Jet Dyeing Machine Research Articles

Development of indoor work environmental air quality index for a dyeing and printing industry

Introduction: Due to various components, materials, and processes, industrial indoor air quality differs from building indoor air. Air quality and the working environment impact health, performance, and comfort. This study developed an Indoor Work Environmental Air Quality Index (IWEAQI) to assess and characterize industrial work environments.
 Materials and methods: Surat “Textile city” is situated in the western part of India in Gujarat state. The small-scale dyeing and printing industry has been selected as a study area. The industry locations like Jet dyeing machine area, stenter machine area, printing machine area, looping machine area and washing basin area has been selected. Various chemicals, adhesives, solvents, dyes, and varied temperature and humidity conditions are used to transform the raw cloth into the finished product. CO, CO2, SO2, NO2, O3, Total Volatile Organic compounds (TVOC), Formaldehyde, Particulate Matters (PM10, PM2.5), WBGT index, humidity, noise, and light were considered to construct IWEAQI. Continuous observations were recorded at minute intervals with a real-time monitoring system. To account for all contributing aspects, United States Environmental Protection Agency (USEPA) air quality index technique was updated for index formulation. IWEAQI was validated using the Pollution Index approach.
 Results: The proposed approach calculated IWEAQI from results. Both approaches gave an index value of 46-80. The developed approach and pollution index method were compared using regression analysis. All study locations had regression values between 0.93 and 0.99.
 Conclusion: The technique classifies IWEAQI as excellent (0-20), good (21-40), moderate (41-60), poor (61-80), and very poor (81-100). From the developed index value, which parameters are influencing the most can be judged.
 

Cotton Dyeing with Cochineal by Just in Time Extraction, Mordanting, Dyeing, and Fixing Method in the Textile Industry

ABSTRACT Cochineal is employed in the field of cosmetics, food, textile, and flavors. The use of cochineal in textile goes back an ancient times in Mexico. These dyes have been used in different natural fibers. After the first quarter of the sixteenth century, cochineal was brought from Mexico to Europe and Asia. Since this date, it has been used very quickly and widely in Europe and Asia. The dye is used as a natural dye all over the world nowadays. Today, the dye is usually dyed with traditional methods. Cochineal is an important natural dye resource for red colors. The use of cochineal has come to importance in the textile industry for the red color in recent years. Cochineal has not been used as an economical, sustainable, and mass production in the textile industry up to now. This study has provided economical, sustainable, and industrial-scale production in the cotton textile industries. Cochineal dyeing recipes were created on industrial-scale samples by the jet dyeing machines. Color change, washing, rubbing fastness 4–5, and lightfastness found 4–5. The optimum conditions were determined for dyeing by the jet dyeing machine. According to the optimum dyeing recipe, cotton fabric was dyed with cochineal.

Sustainable and Mass Production of Cotton Dyeing with Natural Dye (Weld) in the Textile Industry

ABSTRACT The use of natural dyes in textile fibers goes back an ancient times. These dyes have been used in traditional methods until now. The use of natural dyes has come to importance in the textile industry in recent years. This situation desired sustainable, mass, and large-scale productions by the textile industries. Many dye plants used in natural dyeing have been very successful in laboratory studies. However, there are significant problems in using these dyeings in industrial-scale production, and they cannot be applied on an industrial scale in a sustainable way. In this work, weld dyeing recipes were created on industrial scale samples by the jet dyeing machines. Color change, washing, perspiration, rubbing fastness 4–5, and lightfastness found 3–4. The optimum conditions were determined for dyeing by the dyeing machine. According to the optimum dyeing recipe, cotton fabric was dyed with weld by the large-scale dyeing machine. The main coloring compounds are luteolin and apigenin in the weld. The main coloring compounds (luteolin and apigenin), mordant metal (aluminum), fastness tests, color coordinates, and fastness values were investigated in the dyed fabrics by different methods.

Sustainability of Organic Cotton Fabric Dyeing with a Natural Dye (Gallnut) and Analysis by Multi-technique Approach

ABSTRACT In this study, six organic cotton interlock knitting fabric were dyed using gallnut (Quercus infectoria Olivier) four of them were treated with FeSO4.7H2O as post-mordant. The dyed fabrics were analyzed by different analytical and technical methods such as CIEL*a*b*, surface-pH meter, HPLC-DAD, SEM-EDX, FTIR, fastness and antimicrobial tests. Identified dyestuffs with HPLC-DAD were gallic acid, ellagic acid, and their derivatives. In the all dyed fabrics, the detected elements with SEM-EDX are oxygen, silicon, calcium, and sodium. The iron element was found in four dyeings using post mordant. The highest iron percentage are dyeings with a dyeing time of 30 min. The fastness results were good in general. The test of rubbing fastness was 4–5 in dry and the lowest 3 in wet. Washing fastness was found as 4–5 for all fabrics. The antimicrobial test was also carried out against gram-positive bacterium. The results of antimicrobial test against gram-positive bacterium were determined above 91%. Lastly, the dyed fabrics were analyzed by FTIR for determination of the interaction among dye, mordant metal, and cotton fabric. All the dyeings were initially carried out under laboratory conditions, and then applied to jet dyeing machine as protative and sustainable at large scale.

Analysis of Maintenance Systems in Jet Dyeing Machine Components Using the Age Replacement Method

Purpose: The purpose of this study was to determine the maintenance intervals of critical components of jet dyeing machines in an effort to minimize downtime and calculate maintenance costs for engine damage to the jet dyeing. Design/ methodology/ approach: In this study an optimization method was developed to determine the replacement interval of a critical component, namely the Age Replacement Method. Findings: Based on the results of the calculation interval obtained preventive care critical components of jet engines during dyeing 1549 hours. It means that the component must be replaced before operation for 1549 hours or there is 6 times the turnover of prevention under taken in the interval of one year and the resulting decrease in the total cost of 82%. Research limitations/ implications: A review conducted in this paper against one component only, and then it can be developed for this type of component production machines. Practical implications: If the company is implementing a policy of replacement of critical components of the engine on the jet dyeing machine with a method of age replacement, then it will occur treatment cost savings amounting to Rp. 6,752,886 lower when compared with the initial conditions the company previously Rp 37,441,132. Originality/ value: This study combines the Pareto Diagram method and the Age Replacement Method to obtain optimum maintenance scheduling.

High sorption of reactive dyes onto cotton controlled by chemical potential gradient for reduction of dyeing effluents

This research uses soybean oil/water dual-phase solvents system (SWDS) to achieve high dye fixation as well as minimal discharge of waste effluents. Reactive dyeings are one of the most serious pollution sources and few dyeing technologies developed could successfully reduce the generation of toxic substances without decreasing dyeing qualities. Through a remarkable increase in chemical potential of dyes in dyeing medium, SWDS remarkably increased the dye concentration in the internal solvent phase. As a result, % exhaustion of dye was 100%, and % fixation of dye was up to 92% in SWDS. Final discharges of dyes and salts from SWDS were decreased by 85% and 100%, respectively, compared to that from the conventional aqueous system. More than 99.5% of initially added biodegradable soybean oil could be recycled for reactive dyeing without treatments. Furthermore, SWDS could be readily applied in jet-dyeing machines on a pilot scale. Via the reuse of soybean oil, SWDS could save up to $0.26 per kg of fabric compared to aqueous dyeings in terms of materials cost.

綿ニットのスレン染色用全自動液流染色機

綿ニットのスレン染色用全自動液流染色機

Controlling fibrillation – experiences of the dyeing and finishing of lyocell fibres

This review centres on the development of dyeing and finishing technologies for lyocell (TENCEL®) fibres since they were introduced onto the market in 1992. Initially, it will look at the reason for starting manufacture of the fibre and its manufacturing technology. An overview of basic dyeing performance is followed by a critical assessment of the fibre's introduction into the commercial world and the problems that ensued from its fibrillation property. The review then outlines the pioneering process development efforts made in Japan. Dye machinery manufacturers also played an important role in developing processing routes, particularly, but not exclusively, Then, Thies, and Krantz. Courtaulds Tencel formed an alliance with Sir T & A Wardles of Courtaulds Textiles, setting up a project to demonstrate successful jet processing of lyocell fabrics. Investment in jet dyeing machines and personnel was critical: the review explains how it was done and results that were achieved. It also considers how to control fabric behaviour in relation to creasing and fibrillation. The latter phenomenon held the fibre back from knitted applications. Both Courtaulds and Lenzing developed non‐fibrillating versions of the fibres. This review covers these advances, as well as how new markets have been developed for the fibre, such as workwear and bed sheeting. It concludes by looking at the key market segments today and how Lenzing sees the lyocell market evolving.

Deep‐colour vat dyeing of cotton knit fabric on a modified jet dyeing machine

To improve the vat dyeing of cotton knit fabric with Indanthren Black RB Coll. (CI Vat Black 9), the basic parameters of dyeing, including the concentrations of chemicals, the dyeing temperature and duration, and the apparent diffusion coefficient of the dye, were obtained by test dyeing with a stoppered Erlenmeyer flask and the cellophane film roll method. A stable vat dyeing process has been developed on a modified jet dyeing machine for the first time without using nitrogen to purge oxygen. Modifications were made to improve the airtightness of the machine and the equipment in the liquor circulating system, with a water inlet and outlet for the gentle oxidation of dyed fabric, and with monitoring by means of a sensor inserted in the liquor circulating system for in situ measurements of the redox potential and the pH of the dyeing liquors. These measurements made it possible to follow to their completion the process of dyeing and the process of gentle oxidation by overflow washing with water and final oxidation. Optimal conditions with regard to the amount of reducing agent, the dyeing temperature (80 °C), and oxidising processes were established with this machine. It was found that, by using the modified machine and process conditions, dyeing proceeded stably and reproducibly (at 80 °C) to yield grade A dyed fabric. Visual inspection confirmed that faultless deep‐colour dyeing of the fabric was attained. Production has been proceeding successfully for the past 2 years. Owing to its insolubility, complete removal of the dye from the wastewater has been possible.

Practical realisation of ozone clearing after disperse dyeing of polyester

In this study, a novel system utilising ozone in jet dyeing machines is introduced, and the results of ozone‐clearing treatments of disperse dyed polyester on the prototype modified machine are reported. A Venturi injector was mounted on the liquor circulation pipe of the jet dyeing machine to feed ozone gas into the machine. Ozone was generated via an ozone generator by feeding conditioned air into the generator. The ozone gas entering the pipe partly dissolved in the treatment liquor; the dissolved portion and the gaseous ozone interacted via the fabric in the pipe, especially in the nozzle and also at the bottom of the autoclave (machine body). Disperse dyed polyester fabrics of textile‐company mass production were ozone cleared in this prototype. Ozone clearing was achieved in cold water (room temperature), and no other chemicals were used. The colour of the samples, wet fastness properties, and the chemical oxygen demand of the effluent were investigated, and costs were compared with those of conventional reduction clearing of ozone. Results were outstanding: an 83% cost reduction, 67% timesaving, and an 88% COD reduction were achieved.

Development of Vat Dyeing Process for Cotton Knit with Jet Dyeing Machine

A new vat dyeing process for cotton knits with a modified jet dyeing machine has been developed. Proper conditions with regard to the amount of the reducing agent, oxidizing process, and dyeing temperature were searched for with this machine. The dyeing proceeded stably and reproducibly at 60°C by using the modified machine and process. The conventional vat dyeing method of cotton knits with a jet dyeing machine has been performed under nitrogen gas. In the present study, a jet dyeing machine was modified for dyeing the knit roll in the following points. The air tightness of the machine was made sure at the joint parts and window. The machine was equipped with the inlet and outlet to the liquor circulating system for the additions of liquors containing adequate agents. A sensor for in situ measurements of oxidation and reduction potential and pH was inserted into the liquid circulation system. These measurements made it sure that the dyeing, gentle oxidation by washing water, and final oxidation reach to respective quasi-equilibrium states after certain periods. Using this modified machine, vat dyeing at 60°C was examined to confirm the feasibility of fast and uniform dyeing. Increased amount of hydrosulfite in excess to the required amount for the reduction of the dye was used to consume out oxygen in the air space of the machine. The dyed knit was overflow washed with water, four times of the dyeing liquor and then treated with oxidizing agent to complete the oxidation of the dyed knit. It was found by visual inspection that faultless dyeing of the knit with vat dyes, especially in deep colour, was attained at the temperature leading to spare the dyeing period.

An analysis of the factors influencing unlevelness of a direct dye on a pilot‐scale jet dyeing machine

The investigation used a pilot-scale jet dyeing machine to examine the relationship between the dye exhaustion rate per contact and dye unlevelness on the fabric. It was found that a commercially acceptable degree of unlevelness could be obtained for a direct dye on pure cotton fabric as long as the exhaustion rate did not exceed 1.0% per contact, independent of the dye amount used. Bath contacts and fabric contacts influenced unlevelness in equal manner. Non-ionic surfactants, which had been selected so as not to influence the dye exhaustion rate or its equilibrium uptake, appeared to have little or no influence on unlevelness. Control of the dye uptake by electrolyte addition proved to be a more efficient dyeing strategy than controlling it by dye addition, as unlevelness in the first case was much lower at the same exhaustion rate.

Changes in the Static and Dynamic Drape Coefficients of Polyester Fabrics Through the Finishing Stages

Static and dynamic drape behaviors of polyester woven fabrics are s died through representative finishing stages using two sets of fabrics with different conditions of relaxation and weight reduction. The node number n, the revolving drape increase coefficient Dr, and the dynamic drape coefficient Dd increase through the finishing stages, especially with relaxation. The static drape coefficient D, and revolving drape coefficient at 200 rpm D200 decrease through the finishing stages, especially with relaxation. These parameters do not change much after dyeing and raising. The effect of elaxation in a washer is stronger than in a jet-dyeing machine for these parameters. The e fect of weight reduction on D, and D200 appears clearly: the former increases and the latter decreases with a higher ratio of weight reduction.

Impressions of IT MA 1979 (Hanover)

Little of intrinsic novelty for either the textile dyer or printer was on exhibition at Hanover, Refinements to existing machines were many, particularly geared at reducing energy requirements, conserving resources and/or increasing the versatility of substrates handled.The manufacturers of jet dyeing machines (both atmospheric and high–temperature) were noteworthy in this respect, and although there were several exhibits of mercerizing machines for knitgoods, there was no–one yet tackling the fully continuous coloration of them.Washing ranges was another sector where everyone was exhibiting improved machines, usually featuring dwell chambers, counter–current and very low water usage per treated kg of fabric. So/vent washing ranges were featured for preparation and for washing–off of printed synthetic fabrics.Printing machinery, with the exception of the Penta–screen (Stork), showed no novelty.Two suppliers offered indigo dyeing ranges and reported still buoyant interest. Radio frequency, with the exception of Pegg's Electrodry and Stray field's Fastran, received scant attention, whilst dyehouse control systems were more prominent. Finally, three machines (two based on foam techniques) were exhibited which have minimum liquor pick–up as alternatives to padding mangles. Whilst the two foam applicators (Gaston County and Kuster) are both currently being developed for resin finishing, their extension into dye application will be almost inevitable. The third machine, based on centrifugal sprays of droplets (Farmer Norton), looked more speculative with respect to its future adoption. It is not possible in this review to fully describe all the machines which were on display. Accordingly, we have concentrated on machines which were new or novel in some respect, particularly where we felt that these could have an impact on the trade.