Textile Dyeing Machinery

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Text of Textile Dyeing Machinery

  • 1.Prepared By : Mazadul Hasan sheshir ID: 2010000400008 13th Batch (session 2009-2013) Department : Wet Processing Technology Email: mazadulhasan@yahoo.com Blog : www. Textilelab.blogspot.com (visit) Southeast University Department Of Textile Engineering I/A 251,252 Tejgaon Dhaka Bangladesh Prepared By :

2. Total Textile Process at a Glance 3. To Classify Dyeing & Finishing Machinery To Know Function of The Machinery To Know Working Process of The Machinery To Know Some Brand Name To Know Advantage & Disadvantage 4. Textile Dyeing: Dyeing is a coloration process of textile which is invariable carried out in an aqueous medium. In the other hand, dyeing can be define as a process by which a yarn, fabric, garments and any other materials that come to contact of dye by presence of auxiliaries that create the condition of dyeing environment Dyeing machine: The machine which is used to dyeing or coloring of materials like yarn, fabric, garments or any other materials is called dyeing machine. Dyeing machines come in all shapes and sizes to accommodate the various forms and quantities of textile materials. It is impossible to provide exhaustive coverage of this field. Therefore, the most important types of machine, and their problems, will be at the forefront. 5. Types of Dyeing Machine Fibre Dyeing Machine Yarn Dyeing Machine Knit Dyeing Machine Woven Dyeing Machine 6. Package Yarn Dyeing Machine (Vertical Type): 7. Package Yarn Dyeing Machine (Horizontal Type): 8. This types of machine consists of a cylindrical carrier, having perforations over its surface, over which perforated spindles can be placed, radiating from the surface. The top of the carrier is provided with a hook, by which an overhead crane can lower into or raise from an outer cylindrical dye vessel. In case of this types of machine, carrier is filled with package and is placed in the dye vessel by robotics system. This type of machine is suitable for scouring, bleaching, dyeing and washing. According to objective chemicals and auxiliaries are pumped into the dye vessel by centrifugal pump. Then due to circulation of dye liquor in the dye vessel pretreatment or dyeing is performed. Function & Feature: 9. The material is dyed on cross wound packages ,therefore bigger unit weight( 1.2 kg -1.5 kg for cotton) in dyeing is possible. Economical dyeing due to lower liquor ratio, compact and enclosed dyeing vessels . Different liquor ratio is possible in different process steps such as partial filling in washing and soaping and fully flooded in rinsing make the process economical. More uniform dyeing is possible due to higher number of contacts at high and optimized flow rates High temperature ,high pressure and high flow rates results into shorter dyeing cycles Due to complete automation ,the machines are less labor intensive. The main advantages of package dyeing over other yarn dyeing methods are 10. Modern machines with partial loading spindles are more flexible for different size lots . Very less handling and damage to dyed substrate ,due to shorter dyeing cycles. All operations from pretreatment to hydro extraction in single machine are possible The package dyeing machines are more versatile because almost all type of substrates can be dyed and almost all types of dyestuffs applications is possible. The same machines can be used for multiple make ups such as yarn, fiber, tow ,tops, bumps and beams on suitable dyeing carriers. Most advanced machines are equipped with pH regulators and controllers and salt sensors to for achieving very reliable and reproducible results. 11. The OBEM API/V machines are the traditional type, vertical kier dyeing machines They are really the multi- purpose solution apparatuses for processing all kind of fibres and in any type of form like in packages, tops, loose fibre and tow, only by changing the material-holders. The API/V capacity is variable from 20 to 10,000 kg Low liquor ratio, variable from 1:3 to 1:8 PLC Controlled. Fully automatic. OBEM API/V Package Dyeing Machine: 12. Winch Dyeing Machine: Figure: Roto Master (Thies Winch Dyeing Machine) 13. Figure: Schematic view Roto Master (Thies Winch Dyeing Machine) 14. Inner rotating fabric chamber ensures positive fabric transport and gentle treatment of the fabric Electro-pneumatic operated valves Adjustable winch drive combined with programmable nozzle pressure permits fabric speeds of 40-400 m/min Analog Dosing Fully automated dosing of dyes and auxiliaries according to a programmed time and curve (also under HT conditions) Analog level - dyeing kier Controls the liquor level in the machine usig an electrical transmitter Max. operating temperatures to 100C and 140C Automatic control via industrial PC Technical Details of Roto Master (Thies): 15. Winch dyeing machine: A dyeing machine consisting essentially of a dye vessel fitted with a driven winch (usually above the liquor level) which rotates and draws a length of fabric, normally joined end to end, through the liquor In all winch dyeing machines a series of fabric ropes of equal length are immersed in the dye bath but part of each rope is taken over two reels. Winch dyeing machines are a low cost design that is simple to operate and maintain. 16. Principle of winch dyeing machine: The basic principle of all winch dyeing machines is to have a number of loops or ropes of the fabric in the dye bath, these ropes are of equal length, which are mostly immersed in the liquor in the bath. The upper part of each rope runs over two reels which are mounted over dye bath. At the front of the machine, above the top of the dye liquor, is a smaller reel, which is called jockey or fly roller. The fly roller remains freewheeling along with fabric rope. At the back of winch tank is the winch wheel, which pulls the fabric rope from the dye bath over the jockey reel for dropping in the dye bath for immersion. From the dropped location, the fabric rope travels back. To be lifted and fed to winch wheel. The dyeing process on winch dyeing machines is based on higher M: L as compared with other dyeing machines. The process is conducted with very little tension. The total dyeing time is lengthier as compared to other machines. 17. Advantages of Winch Dyeing: Construction and operation of winch are very simple. The winch dyeing machines are suitable for types of wet processing operations from desizing to softening. The winch dyeing machine is suitable for practically all types of fabrics, which can withstand creasing in rope form processing. The tension exerted on winch is less than jigger; the material thus dyed is with fuller hand. The appearance of the dyed goods is clean and smooth on winch dyeing machines. 18. Limitations of Winch Dyeing : Batch dyeing operations needs trimming, sewing, opening out the rope, loading and unloading for individual lots separately. Since several lengths of fabric are run over the winch reel into the liquor and sewn end to end, Continuous length processing is not possible in a single batch. Fabric is processed in rope form which may lead to crease marks, particularly in heavy, woven, thin and light synthetics. Most of the machine works under atmospheric conditions. 19. Jet Dyeing Machine: A machine used for dyeing of fabric in rope form. Jet dyeing machines came into existence with a purpose to minimize or eliminate the drawbacks of earlier machines like winch , jigger and beam dyeing units. 20. Principle: Jet dyeing is a process that can be used for batch dyeing operations such as dyeing, bleaching, washing and rinsing. In this process, dyeing is accomplished in a closed tubular system, basically composed of an impeller pump and a shallow dye bath. The fabric to be dyed is loosely collapsed in a form of a rope, and tied into a loop. The impeller pump supplies a jet of dye solution, propelled by water and/or air, which transport the fabric within the dyeing system ,surrounded by dye liquor , under optimum conditions. Turbulence created by the jet aids in dye penetration and prevents the fabric from touching the walls of the tube, thus minimizing mechanical impact on the fabric. 21. Types of Jet Dyeing Machines: Overflow Dyeing Machine Soft-flow Dyeing Machine Airflow Dyeing Machine 22. Overflow Dyeing Machine Functioning of a Overflow Dyeing Machine: A typical Overflow Dyeing Machine works like this. A winch that is not motor driven usually is located in the top side of the machine where the fabric is hanged. A longer length of textile is made to hang from the exit side of the winch as compared to the inlet side. By applying the force of gravitation the longer length of textile is pulled downward more strongly than the shorter one. Consequently the fabric is soaked in the bath without any sort of tension. The following diagram well illustrates the working process. Advantages: No evaporative losses, No build up of steam condensate in the dyebath, Low liquor ratios, Excellent dye liquor contact, Computer control 23. HTHP Soft-flow Dyeing Machine Technical features: Compact body made of stainless steel. High efficiency heat exchanger for quick heating/cooling. Compact body made of stainless steel. Heating rate - around 4C/Min upto 900C - around 3C/Min upto 135C At steam pressure of 6 Bar. Cooling Rate- around 4C/ Min At water pressure of 4 Bar and 15C. Maximum working temp is 135C. Maximum working pressure of 3.2 Bar. Control manual as well as automatic. Heavy duty stainless steel pump. 24. Airflow Dyeing Machine Features of Air flow Jet Dyeing Machine: Completely Separated circuit for liquor circulation without getting in touch with the textile Bath less Dyeing operation Rinsing process offers all the added benefits of continuous processing as it is no longer a batch operation Extremely low liquor ratio Virtually non stop process Comparatively lesser energy requirement due to faster heating/cooling and optimum heat r