DYEING MACHINE

INTRODUCTION:
Textile materials are dyed in aqueous solutions or dispersions of dyestuffs,
together with dye bath additives such salt, alkali, acids and other auxiliary
.The dissolved or dispersed dyestuff must first be adsorbed on to the fiber
surface and then diffuse into its interior where finally it must be fixed. The
dyeing process is aimed at giving woven or knitted fabric its intended color,
crucial to its ultimate use. The dyeing process can be carried out at different
stages of fiber processing, i.e. in different forms: staple, yarn, fabric and
piece. Common methods of batch, or exhaust, dyeing include beam, beck, jet
and jig processing. Each dyeing process requires different amounts of dye
per unit of fabric to be dyed.
There are three methods to transfer the dye from the liquor to the fiber:

EXHAUST METHOD:
The traditional image of dyeing is that of vessels containing large volumes of
dye solution into which textile goods are placed and dyed through the

application of heat and various chemicals. The modern embodiment of these

long liquor processes is what we refer to here as exhaust dyeing, the
exhaustion being the depletion of dye from the dye bath due to its
absorption by the textile. Typical, but not mandatory, aspects of modern
exhaust dyeing equipment are
Pumped circulation of the dye liquor
A sealed system which can be pressurized
Microprocessor control of heating and flow.
In exhaust dyeing, all the material contacts all the dye liquor and the fibers
absorb the dyes. The dye concentration in the bath therefore gradually
decreases. The degree of dye bath exhaustion as a function of time describes
the rate and extent of the dyeing process.

The machines used in exhaust dyeing method are as follows :

BATCH FORM / OPEN WIDTH FORM/ FABRIC FORM DYEING:

WINCH DYEING MACHINE:
Winch dyeing machines comes with the lucrative options of low cost design,
simplicity in operation and maintenance yet uncompromising features when
it comes to versatility. Mostly woolen fabrics are dyed by using Winch Dyeing
machine. The dyeing machine derives its name "Winch" as the fabric rope
gets circulated in the machine by way of a mechanical action of a horizontal
rotor or reel, called as a winch or sometimes wince. The cross-section of the
winch rotor may be circular or elliptical. As shown in the diagram below, the
winch dyeing machine has a front compartment; a perforated partition
separates it from the main dyeing chamber. It is this front compartment
where dyestuff and dyeing auxiliary additions are made. Gradually they
move to main dyeing vessel from there. The process works like this first a
series of fabric ropes are immersed in the dye bath. This fabric ropes must
be of equal lengths. A part of each rope is then taken over two reels or over
the winch itself. In the subsequent course of dyeing operation a rope of fabric
is circulated through the dye bath and the winch. The dyestuff and auxiliaries
are dosed manually or automatically according to the recipe method.
A schematic representation of a beck or winch is shown in Figure, in which
the fabric in a continuous loop form (referred to as a rope due to the twisted
configuration it tends to adopt) is circulated over two rollers and through the
dyeing liquor, spending most of the time in the dyeing liquor. These
machines are the original fabric dyeing equipment with much of the
construction being made of wood prior to the advent of stainless steel.
The winch or beck dyeing machine is quite simple and serves for all scouring,
bleaching, dyeing, washing-off and softening processes. The machine
contains a length of fabric with the ends sewn together, which is compressed
to form a continuous rope. This rope passes from the dye bath over two
elevated reels and then falls back into the bath The first roller is free-running
(jockey or fly roller). The second (winch reel) is driven and controls the rate
of rope transport and the extent of pleating where the rope accumulates
below and behind\ the winch. Both reels extend the full length of the
machine and accommodate several fabric ropes running side by side. The
fabric rope is held on the winch by friction and its own weight.

JET DYEING:
It was found that in using Winch machines, there were some inherent
problems. So the Jet dyeing machines when they came up in the 1970s were
specifically designed to overcome those shortcomings. In the Jet dyeing
machine the reel is completely eliminated. A closed tubular system exists
where the fabric is placed. For transporting the fabric through the tube a jet
of dye liquor is supplied through a venture. The Jet creates turbulence. This
helps in dye penetration along with preventing the fabric from touching the
walls of the tube. As the fabric is often exposed to comparatively higher
concentrations of liquor within the transport tube, so little dye bath is needed
in the bottom of the vessel. This is just enough for the smooth movement
from rear to front. Aqueous jet dyeing machines generally employs a driven
winch reel along with a jet nozzle.

The following diagram explains the functioning of a Jet dyeing machine:

Types of Jet Dyeing Machine:

1. Overflow Dyeing Machine
2. Soft-flow Dyeing Machine
3. Airflow Dyeing Machine

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

SOFT FLOW DYEING MACHINE:

In the soft flow dyeing machine water is used for keeping the fabric in
circulation. The conception difference of this equipment from a conventional
jets that operates with a hydraulic system is that the fabric rope is kept
circulating during the whole processing cycle (right from loading to
unloading). There is no stopping of liquor or fabric circulation for usual drain
and fill steps. The principle working behind the technique is very unique.
There is a system for fresh water to enter the vessel via a heat exchanger to
a special interchange zone. At the same time the contaminated liquor is
allowed channel out through a drain without any sort of contact with the
fabric or for that matter the new bath in the machine.

Technical features:

Very low liquor ratio- around 1:1(wet fabric)

Can reach high temp. up to 140 C
Easily dye 30 to 450 g/mt.sq.of fabrics(woven & knitted fabrics)
Number of very soft flow nozzles
No pilling effect
Wide capacity

AIR FLOW MACHINE:

This is another development of the very popular jet dyeing machines. The
main difference between the Air Flow Machine and Jet Dyeing machine is that
the airflow machine utilizes an air jet instead of the water jet for keeping the
fabric in circulation. Typically the fabric is allowed to pass into the storage
area that has a very small amount of free liquor. This results in a reduction in
consumption of water, energy and chemicals. The figure below shows how in
an Airflow Machine the bath level is always under the level of the processed
textile. Here the fabric does not remain in touch with the liquor (the bath
used is below the basket that holds the fabric in circulation). This invariably
means that the bath conditions can be altered without having any impact on
the process phase of the substrate.

JIG OR JIGGER DYEING MACHINE:

The jig or jigger is one of the oldest machines for processing woven fabrics in
open-width form. 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, which 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. Fabric is transferred from one roller to the other
through a small volume of liquor.
The jig has a small bath containing the dye liquor (200 to 750 l) and gives a
very low liquor-to-goods ratio of around 1:1. It is therefore useful for those
dyes used on cellulosic fibers that normally give only low to medium
exhaustion. Jig dyeing is a form of padroll dyeing repeated several times.
Only a few meters of the total length of fabric are in the bath solution at any
moment and dyeing occurs almost entirely in the roll of fabric outside the
bath. The rate of dyeing depends on the amount of liquor retained by the
fabric, the degree of exhaustion in the dwell period, and the extent of liquor
exchange during the next dip. The latter is usually around 6070%, but may
be less for heavy fabrics.

Figure: - Illustration of Jig or jigger Dyeing Machine.

Types of jig dyeing machine:
1. Atomospheric Jigs.
2. High temperature Jigs

KIER DYEING MACHINE:

Kiers came in many forms, the most popular being a cylindrical iron vessel
placed vertically and holding two tons of fabric. Liquor percolates through
the fabric and is pumped back, via a multitubular heater, to spray on the
fabric. The machine is included here as historically it holds an important
place in scouring and bleaching practice. In the Western world it has been
superseded by other equipment.
Garrett in a classic paper stated that for successful use of kiers it is essential
to have all air excluded from the kier and:
(1)
(2)
(3)
(4)
(5)

The
The
The
The
The

correct
correct
correct
correct
correct

quantity of cloth in the kier;

loading of the kier;
rate of liquor circulation;
liquor ratio;
steam pressure and volume;

The fabric is rope washed after processing and, if bleaching is to follow

scouring, the kier must be reloaded with intermediate washing. Iron vessels
are unsuitable for peroxide bleaching and so the machine must be suitably
passivated using silicate cement

Figure: - Schematic Diagram of a Typical Kier Dyeing Machine

YARN FROM MACHINE:

HANK DYEING MACHINE:

Hank dyeing machine are mostly used for dyeing of patterned wool carpets.
There are mainly four types of Hank Dyeing machines used. They are the
following, single stick Hussong-Type Machines the double-stick machine,
double-stick cabinet machine, and lastly circular carrier machine. Out of this
four, the first category of Hussong-Type Machines is the most popular one.
The diagram is illustrated below.

Figure: Hank dyeing machine.

A major reason for the decline of hank dyeing is the problem of unwinding.
After dyeing, the wet hanks are centrifuged, hung on poles or hooks, and
passed through a hot air oven. They must then be mounted on a rotating
frame to unwind the yarn. After package dyeing, yarn can be more easily
unwound at much higher speed by pulling it over the top of a stationary
bobbin.

PACKAGE DYEING MACHINE:

A package dyeing machine is typically a cylindrical vessel, about 2 m high
and 2 m wide, with a rounded bottom and lid. The yarn is wound into
cheeses, cones or cakes using perforated former tubes. A series of technical
developments in the recent years has resulted into package dyeing being
developed into a highly sophisticated as well as an economic process. Latest
design Package Dyeing machines are amenable to accurate control and
automation. These features would likely to lead to increases in the
application of package dyeing.

The dye flows through to the yarn package with the help of the deliberate
perforations in the tube package. Once full exhaustion is brought about, the
carrier of colored yarn is consequently removed from the vessel. A large
centrifuge removes excess water from the packages. Finally the yarn is dried
using an infra red drying oven. The image shows the process working of a
Package dyeing machine.

BEAM DYEING MACHINE:

The beam dyeing machine operates with the same principle as that of
package dyeing machine. It can be effectively used to dye yarn or fabric. The
process works like this, fabric or yarn in open width is rolled on to a
perforated beam. The beam then subsequently slid into a vessel that is
closed and pressurized. The color impregnates the fabric as the dye liquor is
allowed to go on circulating through the perforations in the beam. Usually
the beam machines are designed in such a manner so as to hold a single
beam or multiple beams in a batch.
In principle, beam dyeing is similar to package dyeing but with a single large
pakage.This dyeing method is widely practiced for those fabrics that might

crease, extend or abrade when dyed in machines where the fabric is in

motion. Beam dyeing under pressure is easier than jig pressure dyeing.

Figure: - Sectional diagram of a high-temperature beam dyeing machine

CONTINUOUS DYEING METHOD:
Continuous dyeing is a method of dyeing fabrics in which, in an
uninterrupted sequence, they are first impregnated with dyes and chemicals
followed by a fixation step and rinsing and drying. The impregnation of fabric
with dye is generally carried out in a padder as described in the previous
section. Fixation can occur by a number of mechanisms such as steaming,
baking or simply exposure to the atmosphere. Steaming is a very common
component of continuous dyeing ranges for cotton fabrics, the aqueous hightemperature environment allowing the diffusion of dyestuff molecules into
the fiber. Continuous dyeing methods are suited to high production volumes
and respond quickly to the demands of fashion. Virtually all cotton dyes can
be applied by continuous methods and, as mentioned in previous sections, it
is the most important process for application of vats, sulphur dyes and azoic
combinations.

Figure: wash box

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. Some continous method:
Pad- steam =padding +steamer+washing
Pad dry-steam =padding+stenter frame+washing
Wet steam
Thermosol continuous dyeing
TAK &
Space continuous method
Now some are describe bellow:

THERMOSOL CONTINUOUS MACHINE:

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.

Some of the popular methods in continuous dyeing process are Pad-steam,

Wet-steam, thermosol dyeing, TAK dyeing, space dyeing, and pad-steam
dyeing long chain warp dyeing etc.

CONTINUOUS DYEING CARPET:

Continuous dyeing carpet method is used for solid-color cut-pile carpet.
Continuous dyeing is one of the fastest, most cost-effective means of color
application. Long expanses of tufted carpet travel through huge machinery to
be wet and scoured. After some of the water is extracted, the carpet moves
under a dye applicator that flows dye liquor onto it at a rate of 50' per
minute. Next, the carpet is put into a wet heat steamer to fix the dye, after
which it is washed, extracted and dried.

The majority of the continuous dyed carpet equipment used in the world
today is manufactured by two companies in Gemany, Kusters and Fleissner.
This type of continuous dyeing method is favored over beck dyeing due to
the fact that costs are lower for utilities, labor, and raw materials. The reason

for this is that beck dyeing requires more water, about 6 times more water in
fact, for processing the same number of pounds of dyed fiber as compared to
a continuous dyeing line. The need for more water brings the need for more
energy to heat the water, and more chemistry to treat the water and carpet
fibers adequately for the dyeing process

SEMI CONTINUOUS METHOD:

In the process of semi-continuous dyeing that consists of pad-batch, padjig, pad-roll the fabric is first impregnated with the dye-liquor in, what is
called a padding machine. Then it is subjected to batch wise treatment in a
jigger. It could also be stored with a slow rotation for many hours. In the padbatch this treatment is done at room temperature while in pad-roll it is done
at increased temperature by employing a heating chamber. This helps in
fixation of the dyes on to the fibre.

A schematic diagram is given here for the semi-continuous dyeing process

After this fixation process, the material in full width is thoroughly cleansed
and rinsed in continuous washing machines. There is only one point of
difference between Continuous and semi-continuous dyeing process is that in
semi-continuous dyeing, the dye is applied continuously by padding. The
fixation and washing remaining discontinuous. Liquor Ratio in semicontinuous dyeing is not of much importance and is not taken as a
parameter. One of the widely used techniques for semi-continuous dyeing
process is the Pad batch dyeing. A semi continuous method for production of

viscose textile fibers in which spinning is conducted at a rate of 500 m/min

with take-up to a centrifuge is examined. Here 10-20 twisted fibers are joined
into roving, treated on continuous aggregates, and after drying in drums are
taken up on warping beams weighing 10-20 kg. The fibers made by the semi
continuous method have high uniformity of dyeing and high strength of 2830 cN/texs.

PAD BATCH DYEING:

Pad Batch Dyeing is one of the widely used
techniques 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. Pad batch dyeing is a textile dyeing
process that offers some unique advantages in
the form of versatility, simplicity, and flexibility
and a substantial reduction in capital investment
for equipment. It is primarily a cold method that is the reason why it is
sometimes referred to as the cold pad batch dyeing
The technique or process used in pad-batch dyeing starts with saturating
first the prepared fabric with pre-mixed dye liquor. Then it is passed
through rollers. The rollers, or padders, effectively force the dyestuff into
the fabric. In the process, excess dye solution is also removed. After
removal of excess dye stuff the fabric is subsequently "batched". This
batching is done by either storing it in rolls or in boxes. It takes a minimum
of 4-12 hours. The batches are generally enclosed by plastic films. This
prevents absorption of carbon dioxide and water evaporation. Finally as the
reaction is complete the fabrics are washed. This is done by becks, beams,
or any other washing devices.

COLD PAD DYEING PROCESS:

The technique or process used in pad-batch dyeing starts with saturating
first the prepared fabric with pre-mixed dye liquor. Then it is passed through
rollers. The rollers, or padders, effectively force the dyestuff into the fabric.
In the process, excess dye solution is also removed. After removal of excess
dye stuff the fabric is subsequently "batched". This batching is done by
either storing it in rolls or in boxes. It takes a minimum of 4-12 hours. The
batches are generally enclosed by plastic films. This prevents absorption of
carbon dioxide and water evaporation. Finally as the reaction is complete the
fabrics are washed. This is done by becks, beams, or any other washing
devices.

CONCLUSION:
The assignment of exhaust method, continuous method &semi- continuous
method is very important for our study. Dyeing operations are used at
various stages of production to add color and intricacy to textiles and
increase product value. Most dyeing is performed either by the finishing
division of vertically integrated textile companies, or by specialty dyehouses.
Specialty dyehouses operate either on a commission basis or purchase
greige goods and finish them before selling them to apparel and other
product manufacturers. Textiles are dyed using a wide range of dyestuffs,
techniques and equipment.

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References:
- Cotton: science and technology
(Edited by S. Gordon and Y-L.Hsieh)
-Internet browsing.