Skein Dyeing Machine/Arm Dyeing Machine | Working Process of SkeinDyeing Machine

This is the most suitable machine for dyeing delicate yarns (Silk, Bemberg, etc.) since it prevents the material being too tightly packed; in fact other skein dyeing systems frequently produce an excessive packing of the dyed material. The machine is equipped with horizontal arms perforated in the upper part; skeins are stacked and suspended on this rack. The liquor, forced through the arm holes, penetrates the skeins and is then collected in an underlying vat. Standard machines are equipped with a rod which moves the skeins at preset times, changing the bearing point to obtain a more uniform dyeing. During the skein motion, the flow of the liquor is stopped to avoid the formation of tangles in the yarn; since yarns are not fixed to rigid supports, they can thoroughly shrink. This machine does not run under pressure. It is possible to dye at steady temperatures since the liquor is contained in a separate tank. 

Skein Dyeing Machine

Modular skein dyeing machine with pullout arms. Pullout arms also allow the loading and unloading of skeins far from the dyeing machine, without manually intervening in the intermediate dyeing, squeezing and drying operations. It can be used for silk, cotton, viscose and Cashmere yarns.

The operating costs of this machine are generally very high because it require a very high liquor ratio (1:15 . 1:25 . 1:30 ). Standby times for loading and unloading operations are also very high and the arms must be often cleaned. This machine can be used also for scouring and finishing processes.

Some machine manufacturers have designed machines with slant covers to avoid unwanted liquor dripping on the skeins; the skein rotation is determined by the perforated arms, and not by the rotation of the skein-lifting device when the arm is stopped; it is therefore possible to eliminate the sliding contact with the skeins and preserve them perfectly.

There are also package dyeing machines with triangle-shape arms, arranged radially on a variable-speed rotor. When the dyeing process has terminated, the material can be centrifuged and dried, by forcing a hot air flow into the arms and through the skeins.

Winch Dyeing Machines | Working Process of Winch Dyeing Machines |Advantages/Limitations of Winch Dyeing Machine

A dyeing machine consisting essentially of a dye vessel fitted with a driven winch ( usually above the liquor level) which rotates and draws a length of fabric, normally joined end to end, through the liquor.

Winch dyeing machine

Winch dyeing machine is a rather old dyeing machine for fabrics in rope form with stationary liquor and moving material. The machine operates at a maximum temperature of 95-98°C. The liquor ratio is generally quite high (1:20-1:40). Winch dyeing machines are a low cost design that is simple to operate and maintain, yet versatile in application proving invaluable for preparation, washing or after treatments as well as the dyeing stage itself. In all winch dyeing machines a series of fabric ropes of equal length are immersed in the dye bath but part of each rope is taken over two reels or the winch itself. The rope of fabric is circulated through the dye bath being hauled up and over the winch throughout the course of the dyeing operation. Dyestuff and auxiliaries may be dosed manually or automatically in accordance with the recipe method.

A winch dyeing machine

Description and Dyeing Method on Winch Dyeing Machine
The basic principle of all winch dyeing machines is to have a number of loops or ropes of the fabric in the dye bath, these ropes are of equal length , which are mostly immersed in the liquor in the bath. The upper part of each rope runs over two reels which are mounted over dyebath. At the front of the machine , above the top of the dye liquor , is a smaller reel, which is called jockey or fly roller.

The fly roller remain free wheeling along with fabric rope. At the back of winch tank is the winch wheel, which pulls the fabric rope from the dye bath over the jockey reel for dropping in the dye bath for immersion. From the dropped location , the fabric rope travels back . to be lifted and fed to winch wheel.

The dyeing process on winch dyeing machines is based on higher M:L as compared with other dyeing machines. The process is conducted with very little tension . The total dyeing time is lengthier as compared to other machines.

Advantages of Winch Dyeing Machine
1. Construction and operation of winch are very simple.
2. The winch dyeing machines are suitable for types of wet processing operations from desizing to softening.
3.The winch dyeing machine is suitable for practically all types of fabrics ,which can withstand creasing in rope form processing.
4. Thr tension exerted on winch is less than jigger dyeing machine,the material thus dyed is with fuller hand.
5. The appearance of the dyed goods is clean and smooth on winch dyeing machines.

Limitations of Winch Dyeing Machine
1. Batch dyeing operations needs trimming, sewing, opening out the rope , loading and unloading for individual lots separately.
2. Since several lengths of fabric are run over the winch reel into the liquor and sewn end to end,Continuous length processing is not possible in a single batch.
3. Fabric is processed in rope form which may lead to crease marks , particularly in heavy , woven , thin and light synthetics.
4. Most of the machine work under atmospheric conditions.

Specification of Printing Machineries | Machines Used in TextilePrinting

1. Gas Heating Machine
Specification:
Company name : HEBBECHEKER
Model: TS-R
Volt: 400 H3
Power : E.L.KW- 2.2 Amp
Weight: 180 kg
Made in : Germany- 2005

2. Fabric Heating Machine
Specification:
Company name : HEBBECKER
Model No: Magic 5000
Volt: 400 H3
Power : EL.KW: 9.3 Amp
Weight : 44 kg
Made in : Germany-2005

3. Flock Printing Machine
Specification:
Model : VT-M-PP-0610-4645
Volt : 230 H3
Power : EL.Kw- 0.6 Amp
Weight: 980 kg
Made in : Germany-2004

4. Printing Table Heat Machine
Specification:
Model name : Heating carriage
Model no :-KZ02/0098J
Made in : Thailand -2002
Controlling point : Temperature
Controlling system : Manually

5. Curing machine (01)
Specification:
Company name : HEBBECHEKER
Model :VY-1500-4000-g-IR
Volt:400 H3
Power :El.kw-14.6amp
Weight : Kg-1500
Made in : Germany- 2004

6. Curing Machine (02)
Specification:
Model : KZ 04/0143
Made in : Thailand 2004
Temperature : 70-120°c ( very from fabric to fabric )
Controlling point : Temperature
Controlling system : Automatic

7. Curing Matching-(03)
Specification:
Model-KZ 03/0125
Temperature : 70-150°c ( vary from machine to machine )
Controlling point : time and temperature
Controlling system : Automatic and Manual
Made in : Thailand-2003

8. Heat Pressgng Machine
Specification:
Company name : Metalnox
Temperature : 120-190°C ( vary form machine to machine )
Controlling point : time and temperature
Time : 1-4 second
Controlling system : Automatic and manual.
Made in :JARAGVA DO SUL-SC in Brazil

Dyeing Process of Jigger Dyeing Machine | Working Process of JiggerDyeing Machine

Jigger Dyeing Machine:

Jigg or jigger dyeing machine is one of the oldest dyeing machine used for cloth dyeing operations. Jigger machine is suitable for dyeing of woven fabrics, up to boiling temperature without any creasing . Jigs exert considerable lengthwise tension on the fabric and are more suitable for the dyeing of woven than knitted fabrics. Since the fabric is handled in open-width, a jig is very suitable for fabrics which crease when dyed in rope form.

Jigger Dyeing Machine

Some wovens are conveniently dyed on jigger are ,

• Taffettas
• Plain wovens
• Satins
• Poplins
• Ducks
• Suiting and Shirting material.
• Sheetings etc.

But have limited application on fabrics which are tension sensitive such as crepes , flat crepes , knits , net fabrics and elastomeric warps etc.
 
Machine Description
The jigger machines have two main rollers which revolve on smooth bearings and are attached to with a suitable driving mechanism , which can be reversed when required. The fabric is wound on one of the main rollers and fed from the other. The fabric move from one roller to the other through the dye liquor trough located at the lower part of the machine . There are various arrangement of guide rollers at the bottom of liquor trough ,and during each passage the cloth passes around these guide rollers .
 
The concentrated dye liquor is usually introduced directly into the dyebath in two equal portions, which are added just before commencing the first and second ends. The liquor is agitated by the movement of the fabric through the dyebath. Several horizontal spray pipes are fitted across the full width of the trough in order to expedite fabric rinsing.
 
Live steam injected into the bottom of the trough through a perforated pipe across the width of the jig heats the liquor. Some modern jigs also have heat exchangers for indirect heating.
 
Covering the top of the jig minimizes the heat loss to the atmosphere, keeps the temperature uniform on all parts of the fabric and minimizes exposure of the liquor and the cloth to air. Minimizing exposure to air is important when using sulphur or vat dyes since these dyes can be oxidized by atmospheric oxygen.
 
A few meters of leading fabric, similar in construction to the cloth under process, is stitched to each end of the cloth batch , to allow the entire length of the fabric to pass through the dye bath during the dyeing process. When jig processing is completed, the fabric is run onto an A-frame via a nip or suction device to remove extraneous water during unloading.
 
Modern machines such as automatic and jumbo jiggers have full automation in drive , tension regulation and control , fabric speed and metering, smooth and jerk less stop and start , counters for number of turns , gradual and noiseless reversal, automatic temperature regulation and control etc.
 
Dyeing Process by Jigger Dyeing Machine:

The dyeing process on jigger is regarded as a series of intermittent padding operation followed by dwelling periods on the main roller , during which the dyeing action and diffusion takes place. The factors controlling the rate of dye absorption are:

1. The amount of interstitial dye liquor retained in the interstices of the fabric weave.
2. The exhaustion of the interstitial liquor in the dwell period between successive immersions.
3. The degree of interchange of liquor during one immersion (interchange factor).

In the dyeing on jigger machines the cloth revolves on two main rollers , The open-width fabric passes from one roller through the dyebath at the bottom of the machine and then onto a driven take-up roller on the other side. When all the fabric has passed through the bath, the direction is reversed . Each passage is called an end. Dyeing always involves an even number of ends. The dye bath has one or more guide rollers , around which the cloth travels , and during this immersion achieves the desired contact with the dye liquor. During this passage the fabric picks up adequate quantity of dye liquor , excess of which is drained out but still a good quantity is held in the fabric . During rotation of rollers this dye penetrates and diffuse into the fabric. The real dyeing takes place not in the dye liquor but when the cloth is on the rollers, since only a very small length of fabric is in the dyebath and major part is on the rollers . Therefore the speed of cloth during immersion in dye liquor has a very little effect on percentage of shade produced.
 
Some critical problems related to the conventional jigger dyeing machines ( which are minimized in the modern day machines) The major problems are side-to-centre color variations, called listing, and lengthways color variations, called ending.
 
Other problems are

• Temperature control from side-to-side and end-to-end of the roll
• Tension control from end-to-end
• Constant speed control from end-to-end
• Prevention of creases
• Prevention of air

Limitations of Jigger Dyeing

1. Jigs exert considerable lengthwise tension on the fabric and are more suitable for the dyeing of woven than knitted fabrics.
2. In textile preparation due to the swelling and dissolution of size, which makes the fabric slippery and unstable in roll form.
3. The low liquor ratio makes washing-off difficult.
4. There is little mechanical action in a jig machine and it is less suitable where vigorous scouring is required before dyeing.
5. Moiré effects or water marks may arise on some acetate and nylon fabrics because of pressure flattening the structure of the rolled fabric.

Engrave Roller Printing | Working Procdure of Roller Printing |Advantages/Disadvantages of Engrave Roller Printing Machine

Engrave Roller Printing
Roller Printing also called engrave roller printing. It is a modern continuous printing technique. In this method, a heavy copper cylinder (roller) is engraved with the print design by carving the design into the copper. Copper is soft, so once the design is engraved, the roller is electroplated with chrome for durability. This printing technique developed in the late 19th and early 20th centuries. Until the development of rotary screen printing; it was the only continuous technique. Designs with up to 16 colors present no problem in Roller Printing.

Main parts of Roller Printing

1.  Color doctor
2.  Lint doctor
3.  Blankets
4.  Back grey
5.  Furnishers
6. Color box / tray
7.  Color unit

Roller Printing Machine

Working Process of Roller Printing:

This machine has a main cylinder that is fitted with a large gear.In this printing, the print paste is supplied from reservoirs to rotating copper rollers, which are engraved with the desired design. These rollers contact a main cylinder roller that transports the fabric. By contacting the rollers and the fabric the design is transferred to the fabric. As many as 16 rollers can be available per print machine, each roller imprints one repeat of the design. As the roller spins, a doctor blade in continuous mode scrapes the excess of paste back to the colour trough. At the end of each batch the paste reservoirs are manually emptied into appropriate printing paste batch containers and squeezed out. The belt and the printing gear (roller brushes or doctor blades, squeegees and ladles) are cleaned up with water.

The Defects in the Engrave Roller Printing

1.  Scratches
2.  Snappers
3.  Lifts
4.  Streaks
5.  Scumming
6.  Lobbing

Advantages of Engrave Roller Printing Machine

1.  Higher production without rotary screen printing machine.
2.  14 colors can be used for printing.
3.  Medium design can be produced.
4.  Can be used for printing any style.
5.  Any color is used for printing without higher alkali or conc. acid.
6.  Repeats do not exist as printing is continuous.
7.  Higher production by using single color.
8.  Complex design is possible.

Disadvantages of Engrave Roller Printing Machine

1.  Large design is not possible.
2.  Generally, shedding fault is found.
3.  Higher coloring effect is not possible as like block printing.
4.  Lower production by using more than one color.
5.  Changing time is high. 
6.  Engraving the printing roller is expensive Operation

Difference between Rotary screen printing and Copper screen printing

Dyeing Machineries/Printing Machineries/Finishing Machineries | List ofConvensional and Modern Dyeing/Printing/Finishing Machineries

Dyeing Machine:

In the pre-industrial revolution time, dyeing, printing, finishing process were done manually or very convensional process. So amount of production was so little. By the change of time, changing the machineries in dyeing, printing and finishing section. As a result production has become high as well as quality also increased.

Yarn dyeing machine

Convensional and Modern Dyeing/Printing/Finishing Machineries list are given below:

In case of Dyeing:

• Singeing machine:

1. Plate singeing machine
2. Roller singeing machine
3. Gas flame singeing machine

• Desizing machine/ Padding mangle
• Kier boiling machine
• J-box bleaching bleaching machine
• Fiber dyeing machine
• Yarn dyeing machine
• Package dyeing machine
• Fabric dyeing machine
• Jet dyeing machine
• Jigger dyeing machine
• Padding mangle dyeing machine
• Beam dyeing machine
• Winching dyeing machine
• Hank dyeing machine

In case of Printing:

• Roller printing machine
• Rotary screen printing machine
• Flat bed screen printing machine

In case of Finishing:

• Yarn mercerizing machine
• Fabric mercerizing machine:

1. Pad chain type machine
2. Chainless type machine
3. Pad-Chainless type machine

• Brush damping machine
• Spray damping machine
• Embossing calendering machine
• Teasel raising machine
• Card wire raising machine
• Sanforizing machine