Continuous dyeing machines

CONTINUOUS DYEING MACHINES

Prepared by:- Haji Karim Aman [email protected] Indus University Karachi

mailto:[email protected]

CONTINUOUS DYEING MACHINE Dyeing:- Dyeing is the process of the application of color on the textile substrate in aqueous medium.

Method of dyeing: There are three methods of dyeing. a). Exhaust dyeing b). Semi- continuous dyeing c). Continuous dyeing

PAD THERMOSOL DYEING MACHINE

CONTINUOUS DYEING MACHINE Continuous dyeing machine:- Continuous dyeing machine is the such a types of dyeing machine in which the fabric is treated continuously. o Types of continuous dyeing machine1) Pad thermosol dyeing machine2) Pad steam dyeing machine3) Pad dry chemical pad steam dyeing

machine

PAD THERMOSOL DYEING MACHINE Pad Thermosol Dyeing Machine:- This dyeing machine is used to dyed fabric from dark to medium shades. It is based on method to dry to dry the fabric without any contact with steaming. This machine is able to carry the following processes. Reactive dyeing Disperse dyeing Vat dyeing Pigment dyeing.

PAD THERMOSOL DYEING MACHINE PROCESS SEQUENCE IN PAD THERMOSOL Batcher ↓ Scray ↓ Cooling drums ↓ Padding ↓ IR ( pre-drying) ↓ Drying and curing chamber ↓ Cooling drums ↓ Scray ↓ Batcher


PAD THERMOSOL DYEING MACHINE Machine specifications: Manufacture Monforts Monotex (2001) Production Speed 60-100m/min Padder Kuster Chambers 5(3 for drying and 2 for curing)

Padder Capacity 100-150liters Scray Capacity 400-600mters of fabric Trough Capacity 50-60litres VTG/Airing Zone 12m of fabric Thread Length 170m Drying units heating Oil Heating System IR Temperature Range 650-850’C IR vertical tension 2-6bar Liquor Change after 3-4min

PAD THERMOSOL DYEING MACHINE Scary or J-box:- It stores the fabric. It is J-shaped metal holder for fabric.

It prevents the down stop of the machine by storing excess length of the fabric during the batcher change.

It also avoids the slackness and crease formation in fabric, which is formed due to speed variation in machine and batcher, scary synchronize the movement between them.

PAD THERMOSOL DYEING MACHINE Guide roller and guider:-

These rollers are steel rollers used to guide the fabric and to provide tension which prevents the crease formation.

Guider is rubber coated roller is placed at edge of fabric to prevent and control the width of fabric.

PAD THERMOSOL DYEING MACHINE Compensator:- These are used to provide tension to the fabric. If the fabric loosens from any roller during the process, this moves up and down to maintain the tension.

PAD THERMOSOL DYEING MACHINE-Dye Padder:-The padder is mechanical mean of applying dye on fabric.

To apply dye liquor in an even manner to the entire width and the length to a batch of fabric.

The padding operation consist of two parts: first immersion of the fabric in dye-liquor in a trough, and second passing the fabric between the two roller to force the dye-liquor into the fabric and also to squeeze excess amount liquor back to the trough.

Padder is the most sensitive components dyeing system as any fault developed at the padding stage will not be corrected later.

PAD THERMOSOL DYEING MACHINENip rolls:- Nip rolls must be clean. The hardness for woven is 70-80 degree shore and 50-60 shore for knitted fabric.

The padder roll has a steel mandrel that is covered with hard rubber.

Topped by 15mm of the soft rubber. Both the rollers should have exactly the same hardness otherwise there will be a color difference in the face and back side of the fabric.

PAD THERMOSOL DYEING MACHINE Kuster S-padder :- These padders are used to avoid the LCR (shade difference in left, center and right) problem in fabric.

Central pressure of Padder is hydraulic pressure (operated or effected by liquid for e.g.: water or oil) and left and right side pressure of padder are pneumatic (using air) pressures.

PAD THERMOSOL DYEING MACHINEPick up and speed:-The pick up for the different fabric are

Cotton =60-70% P/C (50:50)=45-50% Viscose = 80% Nylon = 30% The speed of the padder is 30-90 min/sec

PAD THERMOSOL DYEING MACHINE Padding Trough:- The trough is placed below and in front of the padder.

It is U-shaped box with one or more free-running guide rollers of about 10cm diameter each.

The dye is fed in through a perforated pipe. running across the entire length of the tank with perforations pointing towards the wall of the trough and away the fabric so as to avoid spraying of the liquor to fabric.

The volume in the pad trough should be relatively small 20-50 liters and automatically controlled at constant level throughout the run.

PAD THERMOSOL DYEING MACHINEResulting in shade difference caused by variations in immersion time and pick up.

The pad liquor turnover time should be as fast as possible less than 5 minutes.

Immersion time:- Should be 1-2s for cotton and 2-4s for viscose.Speed:- Must be constant throughout the run-no stoppages.


Pick up:- Must be uniform aross the width acoss the consistent from batch to batch. Pick up depend upon, Pad pressure and speed (fabric pentration, wetting out)

Dye level in the trough ( dip to nip time)

Dyebath chemicals (penetation accelerant)

Fabric (fibre and construction).

PAD THERMOSOL DYEING MACHINE Airing zone:- Airing zone is used because some times the light GSM fabric has face and back variation so we used airing zone.

The airing zone is placed between the padding and drying for better swelling and peneration of the dye

These rollers are Teflon coated to avoid stains on the fabric due to rusting and stickiness of chemical.

PAD THERMOSOL DYEING MACHINE Infra-Red Predryer:- The intermediate drying phase. To get even and uniform results especially for medium and deep shades.

Dye molecule tend to diffuse with water molecule as they migrate from the wetter towards the drier part if the fabric.

Migration stops when only bonded water molecules and moisture content of the fabric dropped below 30%.

PAD THERMOSOL DYEING MACHINEHow to control dye migration:- Lower pick up (less surface or free water molecule)

Skying between padding and drying (better swelling and penetration)

Addition of electrolyte to increase dye affinity (but rise of tailing)

Infra-red pre-drying (most important)

Well balanced air flow in the dryer.

Inside the IR-dryer

PAD THERMOSOL DYEING MACHINERequirement of an Infrared pre-driers:-

Gas or electrically heated.

The emitted IR wavelength should correspond maximum absorption value of water (3µm)

Equilibrium setting up time.

Air passage before pre-drying (dye penetration).

Cleaning of guide rollers.


We set IR temperature according to following parameters

Fabric Quality Shade(Light/Dark) SHADE LIGHT MEDIUM DARKIR TEMP 650 700-750 800-850

PAD THERMOSOL DYEING MACHNE Thermofixation:- In the thermofixation (also incorrectly called thermosol) process of dyeing the synthetic fibers, the disperse dyes diffuse into the polyster fibers on bringing the dye-padded fabrics to temperature of 200-220ċ for a contact time of 60-30 seconds because the polyester has the compact structure and having 85% of crystalline area so at high temperature the pores of the fiber are open which allows to enter the dye in the highly crystalline area.

PAD THERMOSOL DYEING MACHNE Drying chambers:

There are three drying chambers. There is water blower which sucks air from the atmosphere and circulates that air by centrifugal action in whole chamber.

There is a gauge on each dryer which is showing the balance of air inside the chamber.

PAD THERMOSOL DYEING MACHINE Curing Chambers: There are total two curing chamber i.e. used when dyeing with polyester or with disperse otherwise as a drying chamber.

These chambers are used for high temperature dyes fix up especially for polyester.

Curing(200’C-210’C for 45 – 60sec) The fabric is led vertically around a series of top and bottom parallel rollers set apart a distance 125cm.

The top rollers are driven and the bottom rollers are free running.

PAD THERMOSOL DYEING MACHINE The temperature of the curing chamber

Fabric 1 2 3 4 5

Pc 120 140 160 200 200

cotton 100 120 150 165 165


PAD THERMOSOL DYEING MACHINE Cooling drum:- These are provided at the inlet and outlet side of the thermosol machine.

These are hollow steel drums and used to maintain the temperature of the whole lot water filled inside the drum to cool it.

PAD STEAM DYEING MACHINE

PAD STEAM DYEING MACHINEIntroduction:- A process of the continuous dyeing in which the fabric is open width is padded and then steamed.

Is an ideal machine for reactive dyeing

Light, pale and medium shade can be dyed in this machine.

PAD STEAM DYEING MACHINE Processes:- Reactive dyeing Pad batch dyeing Reduction cleaning Stripping Vat development/vat dyeing Washing/hot+cold Pad steam Wet chemical pad

PAD STEAM DYEING MACHINE Main section of machine Inlet section

padding section

steamer washer

Dryer

outlet section

PAD STEAM DYEING MACHINE Inlet section Inlet consist of following parts

Batcher Tension roller Free guide roller

Stationary roller

PAD STEAM DYEING MACHINE Padder Padder is used for padding. The pressure of the padder is 1.5-2 bar.

The central pressure is hydraulic and side pressure is pneumatic.

We can adjust the pressure of the padder, prevent the listing problem.

The mostly padder used are kuster padder

PAD STEAM DYEING MACHINE Steamer:- Here in steamer temperature is required for the fixation.

This temperature is achieved by saturated steam.

The purpose of using the saturated steam is that the chemicals used for developing should not dry on the surface of fabric preventing fabric from stains.

Here roof temperature is given to avoid water dropping that cause spotty dyeing.

PAD STEAM DYEING MACHINE Steamer temperature 102-105

Fabric dwell time 1 minute

Roof temperature 107-109

Fabric capacity 75 meter

Water 1 ( at end)


PAD STEAM DYEING MACHINE Water lock/seal:- To stable steam to come out from the steamer.

To avoid thermal socks. Temperature here is 40-45 and it serve the following purpose.

1) To cool the fabric.2) Remove excess dye from surface.3) It condense the steam that comes

along the fabric.

PAD STEAM DYEING MACINE

PAD STEAM DYEING MACHINE Washing chamber:- Washing is carried out in order to remove unfixed dye.

After steamer fabric flows from 7 to 8 washer.

1to 4 washer are used for washing of salt and chemical which being applied from trough.

In 5th and 6th washer oxidation is done if required.

If oxidation is not required then soaping is carried out.

The at 7th and 8th the neutralization is carried out.

PAD STEAM DYEING MACINE The chamber are used in number of process a/c to the requirement.

Light and hard soaping Washing RC Vat developing Neutralizing The capacity of the each washing tank is 950-1300 liter.


PAD STEAM DYEING MACHINE Drying Drums:-

These drying cylinder are used for dyeing the fabric.

There are 20 cylinder are used for drying.

Last 2 cylinder contain water while 18 cylinder contain super saturated steam 120c.


Batcher:-After drying the fabric from drying cylinder the fabric is wind on the batcher.

Continuous dyeing machines

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