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POINTS TO DISCUSS
REPRODUCIBILITY RIGHT FIRST TIME DYEING BLIND DYEING CONCEPT LAB TO LAB REPRODUCBILITY LAB TO BULK REPRODUCBILITY AND HOW IMORVE REPRODUCBILITY
What is reproducibility?
To perform something in well manners and with accuracy again and again.
Reproducibility in dyeing??
The ability to produce the same shade with recipe ,at anytime, every time and all the times is termed as reproducibility.
IMPORTANCE OF REPRODUCIBILTY IN DYEING
Approaching better and accurate results Decreases the shade variation Saves time and cost Increases productivity Achieve customer satisfaction
How Reproducibility Is Improved?
Right First Time Concept and Blind dyeing Concept
Right First Time Dyeing
RFT is the level of precision and accuracy of process. Means the work done at first instance must have desired results. No re-working or adjustments
Importance of RFT
RFT eliminates Reprocessing Striping Re-dyeing Re-shading
What reprocessing means here??
More use of dyes and chemicals. More use of water Loss of time and possibly deadlines Lesser production compared to production capacity. More energy consumption More effluent discharge and pollution.
Higher effluent treatment costs Low competitiveness Low image in the global market.
To achieve the RFT the most popular approach is Blind Dyeing .
Blind dyeing concept
It is the practice of carrying out an exhaust dyeing, removing the batch from the, and loading the next batch and only then examining the first batch for shade , levelness etc.
Principle of Blind Dyeing
No-addition dyeing concept
Control of factors affecting dyeing
Practices done to achieve Reproducibility
Process Bind dyeing(RFT) Small addition Large addition Strip or redye Cost 100 110 135 206 Productivity 100 80 64 48 Profit 100 48 -45 -375
The factors effecting the Dyeing Reproducibility
EFFECT OF SUBSTARTE
Quality of fiber Textile yarn Woven fabrics Quality of fabrics Fabric preparation Lot to lot variation
Effect of process conditions
Temperature pH Pickup Methods of conditioning washing
Effect of machine & equipment
Color measuring instruments Color data processing Basis of computer matching Spectrophotometer
Effect of Dyestuff & Auxiliaries
Dye recipe formulation Dyestuff variables Impact of Dyeing auxiliaries
Effect of Water & Steam
Water impurities Hardness in dye bath Bicarbonate in dye bath
Three Key Areas
A recipe should give the same shade every time it is repeated in the lab A recipe developed in the lab should give the same shade in the bulk dyeing as it gives in the lab dyeing. A recipe should give the same shade, all the time it is repeated in the bulk dyeing
FACTORS EFFECTING DYEING REPRODUCIBILITY
Water supply Type of substrate Dye application method Liquor ratio pH of dye bath Time/temperature profile Method of accessing color Weight basis for recipe calculation
Lab-to-lab reproducibility Lab-to-bulk reproducibility Bulk-to-bulk reproducibility
Lab to lab reproducibility
High quality lab recipe must be developed that can b reproduced in bulk and give subsequent bulk continuity. Three problems raise their heads here: Accuracy of lab dyeing Compatible lab dyeing methods that can reproduced in bulk Choice of dyestuff
Aids to improve lab accuracy
Use of automated machinery Lab dyeing machines with sophisticated controllers Using multi-product injection (MPI) facilities Formulation and standards must be held in shade library. Color matching instruments must used.
The following task must be taken care by the textile laboratory. Receiving inspection of textile goods and dyes. Control of water quality. Lying down of quantity criteria. Development of appropriate test methods. Selection of reasonable dyeing and finishing methods
Making of formulation for new articles and shades. Production control. Correction of off-shade dyeing Testing of color fastness and technologies properties. Determination of the cause of problems
Lab to Bulk Reproducibility
When bulk results are correlated with that of lab results then lab to bulk reproducibility is achieved. Good Lab to lab reproducibility attributes to good lab to bulk reproducibility.
Factors concerned for Good Lab to Bulk Reproducibility
Many factors are involved in dye selection. Dyes must be: Compatible Robust Stable Chromopheric content Reactive content in case of reactive dyes
Moisture content Absorption in solution Particle size of dye Meeting the specification
The various factors in substrate specification must be certified such as: Dyeability Quality of fibre , yarn and fabric
Computer color matching
This technology can be major aid in dye house both in cost and speeding up the production. For this database must be updated regularly.
Requirements for lab to bulk reproducibility
A laboratory procedure that reproduce bulk results or can be correlated with them must be available. Process details must be standardized. Accuracy of weighting and measuring must be of higher order in both lab and bulk practice.
Practical Approaches to achieve lab to bulk reproducibility
By optimizing lab conditions compatible with the bulk. By playing with recipe.
How to Optimize lab conditions?
Following Lab conditions can be considered for reactive dyeing: Pad pressure Padder speed Drying temperature Drying time Steaming temperature Steam time
Lab procedure must be reproduced or correlated with bulk system. Dyeing process must be standardized. Accuracy of weighting and measuring at lab and bulk scale. Dyestuff used should be compatible , robust and stable when applied. Data base loaded onto computer should be updated.
Lab dyeing equipments with sophisticated and multi product injection are availed. Standard operating procedure(SOP) Proper control of machine parameters.