Dyeing Laboratory

Dyeing lab
Dyeing lab is the heart of the dyeing factory. Higher precision lab can aid
easily to achieve the goal of the factory.

Main Responsibility:
 Accepting the ’Swatch’ from the buyer and analyze the color & Dyes.
 Preparing the Recipe accurately matching the required color.
 Storing & maintain the dyes to be used for dyeing.
 Producing self-shades & storing it into the computer.
 Record & analysis of chemicals & dyes quality.
 Making plans for bulk dyeing.
 Following the color coding system given by the distinctive buyer & also
prepare own color bank.
 Testing the dyed goods.

Flow of work:
Swatch from buyer/merchandiser

(Contains: fabric construction-gsm-color name-color code-style)

Shade matching by lab works

Shade submission

(Sample match A, B, C)

Approved Rejected

Recipe delivered for bulk-production

 The color standard or sample standard are received from the buyer in the
form of-

1. Pantone
I. Contain color code, no color name
 C-pantone (The swatches are printed with a coated glossy finish)
 U-pantone (The swatches are printed with a matte finish)
 TPX (Textile paper extended range)
 TCX (Textile cotton extended range)
 TPG (Textile paper green)
II. Contain both color name and code
 TN (It is a nylon bright swatch card each of which are made from
double layered 100% nylon loose format fabric and used for
fluorescent)
III. For mélange fabric
 Top dyed mélange
 Melantra mélange yarn
2. Swatch (Small piece of fabric which is the standard)
3. QTX (Quick time extension)
QTX file is a file that contains the reflectance measurements for a color.
QTX file contains-
 Number of reflectance/Transmission
 The starting wavelength(360,380,400)
 Wavelength interval(10 nm)
 Viewing geometry etc.

Information required to process an order-

i. Fabric construction(S/J, Rib, Fleece etc.)
ii. Fiber group (Cotton, Polyester etc.)
iii. Affinity (100% cotton, PC, CVC etc.)
iv. Test parameter (Light fastness, color fastness, wash fastness etc.
Dyeing Laboratory equipment:
1. Datacolor
2. Lightbox
3. Sample dyeing machine
4. Dryer
5. Electrical balance
6. Pipette (manual and digital)
7. Conical flask
8. Measuring cylinder
9. Beaker
10. pH meter

Lab dip:
Lab dip is a process by which buyers supplied swatch is matched with the varying dyes
percentage in the laboratory with The help of “DATA COLOR” or see the previous matching
sample or give the recipe by the practical experience, Lab dip plays an important role in shade
matching & detaching the characteristics of the dyes and chemicals are to be used in the large
scale of production so this is an important task before bulk production.

Lab dip approval process:

Order lab dip from buyer

Computer analysis

Recipe swatch card/pantone number/QTX file

1st correction

2nd correction

Correction until shade match

Shade ok

Sample send to buyer

Get buyer approval

Start bulk production

Datacolor
Datacolor is a unique software solution
that uses the knowledge of the experts in the
company to help them to manage dyeing
recipe and entire process.

Software needed to run datacolor:

1. Datacolor tools (DCE tools)
i. Input of standard: It may have physical standard i.e. swatch, TC, TCX,
TPX, numerical standard such as QTX file.
ii. Pass fail report, fastness properties, color change, color strength,
whiteness, k/s curve, reflectance curve etc.
2. Datacolor match: Recipe calculation, recipe correction, costing,
metamarism index etc.

The standards followed in the lab for color tolerance are:

i. CMC: A color tolerance is a limit to how big the difference in color

between a sample and standard is
allowed to be for the sample to be
considered acceptable. Tolerance values
should correlate to the human eye so
that color is both visually and
numerically acceptable. The CMC
tolerance system is recommended
because the ellipsoids in this system are
based on the color discrimination
threshold of the human eye.
ii. CIE: In case LAB tolerance is rectangular and in case of LCH tolerance is
conical.
Recipe calculation flowchart:

Data color match

Recipe

Measure standard

Standard name + fabric specification

Put standard in aperture

Direct measure (press green)

Dyeset

Color selection

Calculate

Choose correct recipe

No Yes
Print recipe
Flowchart for laboratory correction:

Datacolor match

Recipe

Select the recipe to be corrected

Lab correction

Batch name

Put batch in aperture/select if previously measured

Measure direct (press green)

Select new dye if any needed

Laboratory

Select the correct recipe

Print recipe
 Factors for dye selection:
i. Good quality/ fastness properties
ii. Metamarism free
iii. Easy dyeing in the bulk production
iv. Cost
v. Availability

Shade matching procedure in case of cvc /pc:

Color standard

Color analysis

Recipe prediction calculated by CCM Input database

Initial recipe

Laboratory dyeing of polyester

Laboratory correction
Carbonizing of cotton using 70% H2SO4
Fail
Use L*, a*, b* to match the polyester part

Cotton part dyeing

Laboratory correction
Use L*, a*, b* to match the whole sample

Bulk production
List of machine

Sample dyeing machine 6

Dryer 1

Lightbox 1

Datacolor 1

pH meter 1

1) ECO DYER:

Brand: Rapid
Origin: China
Power: 220 V, 50Hz
Dye vessel: 24
Temp range: 60-130°C

2) Light box:
Brand: Veri vide
Light source: D65,TL83,
TL84,CW,Tungsten
3) pH meter:
Brand: METTLER TOLEDO

4) Datacolor:
Datacolor 650