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BATCHWISE PROCESSINGVIS A- VIS

CONTINUOUS WET PROCESSING

INDIAS STRENGTH &WEAKNESS

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INTRODUCTION

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BATCHWISE DYEING

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THEORY OF DYEING

Dye adsorption & diffusion through the fiber surface should be even inlevel dyeing .

Dye exhaustion is done by thermal diffusion to obtain level dyeing.

Machinery used in batch wise dyeing are :

Beam dyeing

Jigger dyeing

Jet dyeing

Soft flow

Package dyeing

Increase in temperature leads to increase in rate of dyeing. Batch wise dyeing is highly recommended for medium & dark shades.

Batch wise processing is suitable for only small batches(short length).

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JET DYEING MACHINE

y Capacity - upto 400 kgs.

y Material used woven & knitted.

y Its liquor ratio - very low( 1:1).

y Dyeing temperature - high.

y Speed of fabric - 300mts/min.

y It is best suitable for batch wise processing.

y Production /day is 12 batches.

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Problems and RemediesProblems Remedies

Bulk to bulk variation in

shades. Tailing effect is produced.

Face back variation.

Patchiness is seen.

Crease marks formed.

Reproducibility is difficult.

Checking desizing efficiency.

Checking Absorbency afterscouring.

Checking whiteness & residualperoxide after bleaching.

Hardness of water should be

>50 ppm. Maintaining of uniform

temperature & moisturecontent during processing.

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CONTINUOUS DYEING:

y Continuous dyeing is suitable for bulk order fabrics.

y Uniformity of shades is good.

y It is best suitable for garmenting fabrics.

y In continuous dyeing CDR is used for processing.

y CDR stands for Continuous Dyeing Range.

y Export quality goods are processed in CDR.

y I

t is suitable for woven & open knitted fabric processing.y Effluent load is less.

y In this process material is circulated or padded in dye.

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PROCESS SEQUENCE OF CDR:

PAD

DRY

WETSTEAMING

CURE

THERMOSOL

WASH &DRY

CHEMICALPADDING

STEAMING

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CONTINUOUS DYEING RANGE:

y Material used - woven & open knitted fabrics.

yWet pickup decides machine speed.

y CDR is mostly suitable for p/c blends.

y To avoid variation dye solution prepared just beforedyeing.

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VAT DYEING PROCESS SEQUENCE :

DYE PAD

AIRPASSAGE

IR DRYER

HOT FLUEDRYER

CHEMICALPAD

STEAMINGRINSE/

OXIDISE

RINSE/SOAPING

NEUTRALIZING

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S.No CONTINUOUS PROCESSING BATCH PROCESSING

01. Reproducibility is high. Reproducibility is low.

02. Suitable for garmenting. Suitable for tailoring.

03. Less energy required. More energy required.

04. Time required is less. Time required is more.

05. Chemicals used is less. Chemicals used is more.

06. Labour cost is low. Labour cost is high.

07. Less effluent load. High effluent load.

08. Process cost is less. Process cost is more.

09. Water consumption is less. Water consumption is more.

10. Steam required is less. Steam required is more.11. Dye substantivity is less Dye substantivity is more.

12. Large space required. Small space required.

13. Faulty dyeing are not recovered. Faulty dyeing are recovered.

14. Benninger, Monforts & kusters etc Fongs ,Thies etc.

DISTINGUISHING METHODS OF PROCESSING:

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Weakness:

y Massive fragmentation in Indian Textile Industry.y Government & political diversity.y Government rules & regulations subsidiary schemes.y Fluctuating value of rupees.y Lac of Modernization & Automation.y Lac of innovation in global market.y Old technology or traditional machineries.y High power costs.y

High capital costs.y Low economies of scale.y Low collaborative efforts.

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QUERIES ?