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Jigger dyeing machine

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Jigger dyeing machine

  1. 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. 2. Piece Jig Dyeing 1. Fabric is treated in open width and is passed through the dye bath rather than immersed in to a dye bath and this is repeated. 2. There is a degree of tension on the fabric and is therefore used on woven fabrics and not knits.
  3. 3. Jigg or jigger dyeing machine is one of the oldest dyeing machine used for cloth dyeing operations. Jigger machine is suitable for dyeing of woven fabrics, up to boiling temperature without any creasing . Jigs exert considerable lengthwise tension on the fabric and are more suitable for the dyeing of woven than knitted fabrics. Since the fabric is handled in open-width, a jig is very suitable for fabrics which crease when dyed in rope form. Jigg or jigger dyeing machine
  4. 4. 1. Jigs exert considerable lengthwise tension on the fabric and are more suitable for the dyeing of woven than knitted fabrics 2. There are mainly two types of jigger dyeing machine. One is open jigger dyeing machine and other is closed jigger dyeing machine. 3. The number of ends or turns depends upon the type of the fabric and also the percentage of the shade. 4. It exerts lot of tension in the warp direction and because of this normally knitted fabrics is not dyed in jigger dyeing machine. Study of Jigger Dyeing Machine.
  5. 5. Main parts:
  6. 6. A B DD C C E F A=Let off roller B=Take up roller C=Free roller D=Guide roller E=Steam channel F=Dye bath Main parts:
  7. 7. Main parts: 1. Guide roller 2. Take up roller 3. Let off roller 4. Steam channel 5. Dye bath Utilities required: 1. Water 2. Steam 3. Electricity Main parts:
  8. 8. Flow Diagram
  9. 9. Fabric tension: 5 to 70 kg/cm² Speed: 10 to 150 m/min Fabric width, max. 3800 mm Roller width, max. 4000 mm Roller diameter: 270 mm Roller batch dia : 1000 or 1230 mm (dependent on the type of m/c) Fabric height: 365 or 475 mm (dependent on the type of m/c)
  10. 10. Fig: Schematic diagram of Jigger dyeing machine
  11. 11. Technical Advantages: • Fabric Rope Controller 1. automatically calculates the r.p.m. ensuring exact fabric 2. speed and tension providing excellent dye penetration. 3. Automatic sampling point selection. • Direct drive of the main rollers by frequency controlled motors with brake current return provide a considerably shorter braking distance compared with hydraulic • Loading/unloading device for crease-free loading/unloading of the fabric (Option)
  12. 12. JIGGER DYEING MACHINE 1. Based on experience and developments in industry and controller technology, the Thies-Jigger is developed. 2. Suitable for processing fabric at atmospheric temperatures of up to 98°C and in HT execution up to 143°C, this Jigger is especially recommended for the treatment of crease sensitive, permeable and non-permeable articles in open width form, offering optimum flexibility for the finishing of all modern fibres and blends.
  13. 13. 3. Incorporating innovations in step less tension and material speed control and with an economical dye trough designed for uniform dyeing in short liquor ratio conditions. 4. An industrial PC, proven in the exhaust dyeing industry, including PLC and a fabric rope monitoring system is used for the complete machine control, ensuring the maintenance of optimum processing conditions.
  14. 14. Technical Details: Fabric tension 50 - 800 N Fabric speed: 10 to 150 m/min Fabric width up to 5400 mm Roller width up to 5600 mm Roller diameter* 330 - 550 mm Batch diameter* 1000/1230/1450 mm * Depending on the execution
  15. 15. Jigger dyeing machine Based on experience and developments in industry and controller technology, the Thies-Jigger is developed. Suitable for processing fabric at atmospheric temperatures of up to 98°C and in HT execution up to 143°C, this Jigger is especially recommended for the treatment of crease sensitive, permeable and non-permeable articles in open width form, offering optimum flexibility for the finishing of all modern fibres and blends. Incorporating innovations in step less tension and material speed control and with an economical dye trough designed for uniform dyeing in short liquor ratio conditions. An industrial PC, proven in the exhaust dyeing industry, including PLC and a fabric rope monitoring system is used for the complete machine control, ensuring the maintenance of optimum processing conditions.
  16. 16. These machines have been used for a long time to treat medium-size lots of woven with an open-width exhaust dyeing process. The fabric moves while the liquor stands still, except for the very latest machines, which are also equipped with a circulation pump. The fabric pieces are sewn together tail-to-head, forming a sort of “ribbon”. At the head and at the tail of the ribbon two cloths are added (4–5 m long) to allow the regular dyeing of the whole pieces, also leaving the machine drawn-in once the dyeing process has come to an end. The assembled pieces are taken down from a roll, pass through the liquor (they are kept in the correct position by means of transport cylinders and a tension equaliser, which avoids the formation of wrinkles). The fabric is then wound on a takeup roll until the dyeing process has ended. The piece through speed and tensions are adjusted by special devices to avoid any change in dimensional stability, above all when treating lightweight fabrics and/or delicate fibres. Jiggers Theory
  17. 17. The maximum diameter of the roller can be 1,450 mm with a width of the piece of cloth ranging between 1,400 and 3,600 mm. The piece through speed is adjusted between 30 and 150 m/min. and kept constant during the whole operation. Also the tension must be constant and it can be adjusted between 0 and 60 kg. Since the passage time is very short, dyeing occurs above all on the fabric wound on the rolls. The composition of the liquor absorbed must be as uniform as possible on the whole width and length of the fabric piece; for big lots, many additions may be necessary to avoid the so-called head-tail defects. Lightweight fabrics (viscose, nylon) that are stretched excessively during the takeup step can show “shading” defects. Jiggers work with a quite low liquor ratio (from 1:1 to 1:6).Together with standard atmospheric systems, builders also offer HT jiggers inside autoclaves working at high pressure. Jiggers are suitable for dyeing all type of fibres. 6 Jiggers Theory
  18. 18. 1. Direct drive of the main rollers via frequency controlled three-phase motors with brake drive current return (energy saving) 2. A dye trough design ensuring minimum possible liquor ratio 3. Fabric rope monitoring control system for precise calculation and control of the fabric speed and tension 4. Uniform dyeing conditions in the dye trough, independent of the batch size 5. Water meter for controlled rinsing 6. Dosing of dyes and chemicals dependent on the fabric length passing through the dye bath 7. Addition pressure pump for shading corrections and dosing 8. On the HT-Jigger dosing under pressure possible 9. External pump and heat exchanger ensure uniform liquor heating and circulation 10. Sidewise displacement of the main batch roller 11. Analogue level for dyeing kier 12. Floor level track system* 13. Easy maintenance Significant innovations in the process technology ensure modern utilization
  19. 19. 1. Integrated fabric transfer system with spreader for crease-free loading/unloading of the fabric . 2. Centre driven frequency controlled motor drive for loading/unloading of the fabric from and to an A-frame . 3. Function “Salt dissolving” with electric stirrer and automatic brine transfer into the kier . 4. Self cleaning liquor filter . 5. Chamber roof heating . 6. Spraying device in the dye trough for intensive rinsing of the fabric . 7. Moisture extraction device used in the unloading process . 8. Chamber roof cleaning spray . 9. Automation of the loading/unloading port* . Options:
  20. 20. Fig: Atmospheric jigger dyeing machine
  21. 21. 1. Slow start/stop. 2. Trough is entirely built in stainless steel AISI 316. 3. The door of machine pneumatically lifted & lowered. 4. To observe inside of the machine large windows are provided. 5. The doors and windows are sealed with special gasket against steam escape. 6. To prevent dripping of condensate there are steam coils in the hood. 7. Dye liquor circulation by means of pump this circuit is used for better leveled dyeing or switching the flow on the spray pipes for more efficient washing or raising. 8. Dye liquor filter outside the machine with large filtering surface. 9. Service tank for dye stuffs & chemicals. 10. Semi or fully automatic with microprocessor (optional). Technical characteristic:
  22. 22. This machine is for the jig dyeing at high temperature and high pressure conditions of all types of thick, thin fabrics, Terylene, chemical fiber and real silk fabrics. Under normal temperature and pressure conditions, it can replace common jigs to dye all types of natural silk, rayon and polyamide fiber. The machine is reasonably structured, with good safety and capacity, easy to maintain. High-temperature High-pressure Auto jig
  23. 23. 1. Jigs exert considerable lengthwise tension on the fabric and are more suitable for the dyeing of woven than knitted fabrics. 2. In textile preparation due to the swelling and dissolution of size, which makes the fabric slippery and unstable in roll form. 3. The low liquor ratio makes washing-off difficult. 4. There is little mechanical action in a jig machine and it is less suitable where vigorous scouring is required before dyeing. 5. Moiré effects or water marks may arise on some acetate and nylon fabrics because of pressure flattening the structure of the rolled fabric. Limitations of Jigger Dyeing
  24. 24. Some critical problems related to the conventional jigger dyeing machines ( which are minimized in the modern day machines) The major problems are side-to-centre color variations, called listing, and lengthways color variations, called ending. Other problems are 1. Temperature control from side-to-side and end-to-end of the roll 2. Tension control from end-to-end 3. Constant speed control from end-to-end 4. Prevention of creases 5. Prevention of air problems related to the conventional jigger dyeing machines
  25. 25. NOTE : but have limited application on fabrics which are tension sensitive such as crepes , flat crepes , knits , net fabrics and elastomeric warps etc. Some wovens are conveniently dyed on jigger are , 1. Taffettas 2. Plain wovens 3. Satins 4. Poplins 5. Ducks 6. Suiting and Shirting material. 7. Sheetings etc.
  26. 26. MAXI Hydraulic Type Jumbo Jigger Machine
  27. 27. SWR1400 Large-Size Jig Dyeing Machine
  28. 28. HD618 Constant Temperature Dye Jigger
  29. 29. Motor rpm: motor rpm should check to maintain the proper revolution as we need. Proper movement of roller: every free roller should move freely as required. Correct take up & let off: we have to look at the smooth take up of dyed fabric and proper let off of grey fabric without excessive tension in dyeing. Proper concentration of liquor: without even concentration of dyeing liquor even shade would not be achieved. Proper concentration of dye bath is necessary to ensure even and proper shade. Temperature of bath: proper temperature of the dye bath should maintain constantly and should rise and lower evenly with the gradient as require. Maintenance:
  30. 30. 1. Yarn Manufacturing Technology Link : http://www.facebook.com/pages/Yarn-Manufacturing-Technology/485014954866808 2. Fabric Manufacturing Technology Link : http://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605 3. Garments Manufacturing Technology Link : http://www.facebook.com/pages/Garments-Manufacturing- Technology/472364799463126 3. Wet processing Technology Link : http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-/468645219825404 4. Fashion-Design-and-Technology Link : http://www.facebook.com/pages/Fashion-Design-and- Technology/587655294583875?ref=ts&fref=ts My Facebook Textile related Pages http://www.textilelab.blogspot.com (Visit My Blog for more Info )

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