Dying First the fiber directly from the packet are taken out and weighed and then

they are put in the can pressed tightly and then water is put on them to make them develop in the mould. After this dye bath is prepared as per the dyeing requirement and can is put into the dye bath. And then dyed, polyester generally is dyed at 1350C. Process flow chart:

Buyers sample

NPD

Production planning departmen t

Master card

Dyeing machine

Crane

Carrier

Grey/dyed fibre

Prewashing

Dyeing

Drain

Reduction cleaning and again drain

Opener

Trolley

Hydro extractor

Acid wash and drain

Soaping and drain

Continous dryer

Spinning mill

There are various formats available in the dyeing section. In the unit basically yarn dyeing and fiber dyeing takes place.There is no dyeing of fabric. There were total 9 dyeing machines. 400 kg X 1 300 kg X 3 200 kg X 2 100 kg X 3 There is machine called hydro which removes water from the dyed fibers. In the contents of the dye bath there is water softener acid and color. Types of dyes used on fibres: Raw material Polyester Viscose,Cotton,Linen Acrylic Dye type Disperse dye Reactive dye Basic dye Temperature 135c 85c

ERP scheme for the dyed shades: Entrepreneur resource planning scheme consist of a five digit code as follow

series color Shade

SHADES 1. light 2.medium 3. dark 4.hard dark 5. extra hard dark 1. black

COLOR

2.coffee brown 3.navy blue/blue 4.yellow 5.green 6.red/ maroon 7. violet/ purple 8.melange 9.bleach/optical

For ex., if the ERP code is 461254 Then it means the shade is of Red/Maroon color of Hard Dark shade of series 254

Process of dyeing

PRETREATMENT BEFORE DYEING 1.Testing of water:- the water which is used in dyeing process should satisfy some practical parameter such as :a. T.D.S (Total Disperse Solid) b. Hardness of water c. pH Measurement of T.D.S- It is measured by TDS meter. It should be with in range i.e 400 ppm.

Measurement of Hardness:- Take 100ml water add one drop Total Hardness indicator blue colour appears, now add one drop of ammonia buffer now purple colour appears, now add N/50 EDTA solution drop by drop till colour changes to navy blue. Hardness should not exceed above 15 ppm. Calculation of hardness:10 ppm N/50 EDTA=10 ppm Measurement of pH pH is calculated by pH paper. pH should be 7 (neutral) for dyeing process.

Procedure of dyeing Steps of dyeing are as follows: Packing Process After dyeing Hydro Drying

A. Packing:The fibre is packed in a perforated carrier tank with the aid of water. S.N Capacity of m/c 1. 2. 3. 4. 5. 100 Kg 200Kg 400 Kg 50 Kg 300Kg Quantity Capacity of water 700 lit. 1400 lit. 2800 lit. 350 lit. 2100lit. Capacity of fibre Polyester 165 Kg 275 Kg 550 Kg 70 Kg Capacity of fibre Viscose 100 Kg 200 Kg 400 Kg 50 Kg

3 2 1 1 3

FABRIC TYPE Light Medium Dark Heavy Dark Extra Heavy Dark

TIME TAKEN FOR DYEING 2hr15min 2hr45min 3hr25min 3hr55min 4hr10min

B. ProcessThe dyeing process is carried out in dyeing m/c. The diagram below :C. After Dyeing:The following process are carried out after dyeing: 1. 2. 3. 4. Cold wash The dyed fiber is washed with cold water. Reduction- The reduction is carried out to remove extra dye and waste material. Soaping The fiber is washed with the aid of soap. Hot wash and acid rinse now the fiber is finally washed by hot water and acid i.e. Castic soda, Hydro castic, MC Lime and OR.

D.Hydro:Hydro is the process to squeeze the water from dyed fiber. It works on the principle of washing m/c. In 300 Kg capacity m/c the speed is 1300 rpm and the pressure is 1.5 Kg. By the rotation water is squeeze out. A motor is fitted to control the speed of m/c. E. Drying:Fiber taken out from hydro m/c is dried in dryers. PRECAUTIONS 1. The hardness, TDS and pH of water which is used in dyeing should be in required range. 2. The dye should be properly soluble. 3. The temperature rise should be slowly and steady. 4. The holding time in dye bath should followed strictly otherwise sublimation is poor and colour bleeding takes place. Faults in Dyeing process : The faults of textile processing are divided as follows: 1. Pretreatment faults : 21% 2. Dyeing & Printing faults :23% 3. Finishing faults :11% 4. Biological & machine faults :24%

5. Diverse faults :22% 70% of the faults can be attributed to the preparatory pre-treatment, because it is the first stage in processing and all other processes depends on its effectiveness and efficiency. Some of faults due to pre-treatment can be listed as under:

Poor absorbency Catalytic damage/poor fluidity Stains Moire effect Shade change from selvedge to selvedge Shrinkage/distortion Creasing/chafe marks Handling Inferior brightness/luster Cloudy dyeing Skitteriness Pale areas Darkspots Ropemarks

Most of the above faults could be easily corrected with the following precautions:

Use of speciality chemicals Select suitable heat setting temperatures Thorough relaxation of the material Controlled tension and uniformity of batching during pretreatment Checking for rough patches in the machine

The dyeing process which follows pretreatment depends on a number of parameters like:

Time Temperature

Conc. of chemicals and auxiliaries selection pH of the process etc