2. LOADING THE MACHINE
Calculate chamber loading.
Loading the machine in warm water @ 50-
60°C- Chamber being under loaded is a false
impression- during cold rinsing fabric will
increase in volume.
Fabric thoroughly wetted out by increasing the
bath temperature or if necessary adding a
wetting agent to the liquor, before the fabric is
introduced into the machine.
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3. LOADING THE MACHINE
DO NOT over fill the machine Especially when
processing 100% synthetic fabrics, on machines with
large circular kiers because fabric will not float from
centre to the front.
Consider fabric type & width of the chamber while
loading.
Load- not less than 50% of nominal load- or it will lead
to running problem (insufficient fabric to drive the rotor).
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4. CAPACITY
Size of the chamber
No. of chamber
Construction of fabric & width
Fiber to fiber blend
Weight per running meter
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5. CALCULATING CHAMBER LOADING
Rope cycle time & rope speed
Maximum speed depends on machine
Liquor transport system- 250 to 600 m/min
Air transport system- 600 to 1000 m/min
Speed depends on properties of the fabric, rope
length & rope circulation time for level dyeing.
Fabric can run @ lower speed in non- critical dyeing
parts (Bleaching & After treatment)
Weight per running meter = (rope weight/ Rope
length)
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7. ROPE CYCLE TIME & CIRCULATION SPEED
Fabric Rope cycle
times in
minutes
Rope circulation speed m/min
Woven fabric Knit fabric
PES unfixed
PES heat set
1
1-1,5
400
400
250
200
PA unfixed
PA heat set
2-3
2
400
350
300
300
PAC 1-2 300 250
Co - reactive
Co - Vat
2-3
1-2
350
350
225-275
225-275
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8. ROPE LENGTH, WINCH SPEED & ROPE
CIRCULATION TIME
Winch speed= (Rope length/ cycle time)
No. of nozzle passages= (Process time in min/ cycle time)
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9. NOZZLE SIZE
Based on weight per running meter
Greige or raw fabric occupy ½ to ¾ of nozzle opening
For pile / terry fabrics multiply g/m by 1.3
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Nozzle diameter
in mm
Weight per running metre/yard
(g/metre) (ozs/yard)
50 80 - 150 2.8 - 5.3
60 100 - 200 3.5 - 7.0
70 150 - 300 5.3 - 10.6
85 150 - 500 5.3 - 17.6
100 400 - 700 14.1 - 24.7
120 600 - 900 21.1 - 31.8
10. VARIO NOZZLE
Vario nozzle- X
settings
Equivalent
Standard
nozzle size
1 100
2 90
3 80
4 70
5 60
6 50
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Vario nozzle-
XL settings
Equivalent
Standard
nozzle size
1 120
2 110
3 100
4 85
5 75
6 65
11. LIQUOR RATIO
Vary based on weight, construction & quality of fabric.
Include moisture content in fabric before dyeing if fabric is
already wet.
There should be sufficient free liquor to feed the pump but
not excessive.
MLR= Liquor in m/c (l) = 1: …….
Weight (Kg)
Addition during dyeing is also considered as it increases the
volume
Short liquor- increases material to liquor contact
- decreases energy, water, dyes & chemicals
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12. LONG LIQUOR RATIO M/CS
Long horizontal dyeing m/c with long floating action
suitable for wool & polyester
Do Not overload (jam) - there should be space for
fabric to float to the front of the m/c.
Nozzle gap – Polyester (lighter fabric)- 4mm
- Cotton (Heavier fabric)- 5mm
Over loading- needs excessive nozzle pressure &
sufficient water.
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13. LIQUOR VOLUME
“Soft stream V” m/c- in pump running condition-
water level should be 6 inch below the top of the
inner chamber dividing wall.
“Soft stream IV” m/c- half fill main chamber.
Trials should be carried out to fix optimum
conditions for individual fabric.
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14. BEFORE PRE- PRODUCTION CHECK-
OIL, WAX & SPIN FINISH
Leads to “unlevel dyeing”
Problem in batch to batch reproducibility
Higher % in 100% man made fibers- test using soxhlet
extraction
Lubricants- melting point vary- require anionic/ non-ionic
scouring agent
Spin finish contains detergent- combined with detergent in
treatment bath cause instant foaming- causes pump
cavitation, tangling & rope stoppage.
In such case drain the machine- do not add anti foaming
agent.
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15. Check residual oil -if 5% present, then dyes added
is 5% excess- off shade, batch matching problems.
Check water after 5 min
Pale/ white milky -> Safe
White/ pale creamy -> drop the bath
Thick creamy -> drain & refill
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16. AFTER PRE- PRODUCTION
Wetting property- affinity for the dye
Fabric- rinse & dry- put it in water in a glass; Floating- Poor
wetting property; Sink- good wetting property.
Residual size- indicator
Blue spot with red rim- Polyester
Blue brown with orange rim- Polyacrylate
Green- Polyvinyl acrylate
pH- adjust as required
H2O2 – test residual using H2O2 determination paper
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17. SODIUM BICARBONATE
NaHCO3 in water gives buffering effect- water- boil
10-15 min- cool it & check pH.
pH raises- excessive NaHCO3
Use acetic acid.
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18. FABRIC MARKS & OXIDIZED OILS
When roll stored vertically, so stored horizontally
Oil used in knitting & weaving machine may oxidise
when stored
Special scouring agents are available to remove
oxidised lubricants (Hand spotting if req.)
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19. SPOTS OF KNITTING OIL REMOVAL
Check type, amount & water solubility of knitting oil
by water or petroleum ether extraction.
@50-60°C water- add detergent/ anti crease agent/
defoaming agent/ sequestering agent or complex
builder- add fabric (30 min; 60-80°C)- warm over
flow rinse- drop the bath- warm rinse- cold rinse.
Demin can be done in acidic condition.
Single stage H2O2 bleaching.
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20. FABRIC FAULTS CREATED DURING DYEING
Cockling:
Heat sensitive/ thermo plastic fabrics- too low
speed during cooling cause Cockling.
Eliminated by
large dia nozzle
Increasing Liquor ratio
Decreasing fabric speed
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21. CRACK, ROPE/ RUNNING MARKS
Caused based on the material construction & poor
opening of fabric rope
Avoided by pre- setting fabric
Incorrect process procedure.
Increase speed & decrease rate of rise/ cooling
Decrease load & increase nozzle pressure
Viscose blend- drain temperature should not be
high- Shock cooling of static material will cause
crack.
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Occurs in Woven
Pre- setting before dyeing
Increase rope speed
Increase liquor ratio
Occurs in plush & uncut
pile fabric
Increase liquor ratio
Reduce nozzle pressure-
better liquid circulation-
Floating material transport
action.
Crows feet/ wrinkling Hammer finish
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Increase fabric
speed
Increase liquor ratio
Decrease rate of
cooling
Woven/ warp knitted fabric-
stopped during cooling stage.
Check m/c not overloaded &
there is sufficient liquor in the
m/c
Shock chilling may also cause
this effect
Crush marks Elephant Skin/ orange peel effect
24. FABRIC DISTORTION & INCREASE IN WIDTH
Caused by too high material speed
Decrease nozzle pressure
Decrease winch speed
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25. PILLING
Too high mechanical stress on fabric surface
Not necessary to run @ higher speed during
scouring & rinsing
Use right nozzle gap- (100mm dia, 4mm gap)
For cotton/ lycra knit- (100mm dia, 6mm gap)
Syncronize nozzle pressure & winch speed
Set rope turnover time & winch speed then reduce
nozzle pressure
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26. Flash of Rope tangle detector light b/n winch & nozzle
gives metallic click sound.
m/c will use automated/ intelligent system which is self
correcting.
(or) increase nozzle pressure until sound ceases & light no
longer flashes.
Use suitable chemical lubricant, check product
compatibility & anti-foaming property.
Turn fabric inside out- Sometimes it may give crease
marks.
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27. RUNNING PROBLEMS
Flat polyester filament fabrics:
Winch does not transport smoothly with required speed
Increase nozzle pressure
Cotton fabrics:
Winch transport rope without difficulty.
Can reduce nozzle pressure provided material circulates @
even speed.
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28. BALLOONING
Caused by seam densely sewn, So cut 10-15 cm
Vertical slit.
Use chain stitch & butt seam
Small ballooning reduces running marks & gives
better folding.
Compromise b/n degree of ballooning & rope
circulation is necessary.
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29. INTENSIVE FOAMING
Cause cavitation- loss of nozzle pressure & floating
of fabrics.
If foaming is less severe add de-foamer or anti
foaming agent.
If foaming is severe drop the bath & restart the
process with suitable anti- foaming agent.
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30. UN EVEN DYEING
Shade variation in a rope:
Due to rapid addition of dyes & chemicals, use
analogous dosing
Use glaubers salt (fewer impurities), common salt (high
level of impurities) causes corrosion.
Check rope circulation time is correct.
Check correct rope speed for rope length.
Check motor speed synchronized.
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31. ROPE TO ROPE SHADE VARIATION
Same rope length in each chamber
Check nozzle gaps are not blocked
Ensure cartridge filter sleeve sockets correctly fitted
Right quality filter fabric
Same winch speed
Same setting if vario nozzle is used
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32. BATCH TO BATCH SHADE VARIATIONS
Check pH, hardness & sodium bicarbonate for water
daily.
Dye affinity of fabric after scouring & bleaching should
be identical.
Use same program, same liquor ratio & same cycle
time.
Same rope speed based on batch size.
Right chemical @ Right time & right temperature.
Different combination of dyes require different dyeing
programs
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33. DYE SPOTS
Can be reduced by thorough mixing & dissolving of
dye stuffs @ right amount of water & @ right
temperature.
Filter using fine stainless steel mesh when adding
dyes to the chemical addition tank.
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34. MOTES AND PIN-HOLES
Inadequate mote removal usually results when the pH is
too low during bleaching, peroxide decomposition
during bleaching is high, or the motes are not adequately
softened in scouring.
Pin-holes are the result of localized fiber degradation by
hydrogen peroxide and is usually catalyzed by metal
ions such as iron and copper.
There are many sources of these metal ions that should
be checked. They may be present in the water supply.
A common source of iron is rust from water and steam
supply lines. In addition, metal ions are inherently
complexed with the fibers, and the amount will vary with
source of fibers and/or growing conditions.
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