Problems in dyeing and their

remedies








Source: New Cloth Market
Problems in dyeing and their remedies

Source: New Cloth Market

By: Pavan S. Chinta and Sapna Dhar

Abstract

The art of processing of textiles is not new aspect. As the time passes new processes, methods and
machines have been in use to improve the productivity and quality of the processed fabric. In the era of
energy and water saving and eco-friendly processing, to maintain the quality and cost has become tough
task. It is always found that 70% problems of dyeing are attributed to poor treatment of the fabric. Hence it
becomes necessary to give emphasis right from pretreatment to ultimate dyeing steps to achieve best
quality dyed goods. "RIGHT FIRST TIME AND ALL THE TIME RIGHT" dyeing quality can be easily
achieved by strictly adhering to process control parameters of each and every step of fabric processing.

In this paper an attempt has been made to highlight the various problems encountered due to men, machine
and other factors of processing for damage about the possible causes and remedies of these dyeing
problems helps the processes as a ready recockener for avoiding these problems.

Introduction:

The art of processing of textiles today is well known to all processors. In the past the organized sector
dominated the textile scene; whereas today the decentralized process houses are predominant. There is a
shift in emphasis from the requirements related to finished products to environment related requirements.
Requirements related to the finished product fastness & other properties of dyestuffs & chemicals,
processing etc. shift of emphasis environment related requirements, cost reduction, security, energy & water
saving, toxicology, hygiene legal regulations, and competitiveness.

Reduction in costs and utilities are achieved by the trend to telescope processes. In order to be competitive
processors would have to give equal if not better quality then the existing material at the same price.
Considering the energy and labour costs, the only means of maintaining a competitive edge is to lay
emphasis on 'Quality'. Good quality does not necessarily mean increased prices, but in fact would mean
"Doing it right the first time" thereby reduce the costs.

Thus with this theme in mind of "Doing it right the first time" we would have to first understand the problems
in the process of dyeing. So, this paper mainly discusses "Problems in Dyeing & its remedies".

The ultimate law of accuracy states, "when working towards a solution of a problem, it always helps if you
know the answer provided, of course you know there is problem".

Every manufacturing unit has a number of problems, however problem solving cannot be considered to be
astrology or palmistry, but it needs the fullest knowledge of basic facts.

The stages in the processing of textiles are:

GREY CLOTH

PRETREATMENT

DYEING

FINISHING

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
pretreatment, because it is the first stage in processing
and all other processes depends on its effectiveness and
efficiency. Some of faults due to pretreatment 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.












Remedies to above mentioned dyeing problems

Select dyes with better dispersion stability, use efficient dispersants.

Optimizing a dyeing process means adjusting the process parameters in such a way that the entire
operation takes place in the shortest possible time without exceeding the tolerance limits with regard
to reproducibility and levelness. This means rapid heating in the temperature ranges in which the
dye exhausts slowly or is already exhausted; controlled heating when the dye exhibits a particularly
high rate of exhaustion. The individual steps for an optimum dyeing process are:

Heat at the maximum rate to the threshold of the critical temperature rangeg t1(phasea)
o Control the rate of heating in the critical temperature range t1-t2(phase b)
o On reaching t2(upper limit of the critical temperature range) heat again at the maximum rate
to the fixation temperature (phase c)

Select optimum conditions and chemicals
Adjust the machine more carefully
Use antifoamers, e.g. Antimussol brands
Use special chemicals, e.g. Welting agent/defoamer combinations, or greater pressure
Adapt dye selection
o select higher dyeing temperature
o select suitable carriers and chemical
o possibly set fibres at a higher temperature (caution!)

Pay attention to perfect pretreatment
Pay particular attention to the ap-
propriate dyeing process and
programme
Select special dyes (smaIl-mol-
ecule)
Pay attention to stability of dye to
electrolytes
Pay attention to consistent dyeing
conditions
Carry out lab tests
Carry out preliminary tests with
material
Check and adjust dyeing
conditions
Pay special attention to dispersing
instructions
Pay attention to perfect liquor circulation
Pay attention to cleanness in the machine I
Select suitable carriers, use overhead heating in the machine
Use silicone-free defoamers
Drop dyebath hot, shorter dyeing time, use special chemicals
Complete removal of solvents
Do not store material near dyes;use low dusting dyes
Select more suitable dyeing m/c
Straight seams along weft 'and stitches
Avoid prolonged contact with the hot machine
Select suitable setting temperature
Check injection pipe or mount a distribution plate
Check rollers (pickup) regularly
Check temperature and air current over the entire width in the drier
Avoid migration by using lowest possible pickup and a suitable migration inhibitor.
Check fixation units regularly with thermo paper or temperature sensors.
Set roller in motion
Check shore hardness, if necessary re-cover rollers
Check temperature and air current in drying machine
Check the air jets

Trouble shooting during yarn dyeing:

Strength loss
Harsh handle
Channel building
Unlevel dyeing
Poor batch to batch reproducibility
Package deformation & yarn abrasion
Shade variation in Inner, Middle &.Outer layer

Remedies for problems in yarn dyeing:

Package density:
It is said that "well wound is half dyed". A uniform package density has to be ensured both within the package &
among the package to avoid channeling desirable density is approximately 300 g/1.

Angle of winding:
The standard of winding affects the quality of dyeing. Good winding produces a package of even densities with good
running off properties & minimum of end breakage. Package with cross winding are preferable.

Package size:
Uniformity of package size should be ensured before loading.

Perforation of spindle:
Choking of perforation on spindle hinders smooth & uniform flow of liquor leading to uneven results.

M:L Ratio:
It is defined as the ratio of dry material to liquor volume employed. When calculating liquor ratio, one should not forget
to include any addition made during dyeing process which may increase the volume. A proper MLR has to be
maintained during dyeing for consistency of batches.

Pump pressure:
The change in pressure after reversal of cycle should not be significantly high. Necessary action has to be
taken for smooth reversal & prevention of choking of pumps.

Entrapped air:
Complete air removal has to be ensured prior to pressure build up for uniform results.

pH, Temp. & Time:
Optimum values of those parameters have to be maintained during every stage of processing for best
results.

Conclusion

From the foregoing, it can be said that process control is one of the most effective managerial tool. The
extent of reprocessing on account of vigilance of process control in maintaining the processing parameters
at desired level can be reduced thereby maintaining quality & increasing the margin between production cost
and sales price.

References

Process control in yarn dyeing - R. Shrivastava
Towards zero defects - Amubhai Patel
Major fabric defects during chemical processing
Quality and Process control S.M. Doshi & HA Shah
Chemical technology of fibrous materials - F. Sadov
Technology of Dyeing V. A. Shenai
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About the Authors:

Pavan S. Chinta and Sapna Dhar are associated with D.K.T.E.'s Textile and Engineering Institute,
Ichalkaranji.


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