1) DEVELOPMENT
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Customer gives sample with its all specifications like count, color etc. The sample given is generally known as eskloon (handkerchief shape).o
It is then checked in lab. There they will check it in a particular design like how many threads they need.o
Then in hang form dyeing take placeo
Approval from buyer. records of number of chemicals and recipe kepto
If its not correct they will re-produce or re-process. But if the quantity of shade required is very less like 2 warp yarns in long intervals then shade variation in the cone can be tolerated.o
If approved go for bulk order2) BULK ORDER
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Production Planning Department takes charge of bulk order. Depending on load,capacity, constraint, date is fixed.
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CYCLE OF YARN DYEING PROCESS2.1 Receives soft package from winding department
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Yarn packages from winding department been received.o
There is a spring attached to the yarn package which helps in shrinking theyarn package.
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Uniform dyeing not possible if we use paper corn winded Yarn.o
So we generally use spring winding so that more yarn can be wounded aswell as gives uniform winding.
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It basically helps in loading process.o
Recipe is been made according to development stage.o
As per availability of recipe and P.P.C department dyeing is been done.2.2 Loading yarn packages to carrier
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These packages are put in a carriage in compressed form.o
The main principle behind this is mechanism of compression. There is apressing device which compresses the packages.
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There is long cylindrical rod –spindle in which spring wounded yarns arebeen kept. These rods have small pores in it which allows movement of dyeing chemicals in and out during dyeing process.
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In each spindle there can be maximum 11 yarn packages can be kept. But itagain depends on compression mechanism.
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Compression is done according to:-design
:-density package
:- vessel height in which these yarns are been dyed.
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These spindles are attached to a carrier. In one 400 kg carrier there can bealmost 61 spindles.
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The dyeing machine consist of:- :-MicroprocessorIt depends on light, medium, dark, reactive dyes. All details are feeded onto the processor and locked. as per the requirement one program is used.
:-Closing tank
In this chemicals are been put. And tube passes from this tank to main tank through which chemicals pass through.
:-Main tank
It’s the main tank in which carrier is been put.
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First they put the carriage in the main tank in which 900 liters of water isbeen filled.
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Then chemical is put into chamber which later goes to closing tank.o
Programming done-according to chemicals, water, temperatureo
Water coming out from bottom of spindle and spreads out.o
There are mainly two stages;-in –out and out-ino
9-10 hrs is taken for dyeing 1 carrier.o
Capacity is 5-6 tones/dayAfter dyeing process almost double amount of water is present inside the package. Then water comes down due to gravity.
There is another system known as automatic dosing system. In this chemicals are put in different tank according to color we want program is been feeded and the chemicals are taken automatically from these tanks and recipe is made.
In same vessel we can have different capacity. There are carriers known as dummy carriers. These carriers consist of
dummy spindles. Dummy spindles are plain rod which doesn’t have holes in them so that when dyeing process takes place water is not wasted in and out through these spindles. So these rods block the movement of water in and out through the spindle.
Example;-
Suppose in a 100kg m/c we want only 80 kg yarns to be dyed. We have to put all the spindles but we cant waste 20 kg of dyed yarn. And if we use the simple porous spindles then most of the colored water will try to come out of that spindle because the pressure applied is very less in those spindles. So, variation in color may arise. In that situation we use dummy spindles which is covered with the steel for the equal distribution of pressure of water in all the spindles. And it also helps out in shade variation problem.
2.4 Hydro extractor
After dyeing yarn contain almost double amount of water. This is been removed through a hydro extractor. It
consists of a l oading device in which yarns are kept. Then this is put into a
In-out Out-in
Porous
spindle Dummy spindle
(The rod is made of steel and no holes present n it so that it controls the movement of water in and through.)
chamber. Inside this chamber the load rotate in a speed of 1700rpm. Time taken is 10 minutes. Due to the centrifugal force water comes out.
8 yarn package in 1 floor Total 2 floors present
2.5 R.F.Dryer (Radio Frequency Dryer)
After hydro extracting there is still some amount of water present inside the yarn. Through radio frequency further drying is been done.I n this dryer machine electrodes are present, which create an electromagnetic field.H+ and O- polar molecules are been
produced.This start vibrating and create energy. Therefore H+ and O- get split. In
this temperature has to be controlled and also height between these electrodes and yarns have to be maintained.
Electrode 283.0mm Conv.speed 5.7 m/h Anode Ja 11.7 A Grid Ig 2.4 A
After the drying process, the yarn packages are winded in a cone, like 2 yarn packages are winded in one cone to check for the shade variation among different yarn packages.