UNIT-4

CLASS: II FD Subject Handle By: N.Meenakshi

Dyeing machines – fiber, yarn and fabric dyeing machines –loose stock fiber bale – hank
package – jigger – winch – HT Beam jet – padding mangles. Garment dyeing machine
INTRODUCTION:
Dyeing is a process of coloring textile materials for giving attractive look. In broadly we
can explain, dyeing is a process by which a yarn, fabric, garments and any other materials that
come to contact of dye by presence of auxiliaries that create the condition of dyeing
environment. Dyeing operation is done by different types of dyeing machine. The machine
which is used to dyeing or coloring of materials like yarn, fabric, garments or any other materials
is called dyeing machine. Dyeing machines come in all shapes and sizes to accommodate the
various forms and quantities of textile materials. Actually it is the device that is used by different
industries for imparting colors. Various types of dyeing machineries are used to dye the textile
materials.
Types of dyeing machine according to textile material:
A. Fiber dyeing machine
B. Yarn dyeing machine
C. Fabric dyeing machine

FIBRE DYEING

HANK DYEING
Although package dyeing route is much simple and easy to follow for dyeing of different
kinds of yarn,but still the hank route is popular for certain qualities, there are two reasons for
this,

1. The quality and nature of the product does not allow to follow package route.
2. The package route is non practical and non economical.

Process sequence for yarn dyeing in hank form

1. Singeing (for mercerized cotton yarns)

2. Reeling
3. Mercerization (for mercerized cotton yarns)
4. Dyeing
5. Hydro extraction or squeezing
6. Drying
7. Hank to cone winding
Process Flow Chart of Hank Processing
 Package dyeing machines are the most widely used now a days for dyeing of almost all
type of yarns ,due to economical ,automatic and accurate dyeing results. The term package
dyeing usually denotes for dyeing of any type yarn wound on the compressible dye
springs/perforated solid dyeing tubes or cones. Yarn dyeing in package form is done at high
temperature and under high pressure ,with the packages mounted on hollow spindles .These
spindles are fixed on the dyeing carriers ,which is inserted into the dyeing vessel after closing the
lid of the machine ,the dyeing liquor is forced through the packages in two way pattern (inside to
out and outside to in) and goes on circulating throughout the vessel and yarn. Heat is applied to
the dye liquor to achieve the dyeing temperature, time –temperature and flow reversal are
controlled through a programmer.

FABRIC DYEING MACHINES:

The fabric is the one, which is dyed to a much larger extent than in any other form. The
fabrics are woven or knitted in various machines in pieces of short length and these pieces are
sewn together to make a continuous length of fabric. The dyeing may be carried out in rope form
or in open width. The machines in which dyeing is carried out in an open width are jigger and
padding mangles, whereas in winch and jet dyeing machines, dyeing is done in rope form. The
continuous padding machines are used for continuous dyeing, whereas most of the other
machines are batch machines, that is, they handle a finite length of fabric at a time.

JIGGER DYEING MACHINE:

Jigger dyeing machine is the most commonly used for dyeing all kinds of cotton fabric.
There are mainly two types of jigger dyeing machine. One is open jigger dyeing machine and
other is closed jigger dyeing machine. It is one of the oldest types of machine for dyeing woven
fabrics, which must not be creased during dyeing, for example, most taffetas, satins, poplins,
ducks, and suiting. This is most suitable for materials in which the dyes do not exhaust well as
the machine operates with low volume of liquor (i.e., low material to liquor ratio of 1:5 to 1:6).
Advantages of Jigger Dyeing Machine:
 The cloth can be dyed in open width form of full width form.
 Chemical and heat loses are less when compared to winch dyeing machine
 The material to liquor ratio is 1:3 (or) 1:4 which saves considerable amount of
chemical cost and steam cost.
Disadvantages of Jigger Dyeing Machine:
It exerts lot of tension in the warp direction and because of this normally woolen, knitted
fabrics, silk etc are not dyed in jigger dyeing machine.

Winch dyeing machine:

The winch or beck dyeing machine is the oldest form of piece dyeing machine. The
construction is comparatively simple and therefore economical to purchase and operate. It is
suitable for practically all types of fabric, especially lightweights, which can normally withstand
creasing when in rope form such as woolen and silk fabric, loosely woven cotton and synthetic
fabrics, and circular and warp-knitted fabrics. The winch imposes much less length ways tension
as compared to the jigger; hence, it is suitable for delicate fabrics, which are damaged under high
tension. Scouring efficiency is high due to greater mechanical action caused by constant
reformation of length ways folds. Many fabric varieties, such as tubular knitted fabrics are,
therefore, successively scoured and dyed in these machines. Crimps are developed due to the
greater mechanical action combined with low tension. Winch dyeing results in thicker fabric
with fuller handle, more fabric cover, and better crease recovery.
The Winch Machine can operate at maximum temperature between 95-98C. Generally the liquor
ratio is high (1:20-1:40). This machine is used for the fabric in rope form with stationary liquor
and moving material. Fabric path diagram of winch dyeing machine are given below:

Fig: Diagram of winch dyeing machine

Winches are made of high-quality stainless steel (AISI type 316 or equivalent) with welded
joints, ground and polished. The shape and size of the vessel and reel vary considerably
depending on the type of fabric to be processed. Most of the winch machines are about 2.5
meters in length and 0.5 meter (single rope) to 4.5 meters (40 ropes) in width. Most winches are
fitted with an overflow duct at the back, so that rinsing can be carried out in liquor flow from
front-to-back.

Winches are of two types:

1. Deep-draught winches.
2. Shallow-draught winches.

BEAM DYEING MACHINE:

The beam dyeing machine operates with the same principle as that of package dyeing
machine. It can be effectively used to dye yarn or fabric. The process works like this, fabric or
yarn in open width is rolled on to a perforated beam. The beam dyeing machine is suited to
process a wide range of knitted and woven textiles. The fabric in open width is rolled on to a
perforated beam, then subsequently loaded into a vessel that is closed and pressurized. The dye
impregnates the fabric as the dye liquor is allowed to go on circulating through the perforations
(holes) in the beam. Usually the beam dyeing machines are designed to hold a single beam.
In beam dyeing, a length of fabric is wound on a perforated carrier and processed in a cylindrical
autoclave. The system is fully enclosed and is normally pressurised to provide processing at
temperatures up to 130°C (40Mpa, 4 atm.). Pressure beams came into use in late 1950s in order
to dye lightweight, delicate warp-knitted nylon and acetate fabrics and later for dyeing of
polyester fabrics at high temperature. The making of a good beam is an essential prerequisite for
uniform dyeing. The perforated beam must be sufficiently robust to withstand the weight of the
full roll of wet fabric. After invention of jet dyeing machines, fabric beam dyeing machines are
obsoletenow.

JET DYEING MACHINE:

Jet dyeing machine is the most modern machine used for the dyeing of polyester using
disperse dyes. In this machine the cloth is dyed in rope form which is the main disadvantage of
themachine.

Until 1960s, the machines used for dyeing fabrics in batches were the winch, jigger, and
beam. When polyester was first introduced as a textile material, conventional pressure free winch
beck equipped with a hood was mainly used for dyeing using carriers. Soon it became evident
that dyeing above 100°C would be necessary to eliminate the use of carriers and accelerate the
diffusion of the dyes for cutting down the dyeing time. This prompted machine manufacturers to
construct high-temperature or high-pressure modifications of the existing winch dyeing
machines. It was impossible to solve all the problems of polyester dyeing by mere modification
of HT winch beck. It was increasingly felt that dyeing time was too long in these machines. All
the disadvantages of HT winch becks had been overcome by the jet dyeing machine.

Types of jet dyeing machine:

Some Jet dye machines are as follows:
1. Overflow Dyeing Machine
2. Soft-flow Dyeing Machine
3. Airflow Dyeing Machine
Advantages Jet Dyeing Machine:
  Dyeing time is short compared to beam dyeing.
 Material to liquor ratio is 1:5 (or) 1:6
 Production is high compared to beam dyeing machine.
 Low consumption of water
Disadvantages Jet Dyeing Machine:
 Cloth is dyed in rope form
 Risk of entanglement
 Chance for crease formation.
 High initial investment and maintenance cost is high

LOOSE STOCK FIBRE

The loose fiber dyeing carried out by the bulk fiber dyeing machine actually refers to
cotton fibers, wool fibers, and loose latex staple fibers that have been subjected to a comb
spinning process. At this time, attention should be paid to dyeing and then spinning into colored
yarns. The dyeing process. The dyeing is mainly carried out in a special bulk fiber dyeing
machine, and afterwards, a pump should be used to alternately circulate the dye liquor to obtain
uniform dyeing.After the operation of the loose stock dyeing machine, there will be intermittent
and continuous types for the bulk fiber dyeing machine. For this bulk fiber dyeing machine, this
time it will be composed of a charging drum, a circular dye bath and a circulation pump. And
there is a central tube on the drum, and the wall of the barrel and the center tube are covered with
small holes. At this time, the fiber should be placed in a drum, placed in a dyeing tank, put in a
dye solution, and a circulating pump should be started. After that, it should be noted that the
dyeing temperature should be increased.

For the dyeing liquid of the loose stock dyeing machine, this time will inevitably flow out of
the center tube of the drum, and at this time it will directly pass through the fiber and drum wall
from the inside to the outside, and in this regard After that, it will return to the central tube to
form a cycle. Some loose fiber dyeing machines will also consist of a conical pan, a dyeing tank,
and a circulation pump. The false bottom and the lid of the conical pot are covered with small
holes.When intermittent dyeing machines perform dyeing, loose fibers are loaded into the pan at
this time, and care should be taken to put them into the dyeing tank after stamping. However, the
dye liquor flows through the circulation pump through the false bottom and flows upwards out of
the lid. At this time, it will also form a cycle for dyeing.For continuous loose stock dyeing
machines, on this point, it will actually be composed of hoppers, conveyor belts, roll rolls,
steamer boxes and other components. And before the fiber is transported by the conveyor belt to
the roller, it is filled with dye liquor and rolled into the steam box after being pressed by the pad
roller. After steaming, we must pay attention to soaping and washing.

BALE DYEING MACHINE

The newer method is bale dyeing, which is applicable to wool and all types of manmade
fibres. This method follows, splitting the bale covering on all six sides, placing the entire bale in
a specially designed designed machine, and then forcing the dye liquor through the bale of fibre.
This method obviously saves time and labour costs.Although the dye liquor is pumped through
the fibre in large quantities, there may be areas where the dye does not penetrate completely.
However, in subsequent blending and spinning operations, these areas are so mixed with the
thoroughly dyed fibres that an overall even colour is obtained.

In stock dyeing, which is the most effective and expensive method of dyeing, the colour
is well penetrated in the fibres and does not crock readily. Stock dyed fibres does not spin as
readily as undyed fibre because it loses some of its flexibility, but lubricants added in the final
rinsing overcomes most of this difficulty and woolens are often stock dyed.

PADDINGMANGLE
The pad dyeing machines overcome the deficiency of winch and jigger dyeing machines of
smaller batch size and discontinuity in dyeing. Padding mangle offer continuous process of the
fabric in concerned liquor such as pretreatment, dyeing or finishing.
Application of dyestuffs is conducted in the pad dyeing machines with single or multiple dipping
in solution .During padding, the fabric passes into a solution of chemicals, under a submerged
roller and out of the bath. It is then squeezed to remove excess solution .The objective of this
process is to mechanically impregnate the fabric with the solution or dispersion of chemicals Pad
impregnation is common for the dyeing of fabric and for the application of finishing chemicals.

Tension elements
While the cloth passes on to the padding machine no slackness should occur in fabric either in
weft or warp directions and the weft threads of cloth should remain parallel to the nip at the
squeezing point.

The padding mangle bowls

The nip rollers (often called bowls) are the key to successful pad dyeing. In general, two-
bowl nips are preferred for lightweight or standard fabrics running at moderate speeds, whereas
three-bowl arrangements are intended for heavier or more densely woven qualities that may be
more difficult to wet out and thus require a double-dip and double-nip treatment.

DyeingMethod
The padding operation itself consists of two essential steps: thorough impregnation by
immersion of the absorbent fabric in a dye solution containing a wetting agent, followed by
squeezing of the wet fabric between rollers to expel air and replace it with dye liquor, as well as
expressing surplus liquor back down the sloping fabric surface to the pad trough. The cloth to be
padded is taken up by either from the folded form or from the batched condition and fed to the
padding machine over a set of guide rollers. The fabric is straighten in warp as well as weft
directions .It is necessary to attach and end piece on both the sides of batch.
The three main types of automatic level control are:

1. Float switches: these are reliable and are unaffected by foam but they are relatively bulky
2. Conductivity probes: these are small and neat but foaming of the pad liquor adversely affects
their performance
3. Differential pressure detectors: those with a hollow tube projecting downwards from the liquor
surface are difficult to clean and the preferred type is that with a closed diaphragm set in the base
of the vessel.The control of pad liquor temperature is highly desirable to achieve consistent
results.