BATCHWISE PROCESSING

VIS –A- VIS

CONTINUOUS WET PROCESSING
INDIA’S STRENGTH &WEAKNESS
INTRODUCTION
BATCHWISE DYEING
THEORY OF DYEING
• Dye adsorption & diffusion through the fiber surface should be even
in level dyeing .
• Dye exhaustion is done by thermal diffusion to obtain level dyeing.
• Machinery used in batch wise dyeing are :
 Beam dyeing
 Jigger dyeing
 Jet dyeing
 Soft flow
 Package dyeing
• Increase in temperature leads to increase in rate of dyeing.
• Batch wise dyeing is highly recommended for medium & dark shades.
• Batch wise processing is suitable for only small batches(short length).
JET DYEING MACHINE
 Capacity - upto 400 kgs.
Material used – woven & knitted.
Its liquor ratio - very low( 1:1).
Dyeing temperature - high.
Speed of fabric - 300mts/min.
It is best suitable for batch wise processing.
Production /day is 12 batches.
Problems and Remedies
Problems
 Bulk to bulk variation in
shades.
 Tailing effect is produced.
 Face –back variation.
 Patchiness is seen.
 Crease marks formed.
 Reproducibility is difficult.
Remedies
 Checking desizing efficiency.
 Checking Absorbency after
scouring.
 Checking whiteness & residual
peroxide after bleaching.
 Hardness of water should be
>50 ppm.
 Maintaining of uniform
temperature & moisture
content during processing.
CONTINUOUS DYEING:
Continuous dyeing is suitable for bulk order fabrics.
Uniformity of shades is good.
It is best suitable for garmenting fabrics.
In continuous dyeing CDR is used for processing.
CDR stands for Continuous Dyeing Range.
Export quality goods are processed in CDR.
It is suitable for woven & open knitted fabric processing.
Effluent load is less.
In this process material is circulated or padded in dye.
PROCESS SEQUENCE OF CDR:
CURE

DRY THERMOSOL

PAD CHEMICAL STEAMING

PADDING
WASH &
DRY
WET
STEAMING
CONTINUOUS DYEING RANGE:
Material used - woven & open knitted fabrics.
Wet pickup decides machine speed.
CDR is mostly suitable for p/c blends.
To avoid variation dye solution prepared just before
dyeing.
VAT DYEING PROCESS SEQUENCE :
DISTINGUISHING METHODS OF PROCESSING:
S.No CONTINUOUS PROCESSING BATCH PROCESSING
01. Reproducibility is high. Reproducibility is low.
02. Suitable for garmenting. Suitable for tailoring.
03. Less energy required. More energy required.
04. Time required is less. Time required is more.
05. Chemicals used is less. Chemicals used is more.
06. Labour cost is low. Labour cost is high.
07. Less effluent load. High effluent load.
08. Process cost is less. Process cost is more.
09. Water consumption is less. Water consumption is more.
10. Steam required is less. Steam required is more.
11. Dye substantivity is less Dye substantivity is more.
12. Large space required. Small space required.
13. Faulty dyeing are not recovered. Faulty dyeing are recovered.
14. Benninger, Monforts & kusters etc Fongs ,Thies etc.
INDIA’S STRENGTH & WEAKNESS:
Strength :
Availability of raw material.
Wide range of cotton fibers available.
Flexibility of textile materials.
Competition in spinning sector.
Labour cost is low.
Man power is more.
India is biggest exporter of yarn in global market.
Well educated supervisory staff.
Well educated Technical & Managerial skills
Weakness:
Massive fragmentation in Indian Textile Industry.
Government & political diversity.
Government rules & regulations subsidiary schemes.
Fluctuating value of rupees.
Lac of Modernization & Automation.
Lac of innovation in global market.
Old technology or traditional machineries.
High power costs.
High capital costs.
Low economies of scale.
Low collaborative efforts.
CONCLUSION:
Continuous processing is required for “LARGE LOTS”
Batch wise processing is required for “SMALL LOTS”
We should overcome our weaknesses & show our
strengths.
Modify Indian scenario the “ Best”

“So batch wise & continuous textile wet

processing are complementary to each other”
QUERIES ?