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A Continuous dyeing process typically consists the following. Dye application, dye fixation with heat or
chemicals and finally washing. Continuous dyeing has been found to be most suitable for woven fabrics.
Mostly continuous dye ranges are designed for dyeing blends of polyester and cotton. The step of
padding plays a key role in the operation of continuous dyeing. Sometimes Nylon carpets are also dyed in
continuous processes, but the design ranges for them is unlike that for flat fabrics. Warps are also dyed in
continuous process. Very good examples of such warp dyeing are long chain warp dyeing and slasher
dyeing using indigo.
A continuous dye range has been found useful and economically sustainable for dyeing long runs of a
given shade. One important factor that separates continuous dyeing from batch dyeing is the tolerance
factor for color variation. That is more for continuous dyeing as compared to batch dyeing. This is so
because of two reasons a) the speed of the process. b) presence of a large number of process variables
which affects dye application. The process that is illustrated below is designed for dyeing of blended
fabric of polyester and cotton.
http://www.scribd.com/doc/21333479/continous-dyeing-project
Pad thermosol
it is a machine which is used to pad, dry and cure to all kinds of fabrics. This machine is
categorized under continuous process of dyeing
Batcher
Guide rollers
Screy
Trough
Squeezing rollers
Padder
VTG rollers
IR-dryers
Drying chambers
Curing chamber
Piller
Now we will see these parts individually by using figures
Batcher:
When the fabric is taken to dye , it is in the form of batcher that is taken after
mercerizing as shown in the following fig
The fabric width depends on the size of the batcher and the fabric of different length is
winded on it . This length may vary from 100 to 70,000 meters
Guide rollers:
These are the rollers which are used to guide the fabric from different paths. Their function is only to
direct the fabric toward it’s outlet. Guide rollers are shown in the following fig.
Trough:
It is the first main part of this machine. This part is filled with liquor which is filled with dyes and chemicals
it’s capacity is nearly 1400lilres. It is dozed manually as well as automatically. The dozing structure is
shown in the following fig.
The temperature of this bath is room temp. the fabric capacity is 1-1.5m within this dye bath
• Dyes
• Urea (moisturizing agent)
• Soda ash( for reactive dyes)
• Sodium bicarbonate(for pigments)
• Primazol FFAM (anti-migrating agent)
• NF
Padder
This is the main part of the machine. All the pick-up of dye depends upon the padder. It is a pair of two
rollers. Two rollers move in opposite direction to each other. These rollers are also rubber coated but have
special type. L-C-R (left-center-right). This is the most sensitive factor that require more concentration
than any other part. Basically L-C-R fault means that the fabric dye is varying from left,right and center.
The structure of padder is shown in the following fig
VTG Roller:
These are called vertical tentioner guide rollers . These are the rollers that give tension
and rest to the dyed fabric and fabric contact with air. There are 9 rollers that are used
for this purpose,5 above(driver) and 4 down (driven). The structural diagram is shown in
the following fig.
IR dryers :
These are called infra red dryers. IR-dryers are also called pre-dryers. 30% of fabric
is dry in this section. The temperature of these dryers vary from 1000-1300C. these
dryers have very important role in dyeing the fabric uniformly. The fig. of IR is
shown as follows
When the fabric is passed from the padder then there is an uneven dyeing that
cause the face- back problem on the fabric. The structural diagrame of the dye
particles shown in the figure after padding as Two IR are used for heavy quality and
one is used for light quality.And when the fabric is passed through the IR dryers the
dye par2ticles migrate from surface to the core of the fabric with help of infra red
rays. After passing through IR the the dye particles are shown bellow on the fabric
surface
Drying chambers:
There are two drying chambers used for thermosoling .These are the
chambers where thermosoling is done. The fabric passes through the rollers in the
chamber
and thermoil react with fabric in these chambers. The diagram is shown in the
following fig
The thermoil is given to the chambers in pipes attatched to the radiator and it
circulates within the chamber with the help of circulating fans.
The temperature of these dryers vary with quality of the fabric and dye stuff used
because different dye stuff have different range of temperature for it’s fixation ,
20% fabric is dry in these chambers.
Curing chambers:
There are two chambers that are responsible for the curing process. Curing
chambers are used for the fixation of the dye into the fibre.These are the chambers
where remaining fabric is dry i.e 50%. As there is more temperature within these
chambers so we need moisturizing agent that produce the humidity within the
chambers and the fixation process is carried out. For producing the moisture we use
urea as a moisturizing agent. This chemical is mixed with the dye recipe in the
trough. The curing chambers are shown as follows