Yarn Printing

Md.Azmir LatifMSc.Engr.(Textile)

Textile printing

• Textile printing means the localized application of dyes or pigment and chemicals by any method which can produce particular effect of color on the fabric or yarn according to the design.

Yarn printing• Yarn printing means the localized

application of dyes or pigment and chemicals by any method which can produce particular effect of color on the yarn or onto a yarn package according to the design. Yarn printing is also known as “Space Dyeing”. Although the printing of yarns for true patterned effects proved very difficult tom control, the random space-dyed effects that can be more readily attained by a variety of yarn-printing methods have continued to be popular.

Space dyeing• Space dyeing is a process in which yarn is

colored in one by one space by injection of colored dyestuff that means in a specific length of yarn. This producing colored flecked effects on yarns but the two most successful methods entail either warp printing or color application to a tubular knitted ‘sock’. The essential process sequence begins with dye liquor application, followed by steam fixation, washing-off and drying . 

•

Comparison

• Yarn Dyeing• Gives single

shade• No Particular

design provide

• Yarn Printing• Gives Multicolor

shade• Particular

design provide

Yarn Printing

• Textile printing means the localized application of dyes or pigment

• can produce particular effect of color on the fabric or yarn according to the design

• Space dyeing is a process in which yarn is colored in one by one space by injection of colored dyestuff

• contains 1-5 color • Inject dyeing is a process of inject to

bobbin, submitted from colour material (dyestuff )

Specification of M/C• Machine Name:

Bobbin Injection Dyeing Machine ( B I D )

• Manufacturer: LAIP Dyeing Machinery

• Origin: Italy • Colour:1 to 5 • Process:

Discontinuous Process• Media: Alkali & Acid• Capacity: 2-3 ton per

day

Machine Parts

• Six parts• Dyes Tank• Dyes Cylinder• Oil box• Printing Device• Pannel Board• Dryer

Setting System:• Dark Shade:- Double Injection• Light Shade:- Single Injection•  • Steaming Process: 98° C X 60 min for cotton 110 -120° C X 70 min for polyester • Setting Inject Cylinder: 90% colour absorb

overall 30 sec• Ring Inject: Slub effect is possible

Working system of different parts of machine

•Preparation Tank :To prepare the dyes mixture for printing.

•Inject Tank Cylinder : To keep small amount of dye mixture for injection.

•Bobbin Holder:Help to keep package of yarn .

•Printing needle: In B I D machine has 32 needles.Each needle contain 5 pores which passed dyes to package yarn.

•Colour Supply Pipe:Help to pass the dye colour in package yarn.

•Steam Mechanism: It produces steam as 40°c

Working system of different parts of machine

•Hydrolic Press: To produce hydrolic pressure.

•Steamer:It carry & control temperature as 98°c & runs at 60 min.

•Needle head:It is adjust with colour supply pipe.•Top bobbin holder:Help to keep the package of yarn at upper side.

•Monitor:It is the major part of B I D machine.It controls all over process of yarn printing.

•Air pressure:Press the air to passed the dyes in colour supply pipe.

•Motor: It drive the machine & give motion.

Dyeing program of B.I.D machine

• Start ↓• Preparation Tank ↓• Preparation tank 1, tank 2,tank 3,

tank4 ↓• Injection ↓• Send to Drying/finishing

Drying program of Steamer (Dryer)

• Start ↓

• Empty ↓

• Heat/ cool (heating) ↓

• Heat/ cool(cooling) ↓

• Operator call(Unload) ↓

• Packing

Printing Chemical• Leveling Agent • Sequestering Agent• Antifoaming Agent• Caustic• Hydrogen per Oxide• Peroxide Killer • Acetic Acid• Dyes• Salt• Soda• Washing Agent (Detergent) • Finishing Chemical

Production Calculation:Tank Capacity = 340 LThere are four tanks hereSo, Capacity of four tanks = 340X4=1360 LLiquior per package = 2 LSo no of package can be dyed for full tanks liquior = 1360/2 = 680 PkgNeed time per drop = 2minNo of drop for 24 hour = (24 X 60)/2

=720No of package per drop = 2No of package for 24 houe (can be dyed) = 720X2=144040 L. water for 4- times injection for this package dyeing.

Production Calculation for Full Tank Liquor Tank maximum level = 320 LTank minimum level = 20 LLiquore can used for one time = maximum level – minimum level

= 320-20 =300L.

So liquor can be used for 4 tanks = 300X4 = 1200L.

Liquor need for one injection = 10 L.No of injection for full tank liquor = full tank liquor / liquor for one injection

= 1200/10 =120

For one injection 2 package can be dyed So no of package can be dyed for full tank liquor = 120X2=240 LIf package weight = 1.2 KgProduction for full tank liquor = No of package X package weight

= 240X1.2 = 288 Kg

Production Calculation for Bobbin injection dyeing For one injection need time = 2 minNo of injection for 24 hour = ( 24X60)/2

=720For one injection 2 package can be dyed So no of package can be dyed for 24 hour = 720X2

=1440If package weight = 1.2 KgProduction for 24 hours =1440X1.2 = 1728 kg

Production Calculation For steamingNo of package can be loaded in one carrier = 54 Two carrier can be loaded for one batch No of package can be loaded for one batch = 54X2

= 108For one batch unload need time = 90 minSo no of batches can be unload for 24 hours = (24X60)/90

=16No of packages can be unload for 24 hours = 16X108

= 1728If package weight 1.20 Kg Production for 24 hours = 1728X1.2 = 2073 Kg  

Density of soft winding Package M = Package Weight m = Bobbin Weight R = Package radious r = Bobbin radious h = Height of packageNow , Package density = Mass / volumeHere , Mass = M – m = (1050 – 150) = 900And, Volume = π (R² - r² )* h = 3.14{ ( 16/2 ) ² - (6.5/2) ² } *15 = 3004 CcPackage density = M/V

= 900/3004 =0.30 gm/cm³

Production Calculation M/c speed : 1000rpmTotal no. of spindle : 960Efficiency : 85% (assume)Count (Ne) : 30 (assume) 

m/c speed * 60 * 24 * no.of spindle * efficiency * 1.09Production = -------------------------------------------------------------------

840 * count (Ne) *2.2024 

1000 * 60 * 24 * 960 * 0.85 *1.09= ------------------------------------------

840 * 30 *2.2024 

= 23077 Kg/day 

Package Yarn Length Calculation:Length =Count (Ne) X 1.69337 X Weight (gm) of yarnExample: If a package weight is 1000 gm & the yarn count is 24/1. then calculate the yarn lengthWe know, Length = Count x 1.69337 x weight = 24 x 1.69337 x 1000 = 40640.88 m

Production Calculation of Hydro-extractor : Total spindle x 60 x 8 x 3 x efficiencyProduction per day = ------------------------------------------------------ pcs Time per batch 48 x 60 x8 x3 x0.85 = ---------------------------------------- pcs 8 = 7344 pcs = 7 tones

Recipe For Multi Colour ShadeCount : 40/1 CombPackage weight : 1.100 KgMaterial : 10 KgLiquor : 50 L

•73- 009 (Navy) :Tank- 01Denkom BYB= 3.0 g/l = 150 gAlbatex DBC = 0.5 g/l= 25 gPermasol NF = 1.5 g/l =75 gSunfix Yellow SPD =0.558 % = 55.8 gSunfix Red SPD = 1.2408 % = 124.08 gSunfix Navy MFD = 3.74604 % = 374.604gGluber salt = 10 g/l =500 g Soda ash = 5g/l = 250 gCaustic = 1g/l = 50 gpH = 11.05

•45 – 003(Red) : Tank – 02Dencom BYB = 3.0 g/l = 150 gAlbatex DBC = 0.5 g/l= 25 gPermasol NF = 1.5 g/l =75 gSyno Yellow K-3RS = 1.305 % = 130.5 gSyno Red K-3BS = 3.69 %= 369.00 gSyno Blue K-BR = 0.0273 % = 2.73 gGlauber salt = 10 g/l =500 g Soda ash = 5g/l = 250 gCaustic = 1g/l = 50 gpH = 11.23

•08-060(Dark Grey) Tank – 03

Dencom BYB = 3.0 g/l = 150 gAlbatex DBC = 0.5 g/l = 25 gPermasol NF = 1.5 g/l =75 gSyno Yellow K-3RS = 1.041657 % = 104.1657 gSyno Red K-3BS = 0.5117 %= 51.17 gSyno N/B K-BF = 1.7424 % = 174.24 gGlauber salt = 10 g/l =500 g Soda ash = 5 g/l = 250 gCaustic = 1 g/l = 50 gpH = 11.49

•85 – 027 : Tank – 04 Dencom BYB = 3.0 g/l = 150 gAlbatex DBC = 0.5 g/l = 25 gPermasol NF = 1.5 g/l =75 gImco Yellow V - 4 GL = 0.007 % = 0.70 gSyno Blue KHL = 0.03 % = 3 gSyno Turquise HFG = 0.3 % = 30 g Glauber salt = 10 g/l =500 g Soda ash = 8 g/l = 400 gpH = 10.50

•No of injection = single •Setting : 90 % 30 Sec •No of plate = 01•Steaming : 98°c X 60 min •Pattern : Tank 01 = 73 - 009 : Tank 02= 45- 003 : Tank 03 = 08 – 060 : Tank 04 = 85 - 027

Recipe For one Colour Shade (Sky Blue )

Count : 30/1 P.CPackage weight : 1.00 KgMaterial : 18 KgLiquor : 50 LSky Blue (Kcyno:18484 ):Tank (01+02+03 )Balacon ECO = 3.0 g/l = 150 gAlbatex DBC = 0.5 g/l = 25 gPermasol NF = 1.5 g/l =75 gSyno Yellow K-3RS = 0.03 % = 3 gSyno Red HF-3B = 0.129 %= 12.99 gSyno Br. Blue KPL = 0.3627 % = 36.27 gGluber salt = 10 g/l =500 g Soda ash =15 g/l = 750 gpH = 10.50•No of injection = single •Setting : 90 % 30 Sec •No of plate = 01•Steaming : 98°c X 60 min •Pattern : Tank 01 +02+03=Color Tank 04=Water

Recipe For Colour Shade (Black + off white )Count : 40/1 CombPackage weight : 1.00 KgMaterial : 10 KgLiquor : 50 LBlack (Kcyno : 19850):Tank (01+03)Belacom ECO = 3.0 g/l = 150 gAlbatex DBC = 0.5 g/l = 25 gPermasol NF = 1.5 g/l =75 gNova Yellow S-3R = 0.85 % = 85gNova Deep Cherry -SD = 2.40 %= 240 gReactive Black VG = 19.0 % = 1900 gGlauber salt = 10 g/l =500 g Soda ash =15 g/l = 750 gCaustic =2g/l =100 gpH = 10.15•No of injection = single •Setting : 90 % 30 Sec •Steaming : 98°c X 60 min •Pattern : Tank 01 +03 = Black : Tank 02+04= Water

Recipe For Colour Shade (Black + Marun )Count : 40/1 100% ViscosePackage weight : 1.00 KgMaterial : 40 KgLiquor : 200 L

1) Black (Kcyno : 16373):Tank (01+03)Belacom ECO = 3.0 g/l = 600 gAlbatex DBC = 0.5 g/l = 100 gPermasol NF = 1.5 g/l =300 gNova Red .S2B= 0.45 % = 180gReactive Black VG = 9.75% = 3900 gGlauber salt = 15 g/l =3000 g Soda ash =30 g/l = 6000 gpH = 10.10

2)Marun (Kcyno:14784 ):Tank (02+04 )Belacom ECO = 3.0 g/l = 600 gAlbatex DBC = 0.5 g/l = 100 gPermasol NF = 1.5 g/l =300 gSyno Yellow .HB= 2.94 % = 1176 gSyno Red HB = 10.85 %= 4340 gSyno Navy.HB = 0.483 % = 193.20 gGluber salt = 10 g/l =3000 g Soda ash =30 g/l = 6000 gpH = 10.20

•No of injection = single •Setting : 90 % 30 Sec •Steaming : 98°c X 60 min •Pattern : Tank 01 +03 = Black : Tank 02+04= Marun

Shade Dye % Cost $/kg

Light 0.5-1.0 3

Medium 1.0-1.5 3.5

Dark 1.5-2.5 4

Special 2.5- above 5

Cost analysis of Yarn printing

Dyes Tank

• Preparation Tank :To prepare the dyes mixture for printing.

Dyes Cylinder

Inject Tank Cylinder To keep small dye mixture for injection.

Oil box

• connection from one part of machine to another part of machine with plastic pipe ( oil box & printing unit)

• Which help to injection.

Printing Device

• Bobbin Holder: Help to keep package of yarn .

• Printing needle: In B I D machine has 32 needles. Each needle contain 5 pores which passed dyes to package yarn.

Pannel Board

• Monitor: It is the major part of B I D machine. It controls all over process of yarn printing.

Dryer

• HYDRO EXTRACTOR: • Hydro extractor is an important

process stage of drying process as for as the yarn quality & process cost is concerned

Mainly steam/ hot air dryer is used for drying.

Radio Frequency Dryer allows

the drying of natural and man-made fibers in staple, hank, cone, package and top form normally immediately after hydro-extraction. The result is good uniformity and better final handling.

Controlling Parameter:• Dark Shade:- Double

Injection• Light Shade:- Single

Injection• Steaming Process:

98° C X 60 min for cotton

110 -120° C X 70 min for polyester

• Setting Inject Cylinder: 90% colour absorb overall 30 sec

• Ring Inject: Slub effect is possible

Dyes & Chemicals

• Levelling Agent • Sequestering

Agent• Antifoaming

Agent• Caustic• Hydrogen per

Oxide• Peroxide Killer

• Acetic Acid• Dyes• Salt• Soda• Washing Agent

(Detergent) • Finishing

Chemical

Different kinds of yarn count & various types • 20/1----60/1

cotton • CVC (Chief

Value of cotton)• Polyester • Viscose• Grey Millance • PC (poly cotton)

Printing process• Yarn store• ↓• Soft winding• ↓• Batching• ↓• Yarn printing machine• ↓• Adding dyes &chemicals

sequence• ↓

Steaming

• ↓• Machine wash• ↓• Neutralization

• Washing• ↓• Finishing• ↓• Hydro• ↓• Dryer• ↓• Hard winding• ↓• Packing• ↓• Delivery

Sequence for white Printing process

• Yarn store↓

• Soft Winding↓

• Batching Selection↓

• Package dyeing process↓

• Hydro Extractor↓

• Dryer ( radio frequence drayer)↓

• Re-soft winding↓

• Batching Section↓

• Bobbin Injection Dyeing m/c↓

• Steaming Process

• Neutralization↓

• Washing↓

• Finishing↓

• Hydro Extractor↓

• Dryer↓

• Hard Winding↓

• Packing Section↓

• Delivery Section

Sequence for Grey yarn printing process• Yarn store• ↓• Soft winding Section• ↓• Batching Section• ↓• Bobbin Injection

Dyeing m/c• ↓• Steaming Process• ↓• Neutralisation• ↓

• Washing• ↓• Finishing• ↓• Hydro Extractor• ↓• Dryer• ↓• Hard Winding• ↓• Packing Section• ↓• Delivery Section

Buyer

• H&M, • ACS textile, • Okaibi, • AKH knitting, • Bengal Harican, • Nobel Harican,• KCL etc.

Thanks To All