1. Textile Dyeing Machinery

2. Department Of Textile Engineering I/A 251,252 Tejgaon Dhaka Bangladesh
Prepared By :
Prepared By : Mazadul Hasan sheshir
ID:
13th Batch (session )
Department : Wet Processing Technology
Blog : www. Textilelab.blogspot.com (visit)
Southeast University
Department Of Textile Engineering
I/A 251,252 Tejgaon Dhaka Bangladesh

3. Total Textile Process at a Glance

4. Objectives To Classify Dyeing & Finishing Machinery
To Know Function of The Machinery
To Know Working Process of The Machinery
To Know Some Brand Name
To Know Advantage & Disadvantage

5. Introduction Textile Dyeing:
Dyeing is a coloration process of textile which is invariable carried out in an aqueous medium.
In the other hand, dyeing can be define as a process by which a yarn, fabric, garments and any other materials that come to contact of dye by presence of auxiliaries that create the condition of dyeing environment
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. It is impossible to provide exhaustive coverage of this field. Therefore, the most important types of machine, and their problems, will be at the forefront.

6. Types of Dyeing Machine
Fibre Dyeing Machine
Yarn Dyeing Machine
Knit Dyeing Machine
Woven Dyeing Machine

7. Yarn Dyeing Machinery
Package Yarn Dyeing Machine (Vertical Type):

8. Yarn Dyeing Machinery
Package Yarn Dyeing Machine (Horizontal Type):

9. Yarn Dyeing Machinery
Function & Feature:
This types of machine consists of a cylindrical carrier, having perforations over its surface, over which perforated spindles can be placed, radiating from the surface.
The top of the carrier is provided with a hook, by which an overhead crane can lower into or raise from an outer cylindrical dye vessel.
In case of this types of machine, carrier is filled with package and is placed in the dye vessel by robotics system.
This type of machine is suitable for scouring, bleaching, dyeing and washing.
According to objective chemicals and auxiliaries are pumped into the dye vessel by centrifugal pump.
Then due to circulation of dye liquor in the dye vessel pretreatment or dyeing is performed.

10. Yarn Dyeing Machinery
The main advantages of package dyeing over other yarn dyeing methods are 
The material is dyed on cross wound packages ,therefore bigger unit weight( 1.2 kg -1.5 kg for cotton) in dyeing is possible.
Economical dyeing due to lower liquor ratio, compact and enclosed dyeing vessels .
Different liquor ratio is possible in different process steps such as partial filling in washing and soaping and fully flooded in rinsing make the process economical.
More uniform dyeing is possible due to higher number of contacts at high and optimized flow rates
High temperature ,high pressure and high flow rates results into shorter dyeing cycles
Due to complete automation ,the machines are less labor intensive.

11. Yarn Dyeing Machinery
Modern machines with partial loading spindles are more flexible for different size lots .
Very less handling and damage to dyed substrate ,due to shorter dyeing cycles.
All operations from pretreatment to hydro extraction in single machine are possible
The package dyeing machines are more versatile because almost all type of substrates can be dyed and almost all types of dyestuffs applications is possible.
The same machines can be used for multiple make ups such as yarn, fiber, tow ,tops, bumps and beams on suitable dyeing carriers.
Most advanced machines are equipped with pH regulators and controllers and salt sensors to for achieving very reliable and reproducible results. 

12. Yarn Dyeing Machinery OBEM API/V Package Dyeing Machine:
The OBEM API/V machines are the traditional type, vertical kier dyeing machines
They are really the multi-purpose solution apparatuses for processing all kind of fibres and in any type of form like in packages, tops, loose fibre and tow, only by changing the material-holders.
The API/V capacity is variable from 20 to 10,000 kg
Low liquor ratio, variable from 1:3 to 1:8
PLC Controlled.
Fully automatic.

13. Knit Dyeing Machinery Winch Dyeing Machine:
Figure: Roto Master (Thies Winch Dyeing Machine)

14. Knit Dyeing Machinery
Figure: Schematic view Roto Master (Thies Winch Dyeing Machine)

15. Knit Dyeing Machinery Technical Details of Roto Master (Thies):
• Inner rotating fabric chamber ensures positive fabric transport and gentle treatment of the fabric
• Electro-pneumatic operated valves
• Adjustable winch drive combined with programmable nozzle pressure permits fabric speeds of m/min
• Analog Dosing Fully automated dosing of dyes and auxiliaries according to a programmed time and curve (also under HT conditions)
• Analog level - dyeing kier Controls the liquor level in the machine usig an electrical transmitter
• Max. operating temperatures to 100°C and 140°C
• Automatic control via industrial PC

16. Knit Dyeing Machinery Winch dyeing machine:
A dyeing machine consisting essentially of a dye vessel fitted with a driven winch (usually above the liquor level) which rotates and draws a length of fabric, normally joined end to end, through the liquor
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. Winch dyeing machines are a low cost design that is simple to operate and maintain.

17. Knit Dyeing Machinery Principle of winch dyeing machine:
The basic principle of all winch dyeing machines is to have a number of loops or ropes of the fabric in the dye bath, these ropes are of equal length, which are mostly immersed in the liquor in the bath.
The upper part of each rope runs over two reels which are mounted over dye bath. At the front of the machine, above the top of the dye liquor, is a smaller reel, which is called jockey or fly roller. The fly roller remains freewheeling along with fabric rope.
At the back of winch tank is the winch wheel, which pulls the fabric rope from the dye bath over the jockey reel for dropping in the dye bath for immersion.
From the dropped location, the fabric rope travels back. To be lifted and fed to winch wheel.
The dyeing process on winch dyeing machines is based on higher M: L as compared with other dyeing machines.
The process is conducted with very little tension.
The total dyeing time is lengthier as compared to other machines.

18. Advantages of Winch Dyeing:
Knit Dyeing Machinery
Advantages of Winch Dyeing:
Construction and operation of winch are very simple.
The winch dyeing machines are suitable for types of wet processing operations from desizing to softening.
The winch dyeing machine is suitable for practically all types of fabrics, which can withstand creasing in rope form processing.
The tension exerted on winch is less than jigger; the material thus dyed is with fuller hand.
The appearance of the dyed goods is clean and smooth on winch dyeing machines.

19. Knit Dyeing Machinery Limitations of Winch Dyeing :
Batch dyeing operations needs trimming, sewing, opening out the rope, loading and unloading for individual lots separately.
Since several lengths of fabric are run over the winch reel into the liquor and sewn end to end, Continuous length processing is not possible in a single batch.
Fabric is processed in rope form which may lead to crease marks, particularly in heavy, woven, thin and light synthetics.
Most of the machine works under atmospheric conditions.

20. Knit Dyeing Machinery Jet Dyeing Machine:
A machine used for dyeing of fabric in rope form. Jet dyeing machines came into existence with a purpose to minimize or eliminate the drawbacks of earlier machines like winch , jigger and beam dyeing units.

21. Knit Dyeing Machinery Principle:
Jet dyeing is a process that can be used for batch dyeing operations such as dyeing, bleaching, washing and rinsing. In this process, dyeing is accomplished in a closed tubular system, basically composed of an impeller pump and a shallow dye bath. The fabric to be dyed is loosely collapsed in a form of a rope, and tied into a loop. The impeller pump supplies a jet of dye solution, propelled by water and/or air, which transport the fabric within the dyeing system ,surrounded by dye liquor , under optimum conditions. Turbulence created by the jet aids in dye penetration and prevents the fabric from touching the walls of the tube, thus minimizing mechanical impact on the fabric.

22. Knit Dyeing Machinery Overflow Dyeing Machine Soft-flow Dyeing Machine
Types of Jet Dyeing Machines:
Overflow Dyeing Machine
Soft-flow Dyeing Machine
Airflow Dyeing Machine

23. Knit Dyeing Machinery Overflow Dyeing Machine
Functioning of a Overflow Dyeing Machine:
A typical Overflow Dyeing Machine works like this. A winch that is not motor driven usually is located in the top side of the machine where the fabric is hanged.
A longer length of textile is made to hang from the exit side of the winch as compared to the inlet side.
By applying the force of gravitation the longer length of textile is pulled downward more strongly than the shorter one.
Consequently the fabric is soaked in the bath without any sort of tension. The following diagram well illustrates the working process.
Advantages: No evaporative losses, No build up of steam condensate in the dyebath,
Low liquor ratios, Excellent dye liquor contact, Computer control

24. Knit Dyeing Machinery HTHP Soft-flow Dyeing Machine
Technical features:
Compact body made of stainless steel.
High efficiency heat exchanger for quick heating/cooling.
Heating rate - around 4°C/Min upto 900°C - around 3°C/Min upto 135°C At steam pressure of 6 Bar.
Cooling Rate- around 4°C/ Min At water pressure of 4 Bar and 15°C.
Maximum working temp is 135°C.
Maximum working pressure of 3.2 Bar.
Control manual as well as automatic.
Heavy duty stainless steel pump.

25. Knit Dyeing Machinery Airflow Dyeing Machine
Features of Air flow Jet Dyeing Machine:
Completely Separated circuit for liquor circulation without getting in touch with the textile
Bath less Dyeing operation
Rinsing process offers all the added benefits of continuous processing as it is no longer a batch operation
Extremely low liquor ratio
Virtually non stop process
Comparatively lesser energy requirement due to faster heating/cooling and optimum heat recovery from the hot exhausted dye liquors
Reduction in consumption of the chemicals (e.g. salt) dosage of which is based on the amount of dye bath
Lesser water consumption savings up to 50% from the conventional Jet dyeing machines
Sensitivity towards ecology
Economical operation
More safety while dyeing

26. Knit Dyeing Machinery Limitations of Jet dyeing machines
High Initial investments and maintenance cost.
Limited accessibility during the dyeing process.
Foam forming substances are to be avoided.
Any roughness of the  inside surface cause damage to cloth
In case of cloth breakage , rethreading is complicated

27. Knit Finishing Machinery
Hydro-extractor Machine:
Manufacturer: Dilmenler
Extrction: 65% Maximum
Speed : rpm
Extraction time : 5-10in
Function : To remove excess water from fabric by centrifugal extraction.
Working Procedure:
Moving baskets are round and made of steel. There are a lot of holes On the down side of this basket. Through this holes water can be drained out. It is located at the centre of the machine and is rotated by an electric motor.
Hydro-extractor Machine

28. Knit Finishing Machinery
Dewatering or Squeezer Machine:
Manufacturer: Santex
Function:
Open the fabric from the rope form.
Reduce water content
Apply chemicals
Apply overfeed to give some compaction.
Width-wise stretch the fabric
Plait the fabric.

29. Dewatering, Chemicals, Application and Overstretching Machine:

30. Knit Finishing Machinery
Slitting Machine:
Slitting is a process that is applied for cutting the tubular fabric through the intended brake Wales lime on length wise direction prior to stenter processing.
Manufacturer: Bianco
Machine parts:
Rotary blade: To cut the fabric through break wales line
Ring: To help cutting
Guide Roller: To guide the fabric to plaiting
Plaiting: To plate the fabric
Sensor: sense for cutting through break wales line

31. Knit Finishing Machinery
Schematic Digram of Slitting machine

32. Knit Finishing Machinery
Compactor Machine:
Functions:
To control shrinkage
To control Width
To control GSM
To smooth fabric
Heat setting of Fabric for lycra

33. Knit Finishing Machinery

34. Knit Finishing Machinery FUNCTIONAL SELECTION LEGEND
1 –
Fabric Brake
13 –
Felt Centering Rollers
2 –
Fabric Feeding roller
14 –
Felt Tensioning Rollers
3 –
Beater
15 –
Heated Roller
4 –
Safety Photocell indicating Lack of Fabric
16 –
Felt Drawing Rollers Covered with Rubber
5 –
Fabric Conveyor Belt
17 –
Rollers with Loading Cell for automatic Fabric Tension Control
6 –
Photocell Loop Control
18 –
Exit Belt Drawing Roller
7 –
Operator Platform
19 –
8 –
Re – directing Roller
20 –
Movable Arms
9 –
Automatic Spreader Mod. ALBATROS
21 –
Fabric Conveyance Hopper
10 –
Steaming Chamber
22 –
Plaiting Roller
11 –
Motorized Adjustable Rollers
23 –
Fold Pressing Device
12 –
Felt Re – directing Adjustable Rollers
24 –
Plaiting Platform
OPTION:
A –
Ring Spreader for Tubular Fabric
C –
Cardboard Positioning Device
B –
Cooling Chamber at Exit
D –
Cutting Device

35. Knit Finishing Machinery
Stenter Machine:
Manufacturer: Santex
Function:
Apply chemical and softener
To dart set the T/C fabric
Drying of fabric
To control width
Curing of fabric
Apply pigment dyeing
To control GSM
To control shrinkage
To decrease spirality
To decrease bowing effect
Surface coating for teflon finish
Apply soil release chemical finish
Heat set for cotton/lycra fabric
Etc.
Figure: Stenter Machine

36. Knit Finishing Machinery
Schematic Diagram of Stenter Machine

37. Woven Dyeing Machinery
Singing & De-sizing Range:
Schematic Diagram of SWASTIK Singeing & De-sizing Machines

38. Woven Dyeing Machinery
Description of SWASTIK Singeing & De-sizing Machines
Sr No
  Description 1.
Tension Unit With Guide Rollers & Bars 2.
S.S. Pre-drying Cylinder (Optional) 3.
Pre-bushing Unit With Suction 4.
Singeing Chamber With Exhaust 5.
Water-cooled Roller 6.
Water-cooled Burner 7.
Carburetor With Blower 8.
Steam Quenching Device 9.
Post Brushing With Suction (Optional)
10.
De-sizing Unit St-12/St-15
11.
Squeezing Mangle 3 Tons.
12.
Main Drive (A.C. Motor With Frequency Controller)

39. Woven Dyeing Machinery
Feature of SWASTIK Singeing & De-sizing Machines
Special burners, two of which are provided for the machine. These burners have a particular combustion chamber and are provided with water-cooling arrangement. The cloth can be threaded so as to allow singeing of either one or both sides. It is essential to note that the gas consumption per meter of fabric is less as compared with a machine of conventional design.
Both burners are titled away simultaneously (by 45º) by electro-magnets.
High Singeing speeds, infinitely variable between 80 mts. To 150 mtrs/min.
Excellent and uniform singeing effect with economical gas consumption.
Burners turning away automatically when the machine stops.
Efficient dust extraction device
De-sizing compartment with 12 /16 mts. Contents can be provided with a suitable squeezing mangle.

40. Woven Dyeing Machinery
Scouring & Bleaching Range:

41. Woven Dyeing Machinery
Feture of Scouring & Bleaching Range:
Building block structure, suit for different weight fabric and different processing.
High liquid supply system can increase pick-up of liquid quantity, it makes the fabric suck the chemicals equally and fully.
The upper guide rollers of combination steamer are adjusted by frequency conversion transmission. It reduces crinkles due to changes of tension and meets the requirement of high-density poplin.
The fabric is heated enough before folding to insure the chemicals penetrate evenly,
This structure makes the saturated steam easy to penetrate and keeps temperature and humidity of the fabric so that it ensures the consistency of the scouring & bleaching.
It is not easy to get crinkles
Roller width:         mm
  Machine speed:    15-80m/min
  Drive:                  PLC, AC motor with inverter

42. Woven Dyeing Machinery
Technical Details:
Woven Dyeing Machinery
Jigger Dyeing Machine:
Feature:
Atmospheric (up to 98°C) & HT
Economical dyeing & Low liquor ratio
PLC Controlled
Fabric tension: N
Fabric speed:  m/min
Fabric width: max mm
Roller width: max mm
Figure: Thies Jigger

43. Woven Dyeing Machinery
Function of Jigger Dyeing Machine:
A Jig Dyeing machine, is an efficient dyeing technique. It is also known by the name of jigger. Jig Dyeing machine processes fabrics in open width to avoid creasing problems in fabric dyeing. The process works like this. The Jig Dyeing machine operates by transferring the fabric back and forth. This happens from roller to roller via the medium of a dyebath, that is located at the base of the machine. As soon as the second roller gets full, the direction of movement of fabric can be reversed. In Jig dyeing, the duration of the process is measured on the basis of the number of passages or ends of the fabric passing through the dye bath from roller to roller. The end in dyeing parlance is known as the passing of fabric through a dye liquor from one roller to the other one.

44. Woven Dyeing Machinery
Latest in Jig Dyeing Machines:
Features
Operates by electricity, and fully controlled by a PLC
Cutting edge technology in the form of speed measuring device on foot roll barrel. This helps in maintaining uniform line speed along with a reliable testing signal.
Comes with built in dye solution circulatory system and charging system.
Use of latest technologies in the form of automatic:
Reverse
Way-change
Length Count
Temperature Control

45. Woven Dyeing Machinery
Pad Batch Dyeing machine:
Pad Batch Dyeing machine is one of the widely used technique for semi-continuous dyeing process. It is mainly used in the dyeing of cellulosic fibre like cotton or viscose (knit and woven fabric) with reactive dyes. The characteristics of this machine is simple, and flexible and a substantial reduction in capital investment for equipment.
Schematic layout of a pad-batch:

46. Woven Dyeing Machinery
Types of Pad-batch dyeing machine:
Pad-batch process (semi-continuous)
Pad-roll process (semi-continuous)
Pad-jig process (semi-continuous)
Pad-steam process (continuous)
Thermosol process (continuous)
Pad-dry process (continuous)

47. Woven Dyeing Machinery
Special Features of Pad Batch Dyeing Process:
Significant cost and waste reduction as compared to other conventional dyeing processes.
Excellent wet fastness properties.
A uniform dye quality is achieved with even color absorbency and color fastness.
As compared to rope dyeing, Pad batch dyeing produces much lower defect levels
In pad batch dyeing, qualities like high shade reliability and repeatability are common. This is because of high reactivity dyes with rapid fixation rate and stability.

48. Woven Dyeing Machinery
Mercerizing Machine
Function:
Open with mercerizing machine for all kind of cotton & cotton blended as well as PES fabrics.
It will improve the fabric luster, increase the flexibility of the fabric and reduce dyestuff consumption.
During mercerization fabric is treated with 15% NaOH under high tension and pressure.

49. Woven Dyeing Machinery
Sanforizing Machine:
OWER-SHRINK Sanforizing machine (Brückner)

50. Woven Dyeing Machinery
Feature of OWER-SHRINK Sanforizing machine (Brückner):
Better shrinkage results thanks to the high tech drive system with load cell control
Extremely constant shrinkage results thanks to automatic shrinkage control (option)
Production output increased by 20 – 40 % due to an improved geometrical design of the rubber belt unit
Extended life span of the rubber belt due to larger diameter of compression and tensioning rollers and an optimized cooling system
Reproducible results as all machine parameters are automated with recipe administration software. No manual settings (e. g. valves, handwheels) required
Rubber belt resurfacing/grinding unit fully integrated into the machine (no mounting of external unit necessary) – grinding process controlled via PLC to avoid operation errors
Very solid and long lasting machine design with minimized vibrations to ensure a smooth fabric run
All bearings are located outside the wet to avoid corrosion

51. Some Popular Dyeing and Finishing Machine manufacturing Company

52. Some Popular Dyeing and Finishing Machine manufacturing Company

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