Fabric dyeing is the method after
weaving, knitting or non-woven to make fabrics. This is very popular method of
dyeing as the dyed fabrics will be processed further to garment industries very
easily. Dyeing forms of the fabric dyeing can be used in 2 ways.
1. Open width form using the fabrics to spread without any creases
and dye them.
2. Rope form using the fabrics with the
form like a rope.
Dyeing work flow chart:
Scouring
& bleaching
↓
Per
oxide hot with a/acid
↓
Enzymes
wash with a/acid
Leveling
with sequestering
↓
Dyeing
dosing
↓
Salt
dosing
↓
Soda
dosing
↓
Sample
↓
Drain
↓
Washing
off
↓
A/acid
↓
Softener
↓
Unload
Dyeing machine:
Name of the m/c:
Dyeing machine
Brand Name:
Dilmenlar
Manufacturing
Company: Turkey
Year of
Manufacturing: 2004 Machine
capacity: 150 kg
No. of nozzle: 02
Maximum
Temperature: 135°c
Motor: 01
Winch Motor: 01
Pump Motor: 01
The controlled Parameters for dyeing procedure:
pH:
- During H2O2 bleaching Ph: 10.50 – 12
- During neutralization : 6.50 – 7.0
- During Enzyme : 4.50 – 7.0
- During reactive dyeing pH: 9.5 – 11.50
- During Soda dosing : 10.0 – 11.0
- Soaping : 4.50 – 6.0
- During disperse dyeing pH : 4.50 – 5.0
Temperature:
- For cotton scouring : 98°c
- For cotton enzyme : 55°c - 60°c
- For cotton dyeing : 98°c (For hot
brand)
- For salt, Soda : 60°c
- Polyester dyeing : 135°c
- For cotton cold wash : 30°c - 40°c
- For cotton hot wash : 80°c - 90°c
- For cotton acid wash : 50°c - 60°c
- OBA application : 98°c
Time:
- For scouring & bleaching : 60
minute (when temp. 98°c) If 110°c, time 30min.
- For cotton enzyme : 60 minute
- For reactive dyeing : 30 minute
- For disperse dyeing : 30 minute
- For salt dosing : 30 minute
- For soda dosing : 45 – 60 min
M: L ratio:
- For reactive dyeing M: L ratio
maintained between 1: 8
- For disperse dyeing M: L ratio
maintained between 1: 10
The calculated formula followed in production:
01. Color (%) – Required dye (gm)= Total
fabric × Recipe / 100
02. Chemical +
Auxilaries (gm/l) - Required chemical (gm)= Total liquor × chemical(gm/l) /
1000
Working Procedure:
Firstly
the detergent, Anti-creasing agent, Anti-foaming agent and Stabilizer are mixed
in mixing tank, then load to machine at 50°c
↓
The
temperature is risen to 60°c. Now the Caustic Soda is given to bath
↓
The
Hydrogen Peroxide is given at 70°c
↓
Raise
the temperature at 98°c and run for 60 minutes. Here the Ph = 11-12
↓
Rinse the fabric
↓
Hot
wash is done at 80°c × 10 → Drain → Normal wash → Drain
↓
Peroxide
is applied at 60°c and run for 15 minutes → Hot wash
↓
Add Acetic Acid at same temperature and run 10
minutes
↓
pH checked (pH=6.5) → Normal wash
↓
Now Acetic Acid applied at 55°c for pH
control (pH= 4.50) and then Enzyme is given to bath at same temperature with 60
minute
↓
Raise the temperature (Grade rate → 2 C/min)
at 80°c and run 6 minute
↓