'Some of the process sequence with dyeing shade discussion for Continuous Dyeing Range machine (CDR)'



CDR machine is excellent machine for bulk order. Here bulk order more consistency will be there because material handing is very less. This is mostly used for woven and open knitted fabric (very less).


All bulk order can be successfully executed in CDR machine .For Example;-Govt Khakhi, School uniform, police uniform, exports bulk order etc.


Normal Process sequence:-


  1. Pad-dry cures .Example;-Pigment dye etc.


  1. Pad-dry-chemical padding-steaming-washing-drying. For Example;-Vat dye, Reactive dye (Vinyl sulphone), sulphur black etc.


  1. Pad-dry-thermosol .For Example:-Disperse/Reactive Dye and Disperse dye (selected dye otherwise staining chance will be there).


  1. Pad-wet steaming-washing-dry. For Example Selected Reactive Dye shades.


Above all process sequence No 2 process sequence is running smoothly for maximum shade.


Main Important Feature in continuous dyeing range machine can be divided into following section:-


a)    Dye padder- with CVC (Continuously Variable Crown) roller profile. This consists of two S-Rolls padding machine for minimizing centre side variation in fabric.


b)    Infra red drier - The fabric having high moisture content is passed through this zone to reduce the moisture content on the fabric ultimately to avoid migration of dye stuff.


c)    Hot flue Drier - The fabric is subjected to heat treatment gradually to dry or dye fixation depending on the machine configuration.


d)    Chemical padding section: - For reactive (vinyl sulphone) dye in chemical padding section.

 



Chemical Pad liquor.




For Dye conc. <20 gpl

For Dye conc. 20-40 gpl

For Dye conc.>40 gpl





Salt

250 gpl

250 gpl

250 gpl

Soda ash

20

20

20

Caustic soda (50%)

3

4

6

(ml/litre)





For vat dyeing caustic soda and hydroses chemical will be taken in chemical padding section.


These we can see bottom some of the successful recipe running in shop floor.


e)    Steamer:-For Reactive dyeing and vat dyeing steaming temperature at 100-105 degree Celsius (time of contact 15 to 25 minute).


f)     After washing section or soaper machine section.


g)    Vertical Drying range.


h)    Inspection and Batching section:-For printing batching arrangement can be done for finishing in trolley we can be stored.


Here we will discuss some of successful bulk shade discussion which I have seen during my career which will give better picture for CDR machine result.

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Vat Dye some shade for close observation:-


Govt Khakhi shade:-


Quality: - Cotton Woven Fabric Shade:-Khakis

Count:-14 count


Recipe:-

Vat Olive T=2.63 gpl.

Vat Yellow 3RT=3.15gpl.

Vat Brown BR=0.42 gpl.

Antimigating agent=1 gpl

Crypto anionic wetting agent=2 gpl.

Dye Pick Up:-=61.58%

Speed=18 -20 meter/minute.


Chemical Padding:-

Caustic soda/Hydroses=20/20 gpl

Padding pressure=0.5 kg/cm square.


Oxidation:-

Hydrogen perioxide(130 vol)=2-3 ml/litre.

Acetic acid (80%) =1-2 ml/litre.

(Tempature:-5060 degree Celsius)


Pad-dry-chemical padding-steamer--- washing---oxidation--soaping--hot wash-hot wash--wash---drying.


 

School Uniform (Navy Shade):-


Quality:-Cotton Woven Fabric                   Count:-14

Shade:-Navy.


Vat Navy VH=26 gpl.

Vat Black 2BAN=5.5 gpl.

Antimigrating agent=1 gpl.

Crypto anionic wetting agent=2 gpl.

Dye pick up=60-65%

Speed=18-20 meter/minute.

Caustic soda /Hydroses=35/40 gpl


Process:-Pad---dry----chemical padding-steamer- washing---oxidation soaping---hot washhot wash---cold wash--drying.


School Uniform (Blade blue)

Quality:-cotton twill woven fabric              Count:-20 count

Shade: =Blade blue


Recipe:-

Vat Blue BC=13 gpl

Vat Green FFB=1.5 gpl.

Antimigrating agent=1 gpl.

Crypto anionic wetting agent=2 gpl.

Caustic soda/hydroses=35/40 gpl

Process:-Pad---dry----chemical padding-steamer- washing---oxidation soaping---hot washhot wash---cold wash--drying.

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Sulphur Black shade for close observation:-


For Cotton Twill quality (Drill quality).


I)  Sulphur Black dye (grain) =95 gpl

    Crypto-anionic wetting agent=2 gpl

    Antimigrating agent=10 gpl

    Padding----drying-----Chemical padding


II) Chemical Padding:-

    Soda ash=20 gpl

    Sodium Sulphide=95 gpl

    Padding steaming cold wash-oxidation.


III) Oxidation:-

     Potassium dichromate=5 gpl

     Acetic acid=2 gpl

     (50-55 Degree Celsius)


IV) Soaping;-

     Soap=0.5 gpl

     Soda ash=0.5 gpl

     (85-90 Degree Celsius)--------hot wash- hot wash-cold wash-drying.


Final process: - Dye Padding----drying in hot flue drier---chemical padding---steaming cold wash----oxidation----soaping----hot wash----hot wash ----cold wash-----drying and batching for finishing.


(For Fabric neutral PH if required slight acetic acid can be taken in last washing tank)

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For Reactive dye some shade for better picture of CDR machine:-


1) Orange shade:-


Quality;-12 * 10 cotton count twill quality. Weight/meter=470 gram.

Dye padding recipe:-

Reactive orange M2R=75 GPL.

Reactive Yellow M8G=4.5 GPL.

Urea=100 gpl.

Resist salt=10 gpl

Antimigarating agent=1 gpl.

Crypto anionic wetting agent=2 gpl

Chemical padding recipe:-

Common salt=250 gpl.

Soda ash=20 gpl.

Process;-Dye paddry---chemical padding----steaming---washingdrying.


2) Sky blue shade:-


For cotton poplin quality (40 counts):-

Reactive Blue RN;-0.18 gpl

Urea=50 gpl

Sodium bicarbonate=30 gpl

Resist salt=10 gpl

Speed=32 meter/minute.

Pad---wet steaming---washing---drying.


For pigment dyeing some example for better picture:-


3) Green Shade;-


Count=14 count cotton twill quality.

Dye padding recipe:-

Pigment Fine CB=12 gpl

Pigment green ck=45.2 gpl

Pigment T.Blue CBN=3.2 gpl

Binder=50 gpl

DAP=5 gpl

NH4CL=5 gpl.

Speed=18 meter/minute.

Curing temp=150 degree Celsius

Time of contact in curing machine=2 minute and 45 second.

Process;-Padding -----Drying and curing.


From above mentioned recipe we have not gone to detail discussion for process parameter, dyestuff selection and machine section of CDR it is just a process idea for CDR machine which I have seen successfully running hence first sampling has to be done then recipe has to be set in CDR machine .This has to be done from expert view only.

Note: - This Article has been written in good faith for problem solving altitude purpose and sharing of shop floor experience.


Reference taken for machine part description:-



About the Author:


The author is the Product Manager (Reactive Dyes) in Colourtex. Ind. Ltd having 12 years production of experience in cotton, polyester and its blend quality in India and overseas reputed company.