Dyeing Machineries

2. DYEING
Dyeing is the process of addition color to textile
products like fibers, yarns and fabrics. Dyeing is
normally done in a special solution containing
dyes and particular chemical and auxiliaries. In
most of the cases dye molecules form chemical
bond with fiber molecules. The temperature and
time controlling are two key factors in dyeing.
Dyeing operation is done by different types of
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. Actually it is the
device that is used by different industries for
imparting colors. Various types of dyeing
machineries are used to dye the textile materials.

4.  Here a certain/known amount of material/fabric
is brought under repeated contact with dye
liquor & then transported to carry out the
subsequent processes.
 This type of machines allow processing in rope
form (e.g. winches, jets etc.) or in open width
form (e.g. jigger)
 For knit dyeing this process is used almost
everywhere in our country

5.  Here dye solution is applied by Padding
technique and then it is batched/stored in
certain conditions for fixation.
 The subsequent processes (washing, drying,
etc) are done afterwards.

6.  This type of process is aimed at higher
production.
 Here dry undyed fabric enters at one end and
dry colored fabric is leaves at the other end.
This is why it’s also called dry-to-dry
 All the units for example padding, steaming,
washing, drying etc. are just set sequentially.

7. Fig. Schematic diagram of dry to dry process

10. (i) Easiest method of processing.
(ii) Easy handling and storage.
(iii) Ease of transportation as it can be transported to
virtually any distance and any direction by passing it
through circular guides.
(iv)The fabric doesn’t undergo much tension widthwise
which is a very significant factor as winch machine is
extensively used for knits which has low dimensional
stability

11.  Jigger dyeing machine: This machine is used to
dye the woven fabric.
 Winch dyeing machine : This machine is used to
dye both woven and knit fabric. Specially used
for knitted fabric.
 Jet dyeing machine: Knitted and woven fabric
dyed by this machine.

12. Winch dyeing machine is a rather old dyeing
machine for fabrics in rope form with stationary
liquor and moving material. The M: L is generally
quite high (1:10-1:18). Winch dyeing machines are a
low cost design that is simple to operate and
maintain, yet versatile in application proving
invaluable for preparation, washing or after
treatments as well as the dyeing stage itself. 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 or the winch
itself. The rope of fabric is circulated through the
dye bath being hauled up and over the winch
according to the cycle time of the dyeing operation.
Dyestuff and auxiliaries may be dosed manually or
automatically in accordance with the recipe method.

13. A horizontal rotor/reel is used to
circulate the fabric endlessly. This
rotor/reel is known as winch. The
winch may be elliptical or circular in
cross-section. The elliptical winch
exerts minimum tension but high
mechanical action by giving long &
short folds when the fabric rotates.

14.  There are different key features of winch dyeing
machine which are pointed out in the following:
 Winch dyeing m/c is suitable for practically all types
of fabrics which can withstand creasing in rope form
processing.
 Winch dyeing m/c operates at maximum 95-98˚C.
 Here, liquor ratio is generally high ranges from 1:10
to 1:30.
 Here, for all types of rope dyeing the fabric must be
fairly resistant in length ways creasing.
 In case of winch dyeing m/c, a penetrated separate
compartment is positioned in a distance of 15-30cm
from its vertical side which creates an inter space for
heating and for adding reagents.

15.  The rope is passed from the dye bath over two elevated
reels where the first roller is free running and the other
one is winch reel.
 Here, heating can be provided by means of direct or
indirect steam heating.
 Here, winch reel controls not only the rate of fabric rope
movement but also rope configuration in the dye bath.
 Here, winch reel does not grip the fabric positively; it is
done by the weight of the wet fabric and the friction
between the fabric and reel.
 Here, maximum motion speed of the fabric should be
approximately 40meter per minute.
 Winch dyeing m/c is suitable for all types of fabrics
without those fabrics which tend to originate permanent
creases or which could easily distort under the winch
stretching action.
 In the latest winch dyeing m/c, stainless reels with
corrugated and broken surface for increasing frictional
forces are used

16. Sclavos Athena 3A is the newest development of
SCLAVOS in the field of knitted and a range of woven
fabric dyeing machines.
ATHENA 3A INCORPORATES SOME UNIQUE FEATURES
SUCH AS:
 Double Soft Floating dyeing system (DSF)
 Open Plaiter system with Liquor by pass
 Aquachron 3GA continuous washing system for non stop
rinsing operation
 Double Rope operation system for increased capacity of
light weight fabrics
 Automatic Settings Adjustment
 Advanced Automation system for total Interactive control
 Full monitoring of utilities consumptions
 Variable Loading System
 Integrated Control of Liquor Ratio
 Low power pump built in house

17. BENEFITS OF SCLAVOS ATHENA 3A DYEING MACHINE
Fabric Quality
 No surface pilling due to mechanical abrasion
 Low tension and shrinkage
 Minimum fiber loss
 Gentle treatment of delicate fabrics
Performance
 Fast process time
 Low energy consumption
 Minimum water consumption
 Ease of operation
 Batch to batch repeatability/reproducibility
 Tangle free operation
 High capacity for light weight fabrics with no
tangles.
 “Automatic” washing cycle
 Data for costing calculation

18. Double Soft Floating Transport and Dyeing
System
This is the heart of fabric transport and dyeing
technology, which ensures high liquor
penetration and very gentle treatment of normal
and delicate fabrics.
Open Plaiting system with Liquor by pass
A unique plaiting system combined with excess
liquor by pass that guides the flow of the liquor
out and behind of the J Box, ensuring ideal
storing of the fabric inside the J Box.

19. Aquachron Continuous washing system
This is a revolutionary fabric washing system,
working as a continuous rinsing process.
Aquachron obtains high water and energy
savings and considerable decrease of process
time.
This system makes SCLAVOS machines working
with no stop process for drain and fill.
Aquachron system abolishes any need for Stock
Tank in SCLAVOS machines.
Double Rope operation
SCLAVOS has developed the Double Rope
operation system, which is applied in all
SCLAVOS's machines, increasing capacity in light
weight fabrics.

20. Liquor concept
SCLAVOS believes in liquor concept than Air concept
for dyeing cotton and other natural fiber fabrics.
Liquor concept ensures the gentlest treatment, the
lowest power consumption and very user friendly
operation.
SCLAVOS design pumps
Main pump of SCLAVOS dyeing machines has been
designed and manufactured by SCLAVOS
Engineering team for best efficiency and lowest
power consumption.
Automation – Software
Sclavos unique technology needs special support in
terms of automation and software. In order to fit
these needs, Sclavos and Sedo Treepoint, leading
company in Dyehouse automation, are doing
common developments in fabric dyeing machines
controllers.

21. SCLAVOS has developed peripheral systems which
could be fitted onto SCLAVOS machines and
improve energy savings as well as machine’s
efficiency. Such systems are the SCLAVOS Heat
Recovery system and Dry Salt Dosing system.
Dry Salt Dosing (DSD) is a new Sclavos apparatus,
which can be linked to Athena 3A Dyeing Machine
and handle transfer of dry salt during the dyeing
process.
Conventional methods of handling salt transfer use
machine’s additions tank for diluting salt in fresh
water and then transfer the dilution into the
machine or stock tank.
However this is a painful and time consuming job.
Additionally in many cases fresh water use increases
liquor ratio.

23. ADVANTAGES of DSD SYSTEM
 Fast self transfer
 No need for fresh water use
 No operator's involvement

24. Heat Recovery System is the new SCLAVOS heat
recovery system, which recovers energy from
Dyeing Machine’s hot effluent. Recovered
energy heats up incoming cold fresh water,
which becomes hot.
ADVANTAGES:
 Energy saving up to 40%
 No energy losses from external pipe network
 No need for any special infrastructure or space
in the factory
 Low effluent temperature increases efficiency of
Effluent Treatment Plant

25. Image of SCLAVOS Athena3A dyeing machine

30. (a) Winch or reel
Winch is an important part of dyeing machine and used
for moving the fabric through the whole dyeing machine.
Winch is rotated with the help of motor. Fabric is passed
over the winch and fabric dwell time depends on the
winch speed. Winch speed will depend on the rope length
and GSM of the fabric to be dyed. There is opening on
the machine for winch to remove tangled fabric from
winch. Number of nozzle per winch is normally 1 or 2
and total no. of winch per machine will depend on
machine capacity.
(b) Dosing tank
Dosing tank is used for the application of dyes and
chemicals to the dye bath in solution form. Steam line is
connected to the dosing tank. This tank ensures
dissolved chemicals and dyes to the dyeing machine to
ensure fault free dyeing.

31. (c) J-Box
J-box of the machine is where fabric will stored
after falling from the nozzle. J-shape helps the
smooth passage of fabric. This box contains a
deposition tube line attached to the fabric guide.
This box is perforated and ensures easy circulation
of dyeing liquor to the machine.
(d) Nozzle
Nozzle is the part of winch dyeing machine where
dye pick up of the fabric is maximum. After the
winch the fabric is passed through the nozzle. Main
motor is connected to the nozzle and continuously
circulate dyeing liquor to the machine via nozzle.
Fabric passed with the pressure of water and used
for controlling the speed of dye liquor.

32. (e) Heat exchanger
Heat exchanger is used for heating and cooling
the dye bath liquor. Heat exchange process is
achieved by passing steam or water through the
coiled pipe line present in the heat exchanger.
When heat is increased then steam valve is
opened and passed through the coiled pipe line
and dyeing liquor is passed through the heat
exchanger.
(f) Main motor
Centrifugal pump is used for circulating the
liquor through the dyeing machine. Its capacity
will depend on the capacity of the machine.

33. (g) Valves
Different types of valves are used in dyeing
machine. Such as steam valve, water valve,
pneumatic valve etc.
(h) Viewing light
Viewing light is given in the dyeing machine to see
how the dyeing of the fabric is advancing in the
dyeing machine from outside of the dyeing machine
as it is impossible to look into the dyeing machine
due to high steam temperature.
(i) Filter tube
Filter tube is used inside the circulating line and
drain line through which dyeing liquor is passed to
filter impurities. If the filter is jammed then
removed from line and cleaned.

34. (j) Panel board
It is the outer part of the machine. From which
various programs of dyeing process are
controlled. Programs are previously saved in the
memory card of the panel as per dyeing method.
It also contains various types of switch for on/off
system.
(k) Steam line
Steam is essential utility for dyeing without it
dyeing process is quit impossible. Through
steaming process temperature of the dye liquor
are controlled at every stages of dyeing process.

35. Photograph of (a) Viewing light, (b) Winch or Reel, (c) Valve, (d) Nozzle,
(e) Main Pump, (f) Filter Tube

36. Photograph of (g) Heat Exchanger, (h) Panel board and (e) Dosing
Tank

37. FEATURES OF JET DYEING MACHINE:
 It is similar to winch dyeing and fabric is
processed in continuous loop. A typical cycle
takes only 1 minute.
 This machine is used mostly to dye polyester
fabrics as there are many disadvantages with HT
winches which include long dyeing time.
 Fabric in rope form is carried forward by
circulation of dye liquor jet & the fabric is fully
tension less.
 Here substantial kinetic energy in the form of
rapidly moving fluid is introduced in addition to
the mechanical energy in the form of fabric
transport so dyeing process is tremendously
accelerated.

38.  Jet dyeing can usually be operated up to 140°C
under high pressure.
 The cloth is moved along the tube at very high
speeds (up to 400-600 m/min).
 Considerable amount of dye adsorption can
occur when the fabric is going through the
Ventured Tube which might take just 1 second.
Dye diffusion takes place when the fabric is
moving more slowly through the bottom of the
machine in the remainder of the cycle which
lasts about 1 minute.

40. ADVANTAGES OF JET DYEING MACHINE
 Lower material to liquor ratio provides savings
in energy & faster heating and cooling.
 Less lengthways tension & slightly fullness of
handle.
 Vigorous circulation of liquor & material causes
quicker dyeing.
 Frequent movement of fabric minimizes
creasing problem.
 High fabric transport speed by adjusting nozzle
valve to cause level dyeing.
 Less dye at the surface resulting in quicker
washing with marginally better fastness
properties.

41. DISADVANTAGES OF JET DYEING MACHINE
 Typical crease marks which might be developed during
high temperature dyeing making it difficult to remove in
finishing.
 High capital investment & maintenance costs.
 Limited accessibility to the material when the machine is
running, the fabric is loaded & unloaded through a small
port.
 Internal cleaning is difficult as the machine is completely
enclosed. In particular, Polyester Oligomer deposits may
develop on the hot surfaces & later dislodge. (Cleaning is
usually done by circulating Caustic Soda & Sodium
Dithionite solution).
 Any roughness inside the machine causing snagging of
the fabric is difficult to locate.
 Vigorous movement of the liquor may create severe
foaming (mainly in partly filled jet machines). Anti-
foaming agents like silicone or fatty alcohol might be
required.
 The force of the jet may damage delicate fabrics.

42. Features:
 Jigger is one of the oldest type of machine for
dyeing woven fabrics which must not be
creased during dyeing, e.g. most taffetas,
satins, poplins, ducks & suiting. It’s not
suitable to dye knit fabrics as high tension is
exerted on the fabric.
 The machine operates with low material to
liquor ratio (1:5 to 1:6).
 Here the fabric moves in open width through
dye liquor.
 It consists of a V-shaped trough (100 – 150
gallon capacity) with two rollers called draw
rollers fitted above it.

43.  When all the cloth passes through liquor from
one roller to another, the passage is called an
“end” or one “turn”. An even number of ends are
given based on the size of the roll/batch of
cloth, time required for one end (usually 10-15
min), and on the depth of shade being dyed etc.
 When the second draw roller (take-up roller) is
full the direction of the fabric movement is
reversed so the take-off roller becomes the let-
off roller & the let-off roller becomes the take-
up roller after each turn.
 To ensure that complete length of the fabric is
immersed 4-5 metres of cheap end-fabric are
sewn to each end of the roll.

44. Fig. Jigger dyeing machine

45. Thanks