Dyeing Lab Department Calculation and Others - TEXTILE TECHNOLOGY ( ) PDF

2/26/2015
Dyeinglabdepartmentcalculationandothers|TEXTILETECHNOLOGY(
)
DYEINGLABDEPARTMENT
CALCULATIONANDOTHERS
January16,2014PinkSumon
CalculationofLabDip|WorkingProcessinLabDip
LabDip:
Labdipisaprocessbywhichbuyerssuppliedswatchismatchedwiththevaryingdyespercentageinthe
laboratorywithorwithouthelpofDATACOLOR.
Labdipplaysanimportantroleinshadematching&anddetachingthecharacteristicsofthedyesand
chemicalsaretobeusedinthelargescaleofproduction.Sothisisanimportanttaskbeforebulk
production.
Recipepreparationinlabdip
CommonStockSolutions:
1. Red0.1%,0.5%,1.0%,2.0%(verycommon)
2. Yellow0.1%,0.5%,1.0%,2.0%(verycommon)
3. Blue0.1%,0.5%,1.0%,2.0%(verycommon).
Preparation:
Toprepare0.1%Stocksolution,itisnecessarytomix0.1gdyeand100ccwater.
Toprepare0.5%Stocksolution,0.5gdyestuffismixedwith100ccwater.
Toprepare1.0%&2.0%Stocksolutionsimilarprocedureisfollowed.
Toprepare10%StocksolutionofSodaash,10gSodaismixedwith100ccwater.
DepthofShade:
0.5%to5%shadeforthegoods.
LabDipCalculation:
data:text/htmlcharset=utf8,%3Cheader%20class%3D%22entryheader%22%20style%3D%22boxsizing%3A%20borderbox%3B%20display%3A%20block
1/10
2/26/2015
)
Usuallyfollowingcalculationsarefollowed:
DyeSolution=(Shade%*SampleWeight)/(Stocksolution%)(cc).
Salt=(Shade%*Liquor)/1000(gramperliter,gpl).
SodaSolution=(Shade%*100*Liquor)/(1000*Stocksolution%)(cc).
SampleCalculationfor0.5%Shade:
Samplewt.=5mg
Materialliquorratio=1:10
Totalliquor(5*10)=50cc
Dyesolutionrequired=(5*0.5%)/1%=2.5cc
Saltsolutionrequired=(50*25)/(20*10)=6.25cc
Sodaashsolutionrequired=(50*10)/(20*10)=2.5cc
Waterrequired{50(2.5+6.25+2.5)}=38.75cc
WorkingProcedureinLabDip:
Allingredientshadbeentakenaccordingtotherecipeintothepotofsampledyeingmachine.Ataroom
tempthematerialhadrunthenafter10minutesstartedtorisethetemperatureat1C/min.toget60C
temperature.Forperformingtherequireddyeingtemperatureittook30minutes.Thematerialhaddyed
at60Cfor45minutes.Thenthetemperaturewasreducedatroomtemperaturewithinin10minutes.The
fabricwashedincoldwater&thenthematerialwaswashedin1gm/lsoapsolution(liquorratio1:20)at
90Ctemperaturefor15minutes.Thenafterrapidlycoldwashingthematerialwasdried&preserved.And
thenchecktheshadematchwiththerequiredsamplebythelightingbox.Thensendtobuyeror
merchandiserforapproval.
WorkingProcedureofSampleDyeing(KnitDyeingSection):
Normallyatextiledyeingmillgetofferthroughmerchandiser.Merchandisingdepartmentofdyeingmill
sendtheswatchtothecentraldyeinglab.Thenthelabmanageranalysisthecolorofswatchwiththehelp
ofspectrophotometer.Aftershadematchingthreesamplearesubmittedtothebuyerorbuyeragents.
Ifsampleisapprovedbythebuyerthenthissamplerecipearesenttofloorforbulkproduction.Thedyeing
masterdyeingthesampleforbulkproduction.NowIwillgivetheflowchartofsampledyeingforbulk
production.
Sampledyeingmachine
2/10
2/26/2015
)
(ScouringandBleaching)
Waterloadinsampledyeingmachine
Fabricload
Temperatureraisedin500C
Scouringchemicaladded(dosingtime10min)
NaOHdosing(dosingtime5min)
HydrogenPeroxidedosing(dosingtime10min)
Temperatureraisedin1001100Candrunningat30min
Coolingat800C
Ringeornormalwash(10min)
Drainout
Newwaterload
Addacid+OEM(fordestroyingHydrogenPeroxidepower)
pHcheckandobtain4.5byaddingaceticacid
Enzymeisaddedandruntime60min
Samplecheckifapprovedbyincharge
Ringe(runtime15min)
Drainout
(Dyeing)
Newwaterload
pHcheckandobtain5.6byaddingaceticacid
Temperatureraisedat50550C
Dyeingauxiliariesadded(levelingagent,anticreasingagent,sequesteringagentetc)
3/10
2/26/2015
)
Saltaddedandrunningat10min
Colorisaddedanddosingtime30min(Reactivedye,Dispersedye,Aciddyeetc)
Runningtime25min
Sodaash(dosingtime35min)
Samplecuttingforcheckingafter10minlater
Ifapprovethenringeat20min
Newwaterload
Addaceticacidforneutralizationat400Candrunat10min
Ringeat5min
Drainout
Newwaterload
Temperatureraisedat90950Cand10minrunning
Coolingat800C
Ringe(forcutsample)
Shadecheckingifapprovebyinchargethen
Ringeandrunningat15min
Drainout
Newwaterload
Fixingagentadded(GG100,ECO,CR)anddosingtime10min
Ringe(10min)
Drainout
Newwaterload
Softeneraddedandruntime30min
Shadematchingifapprovethen
Fabricunload
4/10
2/26/2015
)
CALCULATIONOFDYEINGRECIPE|CALCULATIONFOR
DYEINGLAB
CalculationforLabDeep:
RecipeCalculationFormula:
Dye=(Shade%*Weightofthefabricingm)/Stocksolution%
Or,
Requiredsolution=WP/C
Where,
W=weightoffabric,yarn,orfiber
P=shadepercentage
C=concentrationofstocksolution
CC=cubiccentimeter.
Forauxiliaries(chemicals)theformulaisasbelow:
Requiredamountofsolution(mls)=(g/lrequired*wtofsubstrate*LR)/(10*concentration(%)ofstock
soln)
Foradditionofauxiliariesinsolidsformsuchassalttheformulais:
Salting/l=(Requiredamount(%)*Sampleweight*LR)/1000
Conversionformulafrompercentagetog/lisasbelow:
g/l=Requiredamount(%)*10.
CalculationofDyeingRecipe
Ifalkaliconc.IsgiveninBe.thentheformulatocalculatethising/lisasfollows:
soln)
Or,
=(Requiredamount(%)*wtofsubstrate*LR)/(Concentration(%)ofstocksoln)
Or,
Requiredalkalisolninc.c.=(g/lrequired*wtofsubstrate*LR)/(10*conversionvaluefromBe.tog/lof
alkali)
Or,
5/10
2/26/2015
)
Requiredalkalisolninc.c.=(Requiredamount(%)*wtofsubstrate*LR)/conversionvaluefromBe.tog/l
ofalkali
Example:Supposealabdeepofafabricsample(1*1rib)hastobeformedwithfollowingdyes&
chemicals:
Dyes:
1.RemaBlueRR=1.122%
2.ReactRedKHW=2.014%
3.ReactYellowKHW=1.486%
Salt=70%
SodaAsh(conc.20%)=5g/l
CausticSoda(38Be)=1.32%
L:R=1:8
SampleWt.=5gm
%StockSoln=1
Therefore,recipecalculationfordyesandauxiliariesing/lwillbeasfollows:
Fordyes:
Weknow,
Dye=(Shade%*Weightofthefabricingm)/(Stocksolution%)
For,
1.RemaBlueRR=(1.122*5)/1=5.61g/l
2.ReactRedKHW=(2.014*5)/1=10.07g/l
3.ReactYellowKHW=(1.486*5)/1=7.43g/l.
Forauxiliaries:
Weknow,
Salting/l=(Requiredamount(%)*Sampleweight*LR)/1000
...RequiredSalt=(70*5*8)/1000=2.8gm.
ForSodaash(conc.20%):
Weknow,
soln)
.
..RequiredamountofsodaashinC.C.=(5*5*8)/(10*20)=1.0
ForCausticsoda(38Be.):
Weknow,
Requiredalkalisolninc.c.=(Requiredamount(%)*wtofsubstrate*LR)/conversionvaluefromBe.tog/l
ofalkali
.
..Requiredcausticsoda=(1.32*5*8)/441=0.12c.c.
[since38Be.NaOH=441gmNaOH100%per1litNaOHsoln]
ExtraWaterrequired:
=M:L(requiredwatertomakesolnofdyes&auxiliaries)=(5*8)[(5.61+10.07+7.43)+(1.0+0.12)]
=4024.112
=15.77(Saltisaddedinsolidform)
6/10
2/26/2015
)
EquipmentsofRecipeSection:
1. MicroprocessorpHMeter(HannaInstrument)
2. Digitalpipette
3. DigitalWeightingMeterwithGlassBox(Explorer,USA)
ProcedureforLabdipbytheDifferentDyestuffintheLaboratory
LabDip:
LabDipDevelopmentmeansthesamplewhichisdyedaccordingtobuyersrequirements(similarshade
andsoon).Dependingonlabdipdevelopmentsampledyeingandbulkproductiondyeingplanning
isdone.Labworkplaysanimportantroleindyeingprocess.Bulkdyeingprocesscompletelydependson
thelabdipdevelopmentwork.Labworkiscompletelymanagedasthefollowingsequence.
Workinlabdip
ProcedureforLabdipbytheDifferentDyestuffintheLaboratory:
Procedurefor100%CottonFabric:
1.Calculatetherecipe.
2.Weightthefabric.
3.Takethebeakerkeepthefabricintothebeaker.
4.Thenthedyes,chemicals&requiredamountofwatertakeintothebeakerbythedigitalpipetting.
5.Thenweightthesaltbytheelectricbalanceandaddintothebeaker.
6.Thenthebeakersetintothelabdyeingmachinefordyeing.
7.Starttheprogramfordyeingthewholedyeingtime60minat60Ctemperature.(Thedyeingtimeand
temperaturedependsonwhichclassesofdyesareusedfordyeing.)
8.After30minaddthethenaddthesodaash.Bypipetting.
9.Againruntheprogramnext30minatthesametemperature.
10.Finishedthedyeingtimethenthesampletakenfromthebeakerfirsthotwash&thencoldwash.
11.Thenacidwashasforneutralization.
12.Thensoapingrequiredsoapsolution10minat90Ctemperature.
13.afterthefabricagaincold.
14.Thendrythelabdipandcomparewiththestandard.
WHATISLABDIP|OBJECTSOFLABDIPS|PROCESS
SEQUENCEOFLABDIP
LabDip:
Alabdipisaswatchoffabrictestdyedtohitacolorstandard.Itisaprocessbywhichbuyerssupplied
swatchismatchedwiththevaryingdyespercentageinthelaboratorywithorwithouthelp
ofspectrophotometer.Labdipplaysanimportantroleinshadematching&thisisanimportanttask
beforebulkproduction.Inpreviousarticleofthisauthorwehavetolearnonflowchartondyeinglab.
7/10
2/26/2015
)
Labdip
TherearedifferentmatchingsystemsfollowedinLabs.Theyare:
1. Tubelightmatching.
2. Sunlightmatching.
3. UltraVioletmatching.
4. Sodiumlightmatching(showroom).
ObjectofLabDip:
Themainobjectivesinlabdipareasfollows:
1. Tocalculatetherecipeforsampledyeing.
2. TocomparedyedsamplewithswatchbylightBoxorSpectrophotometer.
3. Tocalculatereviserecipeforsampledyeing.
4. FinallyapprovedLabDip(Grade:A,B,C&D)
ProcessSequenceofLabDip:
Labdipplaysanimportantroleindyeingprocess.Bulkdyeingprocesscompletelydependsonthelab
dipdevelopmentwork.Labdipiscompletelymanagedasthefollowingsequence.
LabDipRequisitionfrombuyer
Entryinthecomputer
Firstrecipeisgivenbyswatch/pantonenumber
Firstcorrection
Secondcorrection
Gradingofsample(A,B,C,D)
Yarnandknitsamplesendtobuyer
Approvedbybuyer
Orderforbulkproduction
Productioncardwithapprovedsampleandrecipesendtoproductionsection.
PROCESSFLOWCHART/SEQUENCEOFDYEINGLAB
Atfirstdyeingisperformedindyeinglaboratoryandthenstartingforbulkproduction.Alotsofworkisdone
inthedyeinglaboratory.Inthedyeinglab,labdiporsampleisdevelopedbythedyeingmaster.Labdip
playsanimportantroleinshadematching&thisisanimportanttaskbeforebulkproduction.
8/10
2/26/2015
)
DyeingLab
ProcessSequenceofDyeingLab:
Sample/Swatch/Pantonno./TCXno./TPXno.fromthebuyer
DeterminationofsamplespossiblecolorcombinationbythehelpofSpectrophotometerormanual
Dispersionbyautodoser
Trialdyeingoffirstrecipe
Unload
Normalwash
Hotwashwithdetergent
Ovendrying
Ironing
Shadematchinginlightbox(IfOkthensendtobuyerforapproval)
Ifnotok
FirstcorrectiontakesfromSpectrophotometerormanually
Unload
Normalwash
Ovendrying
Ironing
Shadematchinginlightbox(IfOkthensendtobuyerforapproval)
Ifnotok
SecondcorrectiontakesfromSpectrophotometerormanually
9/10
2/26/2015
)
Unload
Normalwash
Ovendrying
Ironing
Shadematchinginlightbox
Ifok
Sendforbuyersapproval
Bulkproductionbyconsideringthebuyersapprovedsampleasstandard
Note:Thisprocedureisapplicableforyarnorfabricdyeing.
RATETHIS:
data:text/htmlcharset=utf8,%3Cheader%20class%3D%22entryheader%22%20style%3D%22boxsizing%3A%20borderbox%3B%20display%3A%20bloc
10/10

Dyeing Lab Department Calculation and Others - TEXTILE TECHNOLOGY ( ) PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Dyeing Lab Department Calculation and Others - TEXTILE TECHNOLOGY ( ) PDF

Uploaded by

Copyright:

Available Formats

2/26/2015

You might also like