DYEING SECTION PROCESS CONTROL OF ROPE DYEING (Part I) (Pure Indigo/Bottoming/Topping)

DATE LOT NO WT. OF FABRIC YARN COUNT YARN MILL PARTY NAME NO. OF BALLS
SAMPLE

:___________________ :___________________ :___________________ :___________________ :___________________ :___________________ :___________________ ACTUAL METERS

Countermtr)

START FINISHED
TOTAL LENGTH (MTRS.)

TOTAL ENDS # OF ENDS /BALL SPEED

:______________ :______________ :______________ :______________ :______________ :______________ :______________

TYPE OF DYEING % INDIGO: # of dips:

MERCERIZED BAUME : __________ Be CONC. OF SULFUR : _____ # of dips :_____

DYEING SEQUENCE : _______________

TIME

SOURCE (Dyebox #)

INDIGO FREE CONC. HYDRO (gpl) (gpl)

pH

FEEDRATE DF Chem. (lpm) (lpm)

REMARKS

Standard Chemistry Control

STOPPAGES / ABNORMALITIES :

TIME
STOPPED

COUNTER

LENGTH AFFECTED

METER

1ST

SHIFT

2ND

SHIFT

3RD

SHIFT

LABORATORY TESTER ________________________ _____________________ _______________________

_______ Be # of dips :_____

_____________

TIME
RESUMED

HIFT

____________

PROCESS CONTROL OF ROPE DYEING (Part II) (Pure Indigo/Bottoming/Topping)

Date Lot No. / RDS # Customer's Name :_____________ Yarn Count :_____________ Wt. Of Fabric :_____________ Speed :_____________________ :_____________________ :_____________________

PARAMETER TO BE CHECKED : I . Pre-treatment : (Before Usage)

Mercerizing Pre-wet Bottoming/Topping FOR BOTTOMING/TOPPING/BLACK

Time

Tank No.

pH

pH

ORP

II . OTHER PARAMETERS (In Process) Source :

FOR MERCERIZED
Mercerized Box
WB before dyeing
Lubrication Box

SULFUR BLACK
Feedrate (lpm)

Time
Baume (Be)

pH

pH

pH

pH

ORP

Initial for Black Standard

1st SHIFT
Production Supervisor

2nd SHIFT _______________

3rd SHIFT ____________

_________________

DYEING SECTION PROCESS CONTROL OF ROPE DYEING (Pure Black)

DATE LOT NO WT. OF FABRIC YARN COUNT YARN MILL NO. OF BALLS PARTY NAME :______________ :______________ :______________ :______________ :______________ :______________ :______________ ORP pH (mV) ( BLACK ) :______________ % BLACK: # of dips: :______________ MERCERIZED BAUME : __________ Be TOTAL LENGTH (MTRS.) :______________ CONC. OF SULFUR : _____________GPL TOTAL ENDS :______________ # OF ENDS /BALLS :______________ DYEING SEQUENCE : ___________ ______________ SPEED :______________ Black Feed
(Li/Min.)

START FINISHED

TIME

SAMPLE ACTUAL SOURCE METERS

(Dyebox #) (Countermtr)

pH (Merc.)

pH (WB)

pH
(Fixatn.)

pH
(Softener)

REMARKS

Standard Chemistry Control

STOPPAGES / ABNORMALITIES :

TIME
STOPPED

COUNTER METER

LENGTH AFFECTED

1ST

SHIFT

2ND SHIFT

3RD

SHIFT

LABORATORY TESTER ______________________ _____________________ _______________________

__________ Be ____________GPL

CE : ___________

EMARKS

TIME RESUMED

RD

SHIFT

________________

ROPE DYEING PARAMETERS & CONTROL MONITORING REPORT

Date Lot No./ RDS No. Type of Dyeing

: : :

Squeezing Pressure (psi) Box No. Function Bottoming/ 1 Pre - wet/ Mercerizing 2 3 4 5 6 7 8 9 10 Washing Washing Washing Dyeing Dyeing Dyeing Dyeing Dyeing Dyeing/
Black Topping

Temperature Target 85 - 90 C Room Temp. Room Temp. 55 - 60 C 55 - 60 C Room Temp. Room Temp. Room Temp. Room Temp. Room Temp. Room Temp. Room Temp. 85 - 90 C Room Temp. 55 - 60 C 50 - 60 C 55 - 60 C 55 - 60 C Actual

Target 65 psi 80 psi 80 psi 60 psi 60 psi 70 psi 70 psi 62 psi 62 psi 62 psi 62 psi 70 psi 70 psi 60 psi 60 psi 60 psi 70 psi 70 psi

Actual

11 12

Washing Washing/ Fixation

13 14

Washing Lubrication

PARAMETER Air Pressure (Main)

Target 6.0 Bars min.

Steam Pressure (Main) 6.0 Bars min.

Checked by

: Laboratory Tester

Noted by

: Rope Dyieng Supervisor

REPORT

REMARKS

Actual

ROPE DYEING OPERATION START-UP CHECKLIST

FREQUENCY : Start-up Operation

Date :

ITEMS TO BE CHECKED
I. STEAM SUPPLY a. Main supply ( __psi minimum) b. Open main and individual supply of drying cylinders - Mercerizing Box - Washboxes - Dyebox # 6 (if required) - Softener II. WATER SUPPLY a. Open line in individual washboxes b. Open slightly drain valve of individual washboxes III. AIR SUPPLY a. Main supply (6 bars min.) b. Open air line valve of individual nip rollers (Box 1-14) c. Push button of squeezing pressure of each nip rollers and set to required pressure (Box 1-14) IV. CIRCULATION a. Open and check all pipeline valves needed b. Switch ON pump to be used V. DYE,CHEM'L AND AUXILLARY FEED a. Open pipeline valves b. Switch ON pump to be used VI . PRE-TREATMENT / BOTTOMING a. Open pipeline valves VII . SOFTENER a. Open pipeline valves VIII . CONTROL PANEL BOARD a. Temperature Settings b. Pumps in use c. Speed

READY FOR USE

NOT APPLICABLLE

REMARKS

Checked by : Supervisor

Noted by : Production Head

ROPE DYEING POST OPERATION CHECKLIST

FREQUENCY : Post Operation

Date :

ITEMS TO BE CHECKED
I. STEAM SUPPLY a. Close main and individual supply of drying cylinders b. Close individual pneumatic steam valve of the following: - Mercerizing Box - Washboxes - Dyebox # 6 (if required) - Softener II. WATER SUPPLY a. Close line valve of individual washboxes b. Drain water of all washboxes III. AIR SUPPLY a. Release button of squeezing pressure of each nip rollers (Box 1 - 14) b. Close air line valve of individual rollers (Box 1-14) IV. CIRCULATION a. Switch OFF pump used b. Close pipeline valves c. Drain Auxillary in the Box V. DYE,CHEM'L AND AUXILLARY FEED a. Switch OFF pump used b. Close pipeline valves c. Drain Auxillary in the Box VI . PRE-TREATMENT / BOTTOMING a. Close pipeline valves b. Drain Solution in the Box VII . SOFTENER a. Close pipeline valves b. Drain Solution in the Box VIII . CONTROL PANEL BOARD a. Switch OFF dye range powwer on panel board after transferring of dyeing liquor.

CLOSED/ SHUTOFF

NOT APPLICABLLE

REMARKS

Checked by : Supervisor

Noted by : Production Head

ROPE/ SLASHER DYEING RECIPE SAMPLE FORM

Date : Subject :

BASED : 1.0 MATERIAL Yarn count Party Name Total Ends Weight of Material Speed 2.0 DYEING Type of Dyeing Mercerized Baume % Indigo Dyeing Chemistry Contro l Indigo Free Hydro pH ORP Indigo Dye Feed Chemical Feed Hydro NaOH

: : : : :

RDS No. : 1.0 MATERIAL Yarn count Party Name Total Ends Weight of Material Speed 2.0 DYEING

: : : : :

: : : : : : : : : :

Type of Dyeing Mercerized Baume % Indigo Dyeing Chemistry Contro l Indigo Free Hydro pH ORP Indigo Dye Feed Chemical Feed

: : : : : : : : Hydro NaOH : :

Topping/Bottoming/Pure Black/ Mercerizing

Topping/Bottoming/Pure Black/ Mercerizing

Initial Sulfur Black BR-200 Sulfur _______________ Reducer (Sodium Sulphide) Wetting Agent Caustic Soda 50% Volume Black Feed Rate Dipping Time of Black : : Initial
Belsoft 200 Volume Temperature :

Feed Sulfur Black BR-200 Sulfur _______________ Reducer (Sodium Sulphide) Wetting Agent Caustic Soda 50% Volume Black Feed Rate Dipping Time of Black : :

Box

Feed

Lubrication:
Feed

Lubrication:
Initial
Belsoft 200 Volume Temperature:

Feed

Prepared by : ___________________

Approved by : ___________________