyester dyeing at 135⁰ C at 2⁰ gradient for 50 min

↓

Sample check

↓

Ok

↓

Temperature cool down at 78⁰ C and drain

↓

Hot wash for 10 min

↓

Rinse for 15 min for light shade and 25 min for dark shade

↓

Add hydrose, soda ash, run at 80⁰ C for 20 min

↓

Drain

↓

Rinse for 10 min

↓

Neutralization by acetic acid at 50⁰ C 20 min

↓

Finishing

So, that’s all about the polyester dyeing as well as synthetic yarn dyeing. You can try it in your practical life and give me a feedback about the result of dyeing process of polyester.

Dyeing Flow Chart of Polyester Cotton | Two Part Dyeing Process

Dyeing sequence of polyester cotton is the combination of polyester and cotton dyeing process. For this reason this dyeing process is called double part dyeing process. In this dyeing process; polyester part is dyed first than cotton part is dyed.

Dyeing flow chart of polyester cotton is given below:

 Carrier and vessel washed by hydrose and caustic at 100⁰ C for 20 min

↓

Load the package in the carrier and feed in the vessel

↓

Add wetting agent, antifoaming agent, sequestering agent and run at 60⁰ C for 10 min

↓

Water solution drain

↓

Add wetting agent, sequestering agent, caustic soda and hydrogen peroxide and run at 110⁰ C for single yarn and 115⁰ C for double yarn for 20 min

↓

Drain

↓

Add peroxide killer and run at 90⁰ C for 10 min

↓

Peroxide check in the package

↓

Drain

↓

Add acetic acid for neutralization and run for 20 min at 50⁰ C

↓

Drain

↓

Take sample and check absorbency

↓

Ok

↓

Dyeing period (Polyester part)

↓

Add leveling agent and acid, run at 60⁰ C for 10 min

↓

P^H check

↓

Color mixing at 70⁰ C for 40 min

↓

Color dosing at 60⁰ C for 20 min

↓

↓

Sample check

↓

Ok

↓

Temperature cool down at 78⁰ C and drain

↓

Hot wash for 10 min

↓

Rinse for 15 min for light shade and 25 min for dark shade

↓

Add hydrose, soda ash, run at 80⁰ C for 20 min

↓

Drain

↓

Neutralization by acetic acid at 50⁰ C 20 min

↓

Take sample

↓

Carbonizing by acid for 10-20 min

↓

Neutralization by acetic acid at 50⁰ C for 20 min

↓

Drain

↓

Dyeing of polyester part complete

↓

Dyeing period (Cotton part)

↓

Add wetting agent, antifoaming agent, sequestering agent and run at 60⁰ C for 10 min

↓

Color dosing at 60⁰ C for 20 min

↓

Color migration at 60⁰ C for 30 min

↓

Salt dosing at 60⁰ C for 20 min

↓

Run the machine for 20 min at 60⁰ C with color and salt

↓

Soda dosing at 60⁰ C for 40 min

↓

Cotton dyeing at 60⁰ C for 50 min

↓

Check sample

↓

Ok

↓

Drain

↓

Rinse for 10 min

↓

Add acetic acid for neutralization and run for 10 min at 50⁰ C

↓

Drain

↓

Add washing chemical and run at 90⁰ C for 20 min

↓

Wash sample check

↓

Ok

↓

Drain

↓

Rinse for 10 min

↓

Add fixing chemical and half acetic acid, run at 50⁰ C for 20 min

↓

Add softening agent and rest half acid, run at 60⁰ C for 20 min

↓

Check finished sample

↓

Ok

↓

Drain

It is note that; dyeing sequence of CVC is as same as P/C dyeing. If we want to dye cvc then we can run the process as same the above process sequence.

Flow Chart Of Knit Mercerizing Process | Cotton Knit Dyeing

We know that mercerizing is a additional process to improve the physical and chemical properties of the cotton yarn or fabric. For cotton knit dyeing; mercerizing is done before dyeing. Mercerized fabric is more suitable than the unmercerized fabric. This process also depends on the buyer requirement. It is not a common operation for the cotton fabric. It is done for the sophisticated fabric. The machine which is used that is vertical type. It consists of vertical washing chamber.



Types of mercerizing process: Mercerizing can be done in the following three stage of the products:

• Grey mercerization (Knitted fabric before dyeing)


• Fabric mercerization(Yarn dyed fabric)


• Collar & Cuff mercerization.

Frequency of mercerization: Mercerizing process could be two types.

• Single Mercerization


• Double Mercerization

Flow chart of mercerization process:

 Fabric entered in mercerizing machine

↓

Impregnation in reaction chamber

↓

Hot wash

↓

Neutralization

↓

Hot wash

↓

Exit

I have given the basic idea about mercerizing process. So, do the same which is given in above.

Dyeing Sequence Of 100% Cotton With Turquoise Color | Dark Shade

Shade of the textile materials depends on the dyes percentage which is used for dyeing. Chemical which is used for dyeing also vary depending on the dyes used. Generally dark shade means the dyes percentage above 2%. Medium shade dyeing and dark shade dyeing process is nearly same.

Flow chart of cotton dyeing with turquoise color is given below:

 Carrier and vessel washed by hydrose and caustic at 100⁰ C for 20 min

↓

Load the package in the carrier and feed in the vessel

↓

Add wetting agent, antifoaming agent, sequestering agent and run at 60⁰ C for 10 min

↓

Water solution drain

↓

Add wetting agent, sequestering agent, caustic soda and hydrogen peroxide and run at 110⁰ C for single yarn and 115⁰ C for double yarn for 20 min

↓

Drain

↓

Add peroxide killer and run at 90⁰ C for 10 min

↓

Peroxide check in the package

↓

Drain

↓

Add acetic acid for neutralization and run for 20 min at 50⁰ C

↓

Drain

↓

Absorbency test of sample

↓

Ok

↓

Dyeing period

↓

Add salt, wetting agent, antifoaming agent, sequestering agent and run at 60⁰ C for 10 min

↓

P^H check

↓

Color dosing at 60⁰ C for 30 min

↓

Color migration at 80⁰ - 90⁰  C for 30 min

↓

Migration package check

↓

Ok

↓

Run the machine for 20 min at 80⁰ - 90⁰ C with color and salt

↓

Soda dosing at 60⁰ C for 40 min

↓

Cotton dyeing at 80⁰ - 90⁰ C for 50 min

↓

Check sample

↓

Ok

↓

Drain

↓

Rinse for 10 min

↓

Add acetic acid for neutralization and run for 10 min at 50⁰ C

↓

Drain

↓

Add washing chemical and run at 95⁰ C for 20 min

↓

Add washing chemical and run at 90⁰ C for 20 min

↓

Ok

↓

Drain

↓

Rinse for 10 min

↓

Add fixing chemical and half acetic acid, run at 50⁰ C for 20 min

↓

Add softening agent and rest half acid, run at 60⁰ C for 20 min

↓

Check finished sample

↓

Ok

↓

Drain

So, dye your textile materials with turquoise color and get the colorful yarns or fabrics.

Dyeing Flow Chart of Cotton With Turquoise Color | Light Shade

Turquoise color dyeing is critical than the normal color dyeing. This type of dyes is used for produce specific color. A flow chart of turquise color dyeing for light shade is given below:

 Carrier and vessel washed by hydrose and caustic at 100⁰ C for 20 min

↓

Load the package in the carrier and feed in the vessel

↓

Add wetting agent, anti foaming agent, sequestering agent and run at 60⁰ C for 10 min

↓

Water solution drain

↓

Add wetting agent, sequestering agent, caustic soda and hydrogen peroxide and run at 110⁰ C for single yarn and 115⁰ C for double yarn for 20 min

↓

Drain

↓

Add peroxide killer and run at 90⁰ C for 10 min

↓

Peroxide check in the package

↓

Drain

↓

Add acetic acid for neutralization and run for 20 min at 50⁰ C

↓

Drain

↓

Absorbency test of sample

↓

Ok

↓

Dyeing period

↓

Add wetting agent, antifoaming agent, sequestering agent and run at 60⁰ C for 10 min

↓

Color dosing at 60⁰ C for 20 min

↓

Color migration at 80⁰ - 90⁰ C for 30 min

↓

Salt dosing at 60⁰ C for 20 min

↓

Run the machine for 20 min at 80⁰ - 90⁰ C with color and salt

↓

Soda dosing at 60⁰ C for 40 min

↓

Cotton dyeing at 80⁰ - 90⁰ C for 50 min

↓

Check sample

↓

Ok

↓

Drain

↓

Rinse for 10 min

↓

Add acetic acid for neutralization and run for 10 min at 50⁰ C

↓

Drain

↓

Add washing chemical and run at 90⁰ C for 20 min

↓

Wash sample check

↓

Ok

↓

Drain

↓

Rinse for 10 min

↓

Add fixing chemical and half acetic acid, run at 50⁰ C for 20 min

↓

Add softening agent and rest half acid, run at 60⁰ C for 20 min

↓

Check finished sample

↓

Ok

↓

Drain

 It’s too much practical; if you want you can try in cotton dyeing for light shade. Don’t forget to inform me about the results.

Dyeing Flow Chart for Acrylic Yarn | Synthetic Fiber Dyeing

In dyeing floor different types of yarn or fabrics are dyed. All of the process is not same. But the basic dyeing process is same for yarn or fabrics.

Acrylic Yarn dyeing process is given below:

 Carrier and vessel washed by hydrose and caustic at 100⁰ C for 20 min

↓

Load the package in the carrier and feed in the vessel

↓

Add washing agent and run at 80⁰ C for 20 min

↓

Dyeing period

↓

Add leveling agent and acid, run at 60⁰ C for 10 min

↓

P^H check

↓

Color mixing at 70⁰ C for 40 min

↓

Color dosing at 60⁰ C for 20 min

↓

Acrylic dyeing at 85⁰ C at 2⁰ gradient for 20 min

↓

Acrylic dyeing at 98⁰ C at 1⁰ gradient for 50 min

↓

Sample check

↓

Ok

↓

Temperatures cool down at 78⁰ C and drain

↓

Rinse for 15 min for light shade and 25 min for dark shade

↓

Add acetic acid, soda ash, run at 80⁰ C for 20 min

↓

Drain

↓

Rinse for 20 min

↓

Finishing

During acrylic dyeing; temperature plays an important role. Temperatures are up and down according to the requirement.

 

Dyeing Flow Chart For Acrylic Cotton | Yarn Dyeing Process

Dyeing is the most critical task for a textile engineer. Acrylic cotton dyeing is the double part dyeing process. Here dyeing is done one part to another. It needs to match cotton part and acrylic part then dyeing will be completed.

Flow chart of acrylic cotton dyeing is as follow:

Carrier and vessel washed by hydrose and caustic at 100⁰ C for 20 min

↓

Load the package in the carrier and feed in the vessel

↓

Add wetting agent, anti foaming agent, sequestering agent and run at 60⁰ C for 10 min

↓

Water solution drain

↓

Add wetting agent, sequestering agent, soda ash and hydrogen peroxide and run at 110⁰ C for single yarn and 115⁰ C for double yarn for 20 min

↓

Drain

↓

Add peroxide killer and run at 90⁰ C for 10 min

↓

Peroxide check in the package

↓

Drain

↓

Add acetic acid for neutralization and run for 20 min at 50⁰ C

↓

Drain

↓

Take sample and check absorbency

↓

Ok

↓

Dyeing period (Acrylic part)

↓

Add leveling agent and acid, run at 60⁰ C for 10 min

↓

P^H check

↓

Color mixing at 70⁰ C for 40 min

↓

Color dosing at 60⁰ C for 20 min

↓

Acrylic dyeing at 85⁰ C at 2⁰ gradient for 20 min

↓

Acrylic dyeing at 98⁰ C at 1⁰ gradient for 50 min

↓

Sample check

↓

Ok

↓

Temperature cools down at 78⁰ C and drain

↓

Rinse for 15 min for light shade and 25 min for dark shade

↓

Add acetic acid, soda ash, run at 80⁰ C for 20 min

↓

Drain

↓

Rinse for 20 min

↓

Take sample

↓

Carbonizing by acid for 10-20 min

↓

Neutralization by acetic acid at 50⁰ C for 20 min

↓

Acrylic part dyeing complete

↓

Dyeing period (Cotton part)

↓

Add wetting agent, antifoaming agent, sequestering agent and run at 60⁰ C for 10 min

↓

Color dosing at 60⁰ C for 20 min

↓

Color migration at 60⁰ C for 30 min

↓

Salt dosing at 60⁰ C for 20 min

↓

Run the machine for 20 min at 60⁰ C with color and salt

↓

Soda dosing at 60⁰ C for 40 min

↓

Cotton dyeing at 60⁰ C for 50 min

↓

Check sample

↓

Ok

↓

Drain

↓

Rinse for 10 min

↓

Add acetic acid for neutralization and run for 10 min at 50⁰ C

↓

Drain

↓

Add washing chemical and run at 90⁰ C for 20 min

↓

Wash sample check

↓

Ok

↓

Drain

↓

Rinse for 10 min

↓

Add fixing chemical and half acetic acid, run at 50⁰ C for 20 min

↓

Add softening agent and rest half acid, run at 60⁰ C for 20 min

↓

Check finished sample

↓

Ok

↓

Drain

 

So, this is the process of acrylic cotton dyeing. Try it in practical and let me know the result.

Dyeing Flow Chart Of Grey Melange || Scouring And Bleaching Process

Grey Melange yarn is the special types of yarn. The fabric which is made from the grey melange yarn is also special. Here I have given a dyeing flow chart by which grey melange yarns are dyed. After dyeing grey melange yarns are used for producing woven and knitted fabrics. Dyeing also done for grey melange fabric but basic dyeing sequence is same.



Dyeing flow chart for grey melange is given below:

Carrier and vessel washed by hydrose and caustic at 100⁰ C for 20 min

↓

Load the package in the carrier and feed in the vessel

↓

Add wetting agent, anti foaming agent, sequestering agent and run at 60⁰ C for 10 min

↓

Water solution drain

↓

Add wetting agent, sequestering agent, caustic soda, hydrogen peroxide, optical brightening agent and run at 90⁰ C for single yarn and 100⁰ C for double yarn for 40 min

↓

Drain

↓

Add peroxide killer and run at 90⁰ C for 10 min

↓

Peroxide check in the package

↓

Drain

↓

Add acetic acid for neutralization and run for 20 min at 50⁰ C

↓

Drain

↓

Add washing chemical and run at 90⁰ C for 20 min

↓

Wash sample check

↓

Ok

↓

Drain

↓

Rinse for 10 min

↓

Add fixing chemical and half acetic acid, run at 50⁰ C for 20 min

↓

Add softening agent and rest half acid, run at 60⁰ C for 20 min

↓

Check finished sample

↓

Ok

↓

Drain

 

Day by day the use of grey melange increased rapidly. The dyeing sequence which is given above is carried out for yarn dyeing.

 

White Dyeing | Dyeing Flow Chart of Scouring and Bleaching With Optical Brightening Agent (OBA)

Dyeing is carried out for changing the appearance of the grey yarn or fabric. Generally dyeing is done with the help of dyes and chemical. Most of the time raw materials become colorful by the application of dyes. But if we want to get a white fabric we need to pass through the wet processing methods. The methods by which we can get white materials that method are called white dyeing. Generally white dyeing is carried out with the optical brightening agent during scouring and bleaching process.



I have given a flow chart of white dyeing by which we can get a white dyed yarn. The process is as bellow:

Carrier and vessel washed by hydrose and caustic at 100⁰ C for 20 min

↓

Load the package in the carrier and feed in the vessel

↓

Add wetting agent, anti foaming agent, sequestering agent and run at 60⁰ C for 10 min

↓

Water solution drain

↓

Add wetting agent, sequestering agent, caustic soda, hydrogen peroxide, optical brightening agent and run at 110⁰ C for single yarn and 115⁰ C for double yarn for 40 min

↓

Drain

↓

Add peroxide killer and run at 90⁰ C for 10 min

↓
Peroxide check in the package

↓

Drain

↓

Add acetic acid for neutralization and run for 20 min at 50⁰ C

↓

Drain

So, it is the most practical procedure of white dyeing. If you have better idea about this process let me know.

Jute Fabric Printing With Basic Dyes | Eco Friendly Jute Products

Jute is a natural bast fiber. Jute fiber is spun for producing jute yarn. Various types of jute fabrics are made from jute yarn. We know that, jute fabric is classified as Sacking, Hessian and C.B.C. Jute fabrics are courser than cotton or other fabrics. For this reason it’s using are not so wide as compared to cotton or other fabrics. For this reason different types of attributes are added with jute fabric for make it user friendly. Now a day’s jute dyeing and jute printing becomes popular to the manufacturer.



The printed jute product which is presented here, it is produced in Star Jute Mills Limited which is an enterprise of Bangladesh Jute Mills Corporation. They also produced all types of Sacking and Hessian jute products which maintain international quality standard.

Jute printing is the process of producing different types of attractive design to the jute fabric. I have described about the printing classification. Among the entire printing process block printing is popular for jute fabric printing.

Materials for jute fabric printing: During jute fabric printing following materials are used.

• Basic dyes


• Acetic acid


• Starch


• Water


• Block


• Soft surface


• Jute fabric

We know that; basic dyes are usually hydro-chloride or salts of organic bases. Basic dyes are insoluble in water but it can be soluble in alcohol or methylated spirit. Its fastness properties are average to good. This is cheap in price and available in the market.

Jute fabrics are print by the basic dyes. Basic dyes printing are carried out in acidic medium. Jute printing can be run by the following recipe:

Basic dyes                               : 30gm/kg

Acetic acid                              : 50gm/kg

Thickeners (Starch 10%)            : 700gm/kg

Water (+,-)                              : 220gm/kg

This recipe is a sample recipe but this amount could be changed. Anyhow, this recipe is calculated for making 1kg print paste.

Sequence of application: Basic dyes printing is carried out as the following sequence.

Fabric pre-treatment

↓

Printing (Block)

↓

Steaming

↓

Drying

↓

After treatment

This is the basic process flow chart of jute printing with basic dyes. During printing process different caution is follow for avoiding printing faults. Before starting printing we should make a printing paste with standard recipe. Block should place in the right place. For a multiple color printing we have to print one by one by specific block. Printing place should be soft. After printing; steaming should be for fixing the dyes uniformly. Stemming also increase the stability of the printing paste. Drying is must after printing. Sometimes after treatment is carried out.

So, print your jute product with basic dyes and make different types of attractive design to attract the buyer.

Re-Winding Section Of Yarn Dyeing Floor | Objectives And Considering Points Of Re-Winding

Re-winding is the last steps of yarn dyeing process. The process which is started by soft winding section, it comes in end by re winding section. After re winding, dyed yarns become ready for packing and delivery to the destination.



In yarn dyeing floor re-winding section is also called random section. In this section dried and dyed yarns are transferred from spring or plastic tube to cone form.

Objectives: The objectives of re-winding are given bellow:

1. To transfer the dyed yarn from tube or spring to cone package.


2. To clean the yarn.


3. To make the yarn in continuous form.


4. To prepare the cone package for the delivery.

Re-Winding machine: In re-winding section, various types of machines are used. One of the most used re-winding machine is GAO14; GROOVED DRUM WINDER which is manufacture by SUZHOU XINSAFANG MECHNICAL & ELECTRICAL. The origin country of this machine is China. It contains 100 Spindle.

Points Need to Consider During Re-winding: During re-winding process various points are considered which are given bellow:

1. Trash: Trash is one of the big problems in random section. Different shaded yarns are re-wind in random section, so color trash fly in the section and enter into package of other color or same color, which destroy the quality of the package. Especially it is harmful for the white or off white color, where other color trash can be identify easily.


2. Wax: Waxes use in random section. Yarn passes through the wax. Wax gives softness and lubricity of the yarn, which facilities better knitting performance.


3. Tension: Tension is given to double yarn not in single yarn. Because tension makes single yarn package hard.


4. Wet Package: Wet package should not re-wind because wet package become hard after re-winding. It also makes beets in the cone package.


5. Cone: Cone should be available.


6. Blower: Blower should work properly, because cleaning performance depends on blower performance.


7. Operator: Operator should aware about the cleanliness.

That’s all about re-winding section. One should be aware about the re-winding process and produce fault free product for the buyer.

Common Yarn Dyeing Faults | Causes And Way Of Remedies

Dyeing is the combination of reaction among fiber, dyes, chemicals and water. In dyeing process different faults can be occur for various factor. Among all of the dyeing process, package yarn dyeing is different. In package yarn dyeing different types of faults are occurs but following are the most common.


Uneven dyeing: A textile engineer must have knowledge about the shade of color. Small percentage of shade difference can move a material to rejection. So, it needs to be high care full during dyeing. Dyeing is a continuous process and during dyeing ones should be sure about the shade of materials that it matched with the standard swatch. Uneven shade means the variation of shade in different layer of a yarn package. We know that package yarn dyeing is done by the In-0ut mechanism of dye liquor. So shade could be varying in various layer of a package. Followings are the causes and remedies of uneven shade.

Causes:

→ Uneven pretreatment (uneven scouring & bleaching).

→ Improper color dosing.

→ Using dyes of high fixation property.

→ Uneven heat-setting in case of synthetic fibers.

→ Lack of control on dyeing m/c


Remedies:

→ By ensuring even pretreatment.

→ By ensuring even heat-setting in case of synthetic fibers.

→ Proper dosing of dyes and chemicals.

→ Proper controlling of dyeing m/c.

Batch to Batch Shade variation: In dyeing; dyeing is done according to the buyer requirement. An order for a specific shade could be small amount or large amount. In mill, different batch is made as per order or depending on the capacity of the machine. For this reason batch to batch shade variation could be take place. Followings are the causes and remedies way of batch to batch variation.

Causes:

→ Fluctuation of Temperature.

→ Improper dosing time of dyes & chemicals.

→ Batch to batch weight variation of dyes and chemicals.

→ Dyes lot variation.

→ Improper reel speed, pump speed, liquor ratio.

→ Improper pretreatment.

Remedies:

→ Use standard dyes and chemicals.

→ Maintain the same liquor ratio.

→ Follow the standard pretreatment procedure.

→ Maintain the same dyeing cycle.

→ Identical dyeing procedure should be followed for the same depth of the Shade.

→ Make sure that the operators add the right bulk chemicals at the same time and temperature in the process.

→ The pH, hardness and sodium carbonate content of supply water should check daily.

So, friends make sure about the yarn dyeing faults and take steps for remove it.

Peroxide, Absorbency And pH Test During Dyeing | Test Carried Out For Better Dyeing

In dyeing process different test is carried out to determine the better dyeing. We know that per oxide is applied during bleaching and it is harmful for human body. So it needs to remove from the yarn or fabric. Some points are need to consider during dyeing. Absorbency and pH test is essential for dyeing and it checks during dyeing. A short description of some test is given bellow.



Test carried out during dyeing process

• Peroxide Test: This test is carried out after bleaching process. This test determines the amount of peroxide present in yarn or fabric. It requires to make sure that material is peroxide free because peroxide is harmful for the yarn or fabric. A peroxide test paper is used. Wet yarn package or fabric is used for this. The test stick is hiding in the middle for 15-20 sec. then takes out from the package or fabric and match with the test scale. If color change then it contains peroxide. If color don’t change then there have no peroxide.


• Absorbency Test: Absorbency test is carried out after bleaching. At first sample is dried and immerse into water. Standard time for absorbency is up to 5 sec. Better absorbency of sample facilities better dyeing operation.


• P^H Test: It needs to control P^H of the dyeing bath, because it affects the exhaustion and fixation rate. Some dyeing process is carried out in alkaline medium and some are carried out in acidic medium. Generally natural fibers dyeing are carried out in alkaline medium and synthetic fibers dyeing are carried out in acidic medium. It also depends on dyes characteristics and what’s type of dyes are used for which fiber. In practical way following parameters are maintained for dyeing cotton and polyester and in different stage of dyeing P^H level vary.

P^H levels for different stages of cotton dyeing

1. Initial Bath pH                                                   :6.5~7.0


2. Before Enzyme, bath pH                                     :4.5~4.7


3. After Enzyme & Aquachoron ,pH                           :5.5~6.0


4. Before Scouring & Bleaching, pH (With Enzyme)      :5.5~5.8


5. Before Scouring & Bleaching, pH (Without Enzyme)  :5.5~5.8


6. Scouring & Bleaching, bath pH                          :10.0~10.5


7. After Scouring & Bleaching, pH                             :8.5~9.0


8. Before Leveling Chemicals, pH                              :6.5~7.0


9. After Leveling Chemicals, pH                                :6.7~7.0


10. After Adding Dyes, pH                                     :6.2~6.35


11. After Addition of Salt, pH                                  :7.5~8.0


12. After Addition of Soda, pH                              :10.5~11.0


13. Before Hot Wash, Bath pH                                 :6.8~7.2


14. Hot Wash, bath pH                                          :8.5~8.7

P^H levels for different stages of polyester dyeing:

1.   Initial bath pH                                                        :6.5~7.0

2.   Scouring, bath pH                                                :10.0~11.5

3.   After Scouring, bath pH                                           :8.5~9.0

4.   Before Addition of Leveling Chemicals, pH                    :6.0~6.5

5.   After Addition of Leveling Chemicals, pH                      :4.5~4.7

6.   After Addition of Colors, bath pH                                :4.2~4.3

7.   During Reduction Clearing, bath pH                          :10.5~11.5

8.   Before Softener, bath pH                                           :6.3~6.8

9.   After Softener Addition, bath pH                                :5.8~6.2

So, that’s all about the test carried out during dyeing. It also increases the dyeing efficiency and these test should carried out during dyeing.

 

Points Need To Consider During Yarn Dyeing Process | Influencing Factor Of Yarn Dyeing

Yarn dyeing process is different from knit dyeing or woven dyeing. During dyeing, textile engineer should give deep concern on the following points. He should give proper instruction to his supervisor or operator to do all the work as per schedule. If any faults occur during dyeing process then it will impact on the dyeing process. In package yarn dyeing process following points are important to consider.

Batch:

1. Batching should be done by same lot yarn and same count yarn.


2. Package level after pressing should be uniform.


3. Package cap should be tight, it should not loose during operation in the dye bath.

Pressure:

1. In-Out and Out-In pressure for each machine should maintain. If pressure vary than In-Out and Out-In will not be uniform, which after the levelness of package.


2. Pressure should maintain during level in and level out process.

P^H:

P^H is one the most important factor in dyeing process. Following is the P^H which should maintain for Cotton:

After salt mixing        : P^H 6-6.5

After soda mixing      : P^H 11-11.5

After process P^H should be neutral.

Checking:

→Checking is important. Checking should be performed in every step of operation.

→Sample checking should be after

● Bleaching (Residue H₂O₂, Absorbency check)

● Color migration (Level check)

● Dyeing

● Washing

● Finishing

→Water level should check.

→Carrier batch should check after every step by open the lid.

→Time and temperature should check.

Measurement: Operator/Supervisor should be aware during measurement. One should be aware about the measurement because a small mistake can vary the shade of the materials.

● Dyes measurement

● Chemical measurement

● Water measurement

● Time measurement

● Temperature measurement

So, if a respective person aware about the points then he or she will get success in dyeing. Let do the same and see the results.

Functions Of Chemical Auxiliaries Used In Wet Processing | List Of Chemical Auxiliaries

We know that dyes and chemicals are the main factor for producing color in yarn of fabric. Different types of chemicals are used during dyeing. In different stages of dyeing processing, various chemicals are used. Every chemical have their own characteristics and they are used in different stages of wet processing.



List of Chemical auxiliaries used in wet processing unit and their function is given bellow:

1. Acid: Acid is used to control P^H. Acid decrease the pH of the solution. If P^H 1-7 then it is called Acidic solution.


2. Basic: Basic is used for increase the P^H of the solution. P^H range of basic is 7-14. This also used as scouring agent.


3. Peroxide Killer: This chemical is used to kill per oxide which is remaining in the material. Peroxide is harmful for the material. A test is carried out to measure the amount of peroxide present in the solution.


4. Bleaching Agent: Bleaching is carried out before dyeing or printing operation. Better absorption of dyes depends on better bleaching. Absorbency test is carried out to test the bleaching performance. Absorbency time should lie under 5 second. It is used for removing natural color from the grey yarn or fabric.


5. Salt/Electrolyte: Salt is used as electrolyte. Salt increase the exhaustion rate of the dyeing process. Different types of salt are used for different shade. The amount of salt used depends on the shade % of the material.


6. Scouring Agent: Scouring agent is used to remove fat, waxes, fragments of cotton etc.


7. Antifoaming Agent: Foam is formed during bleaching and dyeing process. Anti foaming agent is used to resist foam formation. If foam formed it reduces the dyeing uptake %.


8. Sequestering Agent: This agent is used to remove hardness of water.


9. Dispersing Agent: This agent is used for disperse dyes. We know, disperse dye is insoluble in water and dye present in disperse form. By applying this agent dye molecule breaks and become soluble in the solution.


10. Neutralization Agent: This agent is used to neutral the P^H of the solution.


11. Wash/Soaping Agent: Soaping agent is used for washing. It needs to wash dyed material to remove unfix dye from the material. Dark material needs double wash. But light shade materials needs single wash, sometimes no wash is carried out for light shade. It also increases the reflecting properties.


12. Softening Agent: This agent is used to increase softness of the material. This agent used as finishing material.


13. Fixing Agent: This agent is used for fixing of dyestuff and also remove the unfix dye.


14. Brightening Agent: This agent is used to increase the brightness of the material. This agent increases the reflecting property of the material. Standard reflecting value is 85%. But sometimes it is possible to increase it up to 95%. But it is risk because it needs high kier boiler temperature, which reduces the strength of material.

So, we should use the chemical auxiliaries according to their scope of use.

Batching Section In Yarn Dyeing Process | Pressing Machine For Batching Section

In yarn dyeing process; yarns are batched like the batching section of knit dyeing. The activities of yarn dyeing and knit dyeing batching section are almost similar but the process is different. Here grey yarns are the raw materials for yarn dyeing which is supplied from the soft winding section.


Batching is the second important section after soft winding and before bleaching as well as dyeing process. It is the process to make a batch for dyeing. During batch preparation some points are considered. If some fault occurs during batch preparation then it affects the shade of the yarn package.

Steps in Batching: In batching section; spring tubes are pressed by the pressing machine. This is a steps work, in batching section bathing is done as the following:

Soft package from soft winding section

↓

Enter the package into the spindle of the carrier

↓

Pressing by press machine/manually

↓

Prepared for dyeing

Pressing Machine: Pressing machine is used for pressed the spring tube which contains yarn for dyeing. By this machine, cap is fitted on the top of each spindle. During pressing, yarn package density keeps in controlled. Otherwise imbalanced density occur shade problems in dyeing process.

Machine Description: Different types of pressing machines are used for yarn package pressing. One of the most used pressing machine is FONG’S which is manufactured by FONG’S NATIONAL ENGINEERING (SHENZEN) CO. LTD. Its origin country is China.

Parts of Pressing Machine: Followings are the parts of a pressing machine:

1. Punching head


2. Tray(box)/Carrier head


3. Cap plate tray


4. Operator carrier

Advantages of Pressing machine: Pressing machine gives the following facilities over manual pressing:

1. It gives uniform pressure on the entire package.


2. Low pressure variation.


3. Cap is fitted by the machine.

Disadvantages: Although pressing machine has some limitation. Followings are some disadvantage:

1. Only spring package can be pressed.

2. Need more times than manual pressing.

Points need to consider during batching: Various points are considered during batching and pressing. They are as follow:

• Every package in batch carrier should have uniform softness or hardness.


• Batch operator should be aware about lot mixing and count mixing package.


• Operator should feed minimum package and should not feed over range package in a carrier.


• Tube should be neat and clean. If any tube loss its original shape then it should replace by original one. Uneven shade is occurred for tube fault.


• During tube setting big tube part should feed first then small tube part, because it facilities easy remove of package.


• Pressing should be less than 20%.

So, during batching we have to consider the yarn count, yarn lot number and pressing parameters for better dyeing performance.

Working Mechanism of AHIBA NUANCE Sample Machine | Sample Dyeing In Lab

In dyeing lab; sample is developed for matching the shade with the standard swatch or pantone number which is given by the buyer. After produce a dyeing recipe samples are dyed in a sample dyeing machine. In modern time AHIBA NUANCE sample dyeing machine is popular to the textile engineer for sample dyeing. It has different characteristics which are help full for sample production.



There are different types of sample dyeing machine which is used for sample dyeing. Among all of them AHIBA NUANCE sample machine is different. A sample introduction of this machine could be as follow:

Brand Name                : Ahiba Nuance ECO-B

Manufacturer              : SHM.P.R.C

Origin                        : USA

Rating                        : 220 V, 50/60 Hz

Power                        : 3850 W

Temperature               : 140⁰ C (Maximum)

Capacity                    : 20 Tubes

Designed and developed by data color

 

Working procedure of an AHIBA NUANCE sample dyeing machine: Before execute a machine one should have general knowledge about the procedure by which a machine is run. In practical; I have seen that, this machine is best for yarn dyeing lab also used for knit dyeing lab. Anyhow, this machine works as follow:

Each machine contains 20 tubes, 19 tubes is used for dyeing sample and one for sensor. Sensor tube is full of water which quantity is same as others tube water quantity. Sensor determines the temperature of the chamber. There are three coils which give heat to the tube. Dyeing is occurs for this heat. Whole tube carrier rotates clockwise moment for 1 minute and anticlockwise moment for 1 minute. For this reason heat applies through the tube uniformly and shaking occurs also uniformly which is required for better dyeing. The machine works automatically. There are 8 programs which are set for different program Parameter of the program can be changed according to the requirement.

After that, another sample machine is used for sample dyeing. The brand name of this machine is ROACHES which is manufactured by ADVANCED DYEING SOLUTIONS LTD. Origin country of this machine is UK. This machine contains 16 tubes and maximum temperature could be 140⁰ C (Maximum).

Both of this machine’s working procedure is very near similar but controlling system is different from one to another. Price of both machine also differ from one to another. Both sample machines is suitable for yarn dyeing lab for sample dyeing.

So, we can use both of sample dyeing machines for produce desired shade which is needed for bulk production.

 

Soft Winding Section Of Yarn Dyeing Floor | Problems In Soft Winding And Its Solving Way

In yarn dyeing process; soft winding section is the first section. In soft winding section; Yarns are transferred from paper cone to plastic tube or spring tube for facilities the dyeing process. It is one type of re winding process. During re winding different problems could be occur due to the lack of awareness of the respective personnel which can be harmful for the coloration process. Following problems are the most common problems occurred in soft winding section.


Problems in Soft Winding Section: Following problems are generally found in soft winding section.

1. Lot Mixing: Sometimes lot mixing is occurred in this section. Due to these problem different problems is appearing in dyeing section. Shade of the yarn package varied from one package to others. Also shade varies in the same package.


2. Count Mixing : Count mixing is another problem in this section. Sometimes different count yarn package mixed with one another, which produced shade variation in yarn package.


3. Density: Density of yarn package is one of the important factors. Density problem is occurred due to wrong setting of tension, angle of winding, overfeed speed etc. Due to this problem shade variation is occurred package to package.


4. Hardness and Softness: hardness and softness is another problem, sometimes package become hard or very soft due to wrong tension and overfeed speed. Hard package is harmful for dyeing because it does not permit liquor or dye solution to penetrate uniformly through the package. Very soft package make shade variation.


5. Cleaning Device: Cleaning device is used to collect fly or dust, which is with the yarn. If dust does not clean then it increase the tension and package become hard.


6. Yarn Breakage: Yarn breakage is another problem. This problem happens due to low strength of yarn or high tension of winding machine. For this reason production of winding section is hampered.


7. Electrical Problem: It needs to maintain uniform supply of electricity. Due to this problem, flyer become stop but supporting roller moves and yarn wind to tube as line because traversing is stopped.


8. Wrong Program Setting: Wrong program setting is another problem. Tension, angle, overfeed speed should be adjusted to the count of yarn.


9. Winding Fault: Yarn should be feed according to the yarn path; otherwise winding will not be accurate.


10. Lack of spring/Plastic Tube: Spring/Plastic tube should be available, otherwise production efficiency will decrease.


11. Cleanliness problem: Cleaning device should keep clean; otherwise it will be jam by dust which increases the hardness of the package.


12. Manpower: Manpower is essential. Lack of manpower decreases the production efficiency.


13. Health problem: If dust or fly enter into nose or mouth then it creates breath and other physical problem.

Solving way of this problem:

1. Lot should not mix with one another. Numbering should be in every package. Operator should be careful during winding.


2. Different count yarn should keep separately.


3. Tension of each lot package should be uniform and accurate.


4. Cleaning device should keep clean.


5. Different winding parameter which is standard for different count should set properly.


6. Density of each lot package should be uniform and it needs to monitor the process. Density test should work out for each lot package.


7. Better quality yarn should use, it increases the winding efficiency.


8. Operator, helper and others, who enter in winding section, should put musk.

So, we should be careful about the problems which are created in the soft winding section. Also we should take steps for solving these problems.