Raising the IQ of the Dyeing Machine
By Wayne D. Fretland, Gaston County Dyeing Machine Co., Stanley, N.C.
aising the IQ of the dyeing ma-
chine is the elimination and con-
trol of variables by utilizing available
technology in machines andcontrols.
Materials, manpower, methods and
machines’ are focused on in problem
solving when themanufacturing objec-
tives are not met. The success of any
operation depends on managing these
four variables with the most important
factor being the degree of control estab-
lished over the process variables. Uti-
lizing technology that is directly process
oriented is a method of accomplishing
this control a-nd ensuring success.
Sources of the variables will fall in
more than one of the four categories.
Take pH for instance, a relatively
straightforward item, a measure of
ABSTRACT
To a great extent, traditional batch
dyeing machine and controller
designs have relied heavily upon
an operator to control process
variables to achieve the desired
results. The result has frequently
been less than desired, with poor
shade matches, reworks or off-
quality goods resulting in reduced
profits due to lost production and
the cost of correcting the problem
goods.
Today’s integrated dyeing sys-
tems put sophisticated hardware
and software designto good use in
removing variables from the opera-
tion. “Smart dyeing machines” are
capable of consistently delivering
an unprecedented level of dyeing
operational control. Critical pro-
cess variables can be categorized
in four broad areas-machines,
materials, manpower and methods.
The primary focusof this paper is
on the machine, with improve-
ments in machine controls having
a positive impact on the remaining
three process variables.
KEY TERMS
Controls
Dyeing Machinery
Problem Solving
Process Control
Technology
January 1995
acidity or alkalinity. All textile pro-
cesses are pH dependent to some de-
gree; some only require the process to
he alkaline or acidic while others re-
quire a narrow pH range to obtain the
desired results.2
In the plant as the dyer stands in
front of an inspection frame or in a
shade room examining problem goods,
many questions are running through
his mind as he searches for the cause
of the defect. If pH is known to be a
critical control pointfor the process in
question, the dyer will he asking a se-
ries of questions.
Has the strengthof the acidor alkali
changed? (materials related)
Was the acidor alkali weighedprop-
erly? (manpower related)
Was the pH checked correctly, was
the beaker clean, was the pH meter
calibrated? (methods related)
Very possibly the only reliable in-
formation he has is a batch ticket
which shows only that goods the were
processed on Thursday onMachine 13.
This lack of essential information can
be changed and needs to be changed.
The best solution is to control the pH
to a degree that these questions do not
need to be asked.
A very large number of dye ma-
chines in use today were built years
ago when thetechnology did notexist
or were purchased without the tech-
nology. While many of these machines
are doing an adequate job, they only
recognize the variables of time and
temperature and have to he classified
as morons, or to be more politically
correct,as“technologicallychal-
lenged.’’ Technology can upgrade ma-
chine I Q to average or bright or even
genius.
Considering the Alternatives
pH Control
The control of pH is an example of
what can be accomplished by using
current technology at different levels
of capability and complexity.
Monitoring is the first level of con-
trol. Usually the operator is required
to check the pH by taking a bath
sample and carrying it to a pH meter,
generally in a remote location. The
smart machine has pH a sensing device
installed as part of the machine, with a
self-adjusting, self-diagnostictransmit-
ter ensuringreliable data. Thefirst level
of capability wouldbe a visual display
of the pH near or on the machine, thus
saving considerable operator time.
Automatic monitoring, with an ap-
propriate controller, would allow the
gotno-go decision to be based on a pro-
grammed value or range, with the con-
troller automatically comparingthe pH
against the programmed acceptable
range. If the pH is within the accept-
able range, the controller proceedswith
the process. If a no-go situation is en-
countered (pHis outside the range), an
appropriate alarm would advise that
intervention is necessary to correct or
override the deviation.
Automatic control is the final level;
a total hands off automatic pH control.
With the sources of acid and alkali
available to the machine, the control-
ler then makes the appropriate add,
makes the gotno-go decision and auto-
matically adjusts for a no-go situation.
What has been accomplished is that
all the variables that can affect pH, that
is, materials, manpower, methods,have
now been broughtunder controlby the
machine. Not only is there a positive
effect on quality and reproducibility
but a manual step in the process has
been eliminated with subsequent ben-
efits in efficiency and productivity.
As for our dyer scratching his (or
her) head back in the problem goods
area, life has been made a little easier
by either providing answers to the pH-
related questions, or by even making it
unnecessary to ask them. The follow-
ing questions nolonger go through their
minds.
Who checked the pH?
What was it?
Was it right?
Salt Concentration
Another key variable, especiallyin dye-
ing cellulosic fibers is salt concentra-
tion or salinity. Control of this variable
can be handled in much the same man-
ner as pHcontrol, by adding a conduc-
tivity probe to the machine.
23

In someways,themethods of
manually determining salt concentra-
tion are even trickier than pH measure-
ment with respect to method and man-
power variables. Use of the salimeter
is time-consuming, and measurement
of the sample temperature and inter-
pretation of the salimeter [hydrometer)
reading is critical for obtaining good
data. In the case of most direct dyes,
the salimeter isn’t evenuseful to mea-
sure the salt levels employed for these
dyes. As with pH, various methodsof
monitoring and control can be used to
increase the capability of the machine.
Monitoring requires the machine to
be equipped with a visual display of
the conductivity reading, but the op-
erator must be trained to interpret the
data against a conversion chart,or the
display must be calibrated to show
bath concentration.
Automatic monitoring allows the
machine tomake the go/no-go decision
based on an acceptable range already
defined in theprogrammed procedure.
The machine gives an alarm when out
of range, requesting the operator to
make the decision to either adjust the
salt concentration or manually over-
ride the alarm.
Automatic control is reached when
the machine is connected to a salt
source, allowing automatic adjust-
ments until the salt concentration is
correct, without operator intervention.
The dyer nolonger needs to ask the
following questions.
Did someone check the salt?
Was it checked properly?
What was it?
Rinse Cycle
At the front end of the process, saltand
pH monitoring greatly aid in achiev-
ing consistent startingconditions from
batch to batch, improving quality and
repeatability. On the tail end of the
procedure, additional process optimi-
zation for washes and rinses can be
achieved when pH and salinity moni-
toring devices are used. Rinses can be
set to terminate when a desiredpH or
salt concentration havebeen reached.
This isparticularly useful when water
supplies are insufficient, unreliable,
restricted or expensive.
The following questions now be-
come obsolete.
Was all the salt washed out before
the soap?
Was the bath “neutral” before the
fix?
Liquor Flow Rate
An important factor in a package dye-
ing machine or in any machine where
the goods are stationary and the dye
liquor is pumped is the liquor flow
24
rate.3 With the additionof a flowmeter
to the machine, the flow can now be
measured directly instead of interpret-
ing indirect flow indicators such as
differential and pump discharge pres-
sures. When flow can be controlled,
the greatest benefit derived is in pro-
cess optimization. Knowing the vol-
ume of the machine and the flow, bath circulate one time) in piece dyeing is
turnovers are easily calculated. With
performance and exhaustioninforma-
tion from dye manufacturers, bath
turnover data can be utilized to im-
prove quality and efficiency. The rate
of increase in bath temperature and
time required for circulation steps can load, yield, etc. The smart machine
be determined using bath turnovers
rather than minutes.
Several questions will no longer
need to be asked.
What is the flow?
What is the bath turnover time?
Was there enough flow for the rate
of temperature rise?
Was the hold time sufficient to
achieve equilibrium?
Differential Pressure
Another methodof controlling flowin
a package dyeing machine is withdif-
ferential pressure (dP). This is espe-
cially important when dealing with
variations in load size and package
density. With the additionof a device
to measuredP, thepressure drop of the
liquor passing through the resistance
of the package can be accuratelymoni-
tored.*
The next step to control the dP re-
quires that the smart machine be
equipped with variable speed drive.5
The machine can thus adjust to the
changing dynamics of the system-as
the package gets more dense or as the
package gets less dense, as is the case
in rayon and acrylic dyeing, respec-
tively. This will also compensate, to a
degree, if bypass occurs during the
cycle. An added benefit of slowing the
pump during flow reversal results in
less yarn damage, which is often seen
in machines when the flow direction
is changed abruptly.
Somepackagedyeingmachine
manufacturers have produced produc-
tion machines which dye both rayon
and wool successfully in the same
machine. Thiscapability requires pre-
cise f€ow control to both penetrate
dense rayon packages as well as dye
the wool while maintaining thepack-
age integrity so that backwinding the
wool isn’t necessary.
The following questions no longer
need to be asked.
Is there enough pressure to penetrate
the package?
Is there excessive flow, risking fiber rors are eliminatedand chemical waste
damage?
E
Is the pump cavitating?
Turnover Time
Just as flow and differential pressure
are key control points for successful
package and beam dyeing, control of
strand turnover time (the time takesit
for the strand in a given chamber to
equally critical. The smart piece dye-
ing machine will vary the lifter reel
speed and jet pressure to achieve a con-
sistent turnover timefrom load toload,
automatically compensatingfor
changes in the strand length due to
will also monitor the strand turnover
time to makeautomatic adjustmentsto
ensure consistency from chamber to
chamber, even with load differences
between the chambers.
The dyer no longer needs to askthe
following questions.
Was the fabric running during dye
exhaustion?
Was it running fast enough?
Is the port-to-port shading due to
slow fabric speed?
Mix Kitchen Tanks
The next feature of the smart machine
involves the chemical/dye mixing area.
The advantages offered in automatic
drug room tanks lie primarily in the
realm of quality. When the common
variables are taken awayby providing
the machine with automatictempera-
ture control, automatic level control
and automatic mixercontrol, improve-
ments in quality result.
Depending on the size of the mix-
ing tank relative to the machine, the
drug room adds can have a significant
effect on the machine’sfinal liquor ra-
tio. With automatic drug room tanks,
the volume added with every drop is
known andconsistent and thedyer can
compensate to eliminate that variable.
The following questions are now
obsolete.
Was the dye mixed at the proper
temperature?
Was there enough water to mix the
dye properly?
Did the dye mixlong enough before
being added?
Chemical Metering
A logical extension whendealing with
drug room variables is chemical me-
tering. Chemical metering is the pro-
grammed, automatic,metered delivery
of a chemical from a bulk source to a
certain destination, suchas a mix tank,
charge tank, side tankor kier.
One of the main advantages to
chemical metering is that weighing er-
is minimized, which has an enormous
Vol. 27, No. 1
impact on chemical cost reduction. Do I have enough water? Materials
Also, as stricter guidelines for the use Are the goods “clean”? Almost every dyeing operation has a
and handling of chemicals are im- testing area to ensure that the raw ma-
posed, chemical metering minimizes Process Related Controls
terials (dyes, chemicals, water and
employee exposure to chemicals, thus Many of the smart functions discussed goods to be dyed) meet the necessary
reducing the needfor employee expo- have been made possible through the standards for fitness for use. The ma-
sure monitoring, protective equipment, speed andpower of modern computer- chine hasvery little controlover these
etc. Elimination of drum handling, based and PLC-based controllers. The variables; however, by use of controls,
storage and disposal is accomplished growth and changes in thefield of com- the machine can compensatefor den-
through the use of totes and bulkstor- puters have given us the ability to ob- sity differences from load’to-load or
age tanks whichare an integral part of serve and control the process to an ex- fiber-to-fiber and for insufficient wa-
chemical metering systems. tent that was notpossible or was cost ter or steam. The computer can make
The following concerns are reduced. prohibitive in the not so distant past. adjustments for dye and chemicaldif-
Was the correct chemical weighed? When the smartmachine/controller ferences and allow the machine to
Wasthechemicalweighedcor- is interfaced with a central hostlsuper- adapt to the dynamics of the systemas
rectly? visor system, the process-related con- the goods swell or shrink or get softer
Was the chemical actually addedto trol can be expanded to include sev- or harder.
the machine? eral other concerns in manufacturing.
When? Manpower
Where can the drum inventory be DyeKhemical Weigh
Room Supervisor
There are countless training and hu-
stored? man resource managers striving toim-
How can empty drums be disposed? Scales can beinterfaced with the host, prove the level of training and educa-
with a screen indicating the chemical tion of the people responsible for the
Liquor Ratios and the amount to be weighed. The operation andperformance of the dye
Liquor-to-goods ratio is a variable computer requiresdrum verification of machines. Thesuccesses are frequently
which is critical, hard to control and the productbeing weighed and will not cancelled by absenteeism and turn-
most often ignored. However,constant accept a weightoutside a specified tol- over. With a smarter machine, human
liquor ratios are possiblewith the cur- erance of the target weight. In addition intervention is minimized resulting in
rent technoley. With the proper con- the hostmakes automatic adjustments a minimalnumber of human errors and
troller and devices to measure levels for strength differencesto the standard the minimization of training require-
or quantities, dyeings become more on dyes andchemicals. ments.
obtainable. These machinery controls These controls reduce two con-
are a mustin any dyehouse even think- cerns. Methods
ing of adopting a “no-add” approach. What was weighed? A highly technical area is involved in
With accurate levelcontrol, a smart Was the correct amount weighed? recommending procedures and prac-
package dyeing machine can dye vari- tices. Theperformance potential isre-
able load sizes atthe sameratio, greatlySteam Supply and
Demand Monitoring
flected by the training, abilities and
increasing a package machine’s versa- expertise of the technical person or
tility. This approach also works with With the host system monitoring the staff. With “smart machine” technol-
piece dyeingmachines to obtain a con- plant steam supply to the dyehouse, ogy there is a great degree of confi-
stant ratio when the batch-to-batch the process for a scheduled batch will dence that the procedure was followed,
load sizes areconsistent. With a flow- not be started if the current steam sup- allowing changes to be evaluated on
meter to measure water delivery,ratio ply is inadequate to meet the pro- their variability alone. As additional
fills can be used to deal with inconsis-grammed ramp rate. This ensuresstrict controls are implemented into dyeing
tent loads. Flowmeters alsoreduce the adherence to the process and allows procedures, reproducibility and qual-
impact of varying water availability or the host system to activate a back-up ity are improved.
pressure during overflow washing. steam supply on demand. Obviously there are many more
Questions nolonger asked are: Two additional questions the dyer benefits to be realized from comput-
Was the formula adjusted for that no longer needs to ask are: ers and controls that are less process
machine’s volume? Was the rateof rise right? related and more data oriented. These
What is the effect of the liquor ratio Was the run timeexceeded because include inventory control, formula
difference? the ending temperature requirement andproceduremanagement,cost
How much can the liquor ratio was not satisfied? analysis, graphs and numerous reports
change before the formula must be to assist management. Thisis beyond
changed? Supervision of
All Machine Controllers
the scope of this paper and is more
Shouldchemicalsbebasedon consistent with raising the IQ of the
weight of goods or weight of bath? When the host system monitors all of total operation.
the machine controllers, it provides
Final Rinse time and warnings for operator inter- Summary
Most of the water used in any wet pro- vention for problems or changes. It Of the four variables that have an in-
cess is forrinsing,washingand warns operators through monitors and fluence in the quality of the dyeing
cleanup. Improved rinsing methods in display alarms when procedure crite- produced, this paper has focused on
package dyeing and inpiece dyeing are ria are not being met. The display is the machine aspect.As can be seen by
used by the smart machineto provide color-coded to prioritizethe operator’s the questions that no longer need to be
significantly more efficient washing, response to the alarms. asked after implementing controls; in
lowering water consumption and gen- Two additional questions can now effect, raising the IQ of the dye ma-
erating less effluent to deal with.6 be eliminated. chine, has a very positive impact on
Two questions can be eliminated Was the procedure followed exactly? the remaining three variables-mate-
with the useof a smart machine. Were there any problems? rials, manpower and methods.

January 1995 25
 Off-quality, lost efficiency and hu-
man errors are all black holes which
absorb a company’s resourcesand give
nothing in return. A company cannot
remain in business and be competitive
when process variables determine
whether the bottom line will be writ-
ten in red or black ink. Raising the IQ
of the dye machine is not a challenge,
not a threat, but an opportunity. An op-
portunity to improve quality, lower
costs and be known as a “World Class”
manufacturer and supplierof goods in
a global market.
References
1. Frctland, W., Book of Papers, AATCC Yarn
Dyeing ‘94: Back to the Basics Symposium.
Charlotte, N.C., April 1994. p l .
2. Turner, C. T., Book of Papers, AATCC Con-
tinuous Improvement in Yarn Dyeing Sympo-
sium, Southern Pines,N.C.. April 1991.
3. Hoffmann, Fredgar, Textile Chemist and Col-
orist, Vol. 22,No. 10, October 1990, p11.
4. Von der Eltz. H. IJ.and S. Glander. Melliand
Textilberichte. Vol. 59, No. 10, October 1978.
p827.
5 . Fulmer, T. D., America’s Textiles Interncl-
tional, Vol. 2 1 , No. 1 , January 1992, p68.
6. Weaver. T. M., American Dyestujy Reporter,
Vol. 82, No. 9, September 1993,1150.
Author’s Address
Wayne D. Fretland, Gaston County
Machinery Co., P.O. Box 308, Stanley,
N.C. 28164.

Call for Papers

AATCC’s 1995 International Conference & Exhibition
October 8-11 Atlanta, Georgia
he technical programis now being developed for AATCC’s Finishing
T 1995 International Conference & Exhibition to be held Moderator: A. KENT SNOW, Mount Vernon
October%-11 in Atlanta. Trion, Ga. 30753; telephone 706-734-0507.
Mills, P.O. Box7,

The program will feature 16 technical sessions including

the traditional Intersectional Technical Paper Competition, the Environmental
Student Paper Competition andthe Olney Medal Address. Moderator: GEORGE L. BAUGHMAN, Universityof Georgia,
If you are interestedin presenting a paper at the conference,
Dawson Hall, Athens, Ga. 30605; telephone 706-546-3342.
please submit a summary of the proposed paper (300 words or
less) prior to February 1, 1995 to the appropriate session mod- Dyeing/Printing
Moderator: DAVE LAMB, Dundee Mills Inc., Lowell Bleachery
erator (see below) or to Jerry G. Tew, technical director, AATCC
Technical Center, P.O. Box 12215, Research Triangle Park, South, P.O. DrawerE, Griffin, Ga. 30224; telephone404-412-
N.C. 27709; telephone 919-549-8141; fax 919-549-8933. 5527; fax 404-41 2-5504.
Today’s Business Climate ColorScience
Moderator: To Be Determined. Moderator: PATRICK F. CHONG, Spartan Mills, P.O. Box
Carpet 1658, Spartanburg,S.C. 29304; telephone 803-587-0405; fax
Moderator:JOSEPH J. SMREKAR, Milliken& Co., 300 Indus- 803-587-0291.
trial Dr., LaGrange, Ga. 30240; telephone 706-880-5143; fax’ General
706-883-5338.
1 Moderator; JAMES W. RUCKER. North Carolina State Uni-
Preparation versity College of Textiles, P.O. BoX8301, Raleigh, N.C. 27695;
Moderator; MACKE.ATKINSON,Galey & Lord, P.O. Box telePhone919-515-6546.
157, Society Hill, S.C. 29593; telephone 803-378-4511.
Dyeing
Quality Moderator: BARBARA M. GATEWOOD,
Kansas State
Moderator: WILLIAM C. LITTLE, Forstmann& Co., P.O. Box I University, Dept. of Clothing and Textiles, Justin Hall, Man-
1049,Dublin, Ga. 31040;telephone 912-275-5671.
Garment Wet Processing
1 hattan,Kan.66506;telephone91
5504.
3-532-6993; fax: 913-532-

Moderator: CINDY B. BELLAMY, Graniteville Co., P.O. Box 0 PosterSession

128, Graniteville, S.C. 29829; telephone 803-663-5189. Organizer: BRENDAJ. TRASK-MORRELL, Southern Regional
Research Center, ARS Div., P.O. Box 19687, New Orleans,
NewTechnologies La. 701 79; telephone 504-286-4532.
Moderator: WAYNE C. TINCHER, Georgia Instituteof Tech-
nology, School of Textile & Fiber Engineering, Atlanta, Ga.
30332;
telephone 404-894-2197; fax 404-894-8780. Publication of Papers
History 1 In accepting an invitation to present a paper at the confer-
Moderator: To Be Determined.
i ence, speakers agree to provide AATCC with the full text of
their paper by July 1, 1995. Paperspresented at the confer-
* Fibers ence become the property of AATCC and cannot be pub-
Moderator; W. FRANK TAYLOR, Amoco Fabrics & Fibers lished elsewhere without the express, written permission of
803- AATCC. Guest speakers receivecomplimentary registration
Co., P.O. Box 5708, Spartanburg, S.C. 29304; telephone
576-4566. for the conference.

26 Vol. 27, No. 1