Presentation on

DYEING MACHINARIES Presented by

Mohammad Irfan IqbalLecturer, Department of Textile Engineering

Types of Dyeing machine1. Fiber dyeing machine2. Yarn dyeing machine

a. Hank Dyeing Machine

b. Package Dyeing Machine3. Fabric Dyeing machine.

a. Jet Dyeing Machine

b. Jig Dyeing Machine

c. Padding mangle Dyeing Machine

d. Winch Dyeing Machine

e. Soft flow dyeing machine.

The basic requirements of a dyeing machine

• It should provide sufficient movement for the liquor to penetrate uniformly into every part of the goods.

• The movement must not be vigorous that it will damage fiber materials.

• The machine must be constructed of a material which will withstand prolonged boiling with acid or alkaline solutions.

• The heating arrangements must be such that a comparatively uniform temperature will be maintained throughout the liquor.

• There should be some means of adding the concentrated dyestuff solution in such a way that it becomes well diluted before it comes into contact with goods.

• All moving parts and electric motors should be protected against the corrosive action of steam and acidic atmospheric condition.

Package Yarn Dyeing Machine (Vertical Type):

Yarn Dyeing Machinery

Package Yarn Dyeing Machine (Horizontal Type):

Yarn Dyeing Machinery

Winch dyeing machine

Features:• The fabric is immersed and pulled on from dye

liquor with the help of winch and guide roller.• Consists of a heat container and a revolving

winch.• Fabric moves but liquor stationary.• The fabric is dyed in rope form• M:L= 1:20-1:40

WINCH DYEING M/C

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.

Jet Dyeing Machine

Types of Jet Dyeing Machines:

Overflow Dyeing MachineSoft-flow Dyeing MachineAirflow Dyeing Machine

Jet dyeing machine

1. Main Vessel or Chamber2. Winch roller or Reel3. Heat Exchanger4. Nozzle5. Reserve Tank6. Chemical dosing tank7. Utility lines i.e. water line, drain line, steam inlet etc.8. Controlling unit or Processor9. Fabric Plaiter10. Different types of motors & Valves

Main Parts of Dyeing Machine:

Main Pump

LODING FABRIC ON THE MACHINE

RUNNING MACHINE

UNLODING FABRIC ON THE MACHINE

AUTO DOSING SYSTEM FOR KNIT DYEING MACHINE

Dyeing Floor

BACK VIEW OF A DYEING MACHINE

Dosing Pump

PT TANK

Bath

Main Pump

Heat Exchanger

Drain

Dosing Line

Nozzle

Steam valve

Heat Exchanger

Storage Tank

Control Panel

Main PumpDosing Pump

Steam valve Nozzle

FRONT VIEW OF A DYEING MACHINE

LIQUOR CIRCULATION PATH- MOTOR , VALVE ,HE, RESERVE TANK

Main Pump

Heat Exchanger

Lint Filter

Doing Tank

Pneumatic Valve

Unload Motor

Drain Line

Water Label

Nozzle AirFlow

Dosing Pump

Dye Bath Chamber

Popular Dyeing

Machine

Popular Dyeing

Machine

Popular Dyeing

Machine

Popular Dyeing

Machine

Popular Dyeing

Machine

SOFT FLOW DYEING MACHINE

Soft Flow Dyeing Machine:In the soft flow dyeing machine water is used for keeping the fabric in circulation. The conceptional 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.

Classes:• According to operating temperature

soft flow dyeing machine can be categorized into two classes– Atmospheric machine

• Capable of operate at 98˚C • Can not dye polyester • Most of these are bell shaped

– High pressure & High temperature machine• Capable of operate at 140˚C• Capable of dyeing most of the fibre type. • Most of these machines are apple shape

or banana shape

Basic Description: Outer components

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2

3

4

5

9

8

7

6

10

1112 13

1. Loading Creel2. Reel/ winch3. Outer shell4. Operator rail5. Main pump6. Heat exchanger7. Fibre filter8. Control panel9. Dosing tank10. Stirrer motor11. Reel motor12. Lid window13. Operator panel5

Basic Description: Inner component

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2

3

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8

1. Reel/ winch2. Soft flow nozzel3. Fabric4. Plaiting device5. Soft Flow Nozzel6. Liqour Separator7. Dirty Flow out8. Fresh flow in

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16

32

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7

1511

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14

9

5

517

1. Liquor to nozzle2. Inlet steam valve3. Heat exchanger4. Filling pump valve5. Salt dosing valve6. Dry salt system7. Main pump8. Dosing tank steam valve9. Dosing tank level sensor10. Side tank dosing valve11. Side tank dosing pump12. Drain valve13. Dirty drain valve14. Fresh water inlet valve15. Aquachron heat

exchanger16. Machine level sensor 17. Machine wash sprayer

Mechanical Components• Reel / winch : Main component for fabric

transport through the machine, reel is geared to the reel motor, reel speed determines the fabric passing speed and responsible for cycle time adjustment. Reel speed is limited and directly proportional to the machine loading capacity. Reel metal bar is covered with silicone rubbery material which can withstand high temperature and wide pH range.

• Plaiter : this is the plaiting device that enables plaited arrangement of fabrics inside the machine, in different machines plaiting length is adjustable (Fongs Jumbo jet), and most of the machine plaiting distance is fixed

• Heat exchanger: inner tube heat exchanger is most common, steam is passed through the heat exchanger inner tube, liquor flow gain heat from contact of inner tube. Heat exchanger not only used for heating also used for cooling by flowing fresh water through the inner tube.

• Soft flow nozzle: The special pump design permits a high volume liquor flow, with complete bath circulation in maximum 45 seconds, at low operating nozzle pressures of 0.07 to 0.3 bar. This high volume circulation via the “intensive” zones

, means that the liquor fabric contacts at a given fabric speed are much more than in other machines and, therefore, level dyeing can be achieved at relatively low fabric speeds

• Valves: machine liquor flow and steam flow is regulated with pneumatic butterfly valve, a large no of valves are present at different flow points, valve technology is one of the important area of modernization of liquor flow. Pulse valve is recently replaced with analogue valves, in many cases adjustable or regulatory valve is replacing fixed valves.

• Gear, shafts and bearing: machine moving mechanism also consist of gears, shafts and ball bearings.

Electrical components:

– From the below chart we can see that a 250 kg machine has capacity of lifting 500 ltr/ minute of water and pumping through out the machine. This is capacity of the main pump beside this pump a dyeing machine can contain several pumps even at the drain area, at the dosing tanks etc.

• Pump:

• Motor:A dyeing machine contain below motors– Main pump motor,– Main reel/winch motor,– Plaiter motor– Unload reel motor– Add pump motor– Mixer motorBelow is the capacity and electrical requirement of these motor

Sensors and controller:

• Level sensor: – This is one of the most important

sensor of the dyeing machine, several level sensor is connected to the machine, on is on the machine inside to measure the total liquor, another two in each side tanks. Machine control is depends on this sensor readings. Dyeing machine size is a non symmetrical, so calculation of liquor volume is not possible from the size of the machine, this is the main reason to install level sensors inside the machine.

Level sensors in side tank

Sensors and controller:

• Magnetic sensor– In dyeing machine each rope is connected with a magnet

and while rotation through out the machine this magnetic field can be identified by a magnet sensor, from this senses machine calculates the actual rotational speed and cycle time which is very important to maintain. Each port of machine contain one magnetic sensor.

• Flow meter– Besides the level sensor most of the recent machine

contain at least one flow meter, the initial filling is done by a digital flow meter which can tell the actual quantity of the water inside the machine.

Operational features• Loading /Unloading:

– Machines are loaded through the loading reel and rope ends are tied or sewn with a overlock swing machine. A magnet is also connects to the rope ends to calculate the fabric speed and find the rope end to unload.

– Machine capacity depends on the rope length. Fabric of 450 gsm and 130 gsm has different rope length. Thats why in a 500 kg machine 130 gsm fabric can not be loaded due to the longer cycle time. This why machine capacity sometimes calculated in rope length also. Calculation of rope length is as below

– in most of the cases and machines single rope is loaded in a chanber, but new machines like Athena 2 and athena 3 has capability of loading two rope at a time with special knoting technic that allows maximum production even at low GSM fabric.

Filling and Liquor ratio control:

• Feeling is done by flow meter which is recorded in actual liters, but it is possible only for the first fill and when the fabric is in the machine then filling in exact quantity become difficult. As fabric retention varies greatly. To minimize such problems engineers develop different systems one is through level sensor and another is memorizing initial fill level and subsequent fill is maintained by level sensor previous memorized level.

Maintenance Schedule• AFTER THE FIRST 200 WORKING HOURS OF THE MACHINE, CHECK ALL

HEAT EXCHANGER BOLTS OF THE MACHINE.• AFTER THE FIRST 500 WORKING HOURS OF THE MACHINE , CHECK ALL

THE BOLTS ON THE MACHINE.• PNEUMATIC VALVES, ELECTRIC MOTORS AND REDUCERS AS WELL AS

OTHER PERIPHERAL COMPONENTS OF THE MACHINE , SHOULD BE CHECKED AND MAINTAINED APPROPRIATELY.

• IN CASE OF AN INADVERTENT HIT TO THE ADD TANK(S) MIXER SCREW CONVEYOR, DISMANTLE THE SCREW CONVEYOR AND CHECK THE PROPER ALIGNMENT. PROPER ALIGNMENT IS CRUCIAL FOR THE PROPER OPERATION OF THE MIXER.

• OPENING OF THE MANHOLE DOOR:• SKILLED AND ATHORIZED PERSONS ONLY SHOULD DO THE OPENING

OF THE MANHOLE DOOR.• CHECK THE O-RING FOR WARE AND REPLACE IT CAREFULLY IF

NECESSARY.

THANK YOU