Textile Manufacturing Process

  Dyeing of Jute Fabric With Basic Dyes Basic Dyes Basic dyes are cationic soluble salts of colored dye bases. Basic dyes are applied to the substrate with an anionic character where electrostatic attraction is formed. Basic dyes are powerful coloring agents. It is applied to jure, wool, silk, cotton, and modified fiber. Objectives of Dyeing To know about the basic dyes To dye the fabric with basic dyes To know the function of used chemicals in dyeing To know how to improve the dyeing process Jute Dyeing Recipe Sequestering agent - 1cc/L Acetic acid- 2cc/L Dyes - 1% (o.w.f) Salt - 12 gm/L pH - (4.5-5.5) Temperature - 80 C M:L - 1:70 Time - 30 minutes Function of Used Dyeing Chemicals Dyes - To impart color Acetic acid - To create an acidic medium for the reaction of dye with fiber Sequestering agent - to remove hardness from water Salt - It acts as a catalyst that accelerates the absorption rate Working Procedure First, collect all the chemicals like sequestering agent, salt, aceti

  Dyeing Process of Cotton Fabric With Sulphur Dyes Sulphur Dyes Sulphur dyes are highly colored, water-insoluble compounds and have to be converted into Water Soluble substantive forms before application to the textile materials. This conversion is carried out by a treatment with a reducing agent like dilute aqueous Na2S. Apparatus Required for Dyeing Beaker Glass Rod Cylinder Electric Balance  Thermometer Dryer Nature of the Sample: 100 % cotton knitted fabric Objectives of Sulphur Dyeing: To learn about how to cotton fabric dyeing with sulphur dyes To know about sulphur dyes To get an idea about the function of used dyeing chemicals To know how to improve the dyeing process Function of Used Dyeing Chemicals Sequestering Agent- To remove the hardness from water Alkali - It converts oil into water-soluble fatty acid and soap Salt - It acts as a catalyst that accelerates absorption rate and reduces surface tension.  Hydrose - It acts as a reducing agent H2O2 - It helps to insoluble

  Fig: Desizing Process Desizing Process of Cotton Fabric With Enzyme Desizing Process Desizing is done to remove the size from the warp yarns of the woven fabrics. Warp yarns are coated with a  sizing agent to reduce their frictional properties decrease yarn breakage and improve weaving productivity. The sizing material presents the warp yarns act as a resist towards dyes and chemicals in wet processing. So, it must be removed in any subsequent wet processing of the fabric. Apparatus Required for Desizing:  Beaker Electric Balance Measuring Cylinder Dryer Thermometer Sample Nature 100 % Cotton fabric Objectives of the Desizing Process To know about the de-sizing process of cotton fabric To increase the absorbency power of the fabric To increase the affinity of the fabric to the dye chemicals To make the fabric suitable for the next process To increase the lustre of the fabric Recipe for Desizing of Cotton Sequestering Agent - 1cc/L Enzyme- 10% o.w.f Acetic Acid - 1.5 cc/L pH - (4.5-5.

  Printing of Cotton Fabric With Pigment Pigment Printing Pigment printing has gained much importance today and is the most commonly used technique for most fibers. Pigments can be used on almost all types of textile substrates. There are two types of screen printing. Rotary Screen Printing Flat Screen Printing Objectives of Pigment Printing To print the fabric with print To know the function of used chemicals in printing To get the desired design of goods To get knowledge about pigment printing To get the desired shade To print cotton fabric Sample Nature 100 % Cotton Knitted Fabric Apparatus Required for Printing Beaker  Glass Rod Pipette \Electric Balance Measuring Cylinder Screen Squeezer Curing Machine Recipe Used for Pigment Printing Sequestering Agent - 10cc/L Pigment - 20 gm/Kg Urea - 100 gm/Kg Binder - 200 gm/Kg Fixer - 10 gm/kg Thickener - 30 gm/kg Acetic Acid - 10cc/L Function of Used Chemicals Sequestering Agent: Remove the hardness of water Pigment: Impart color to the p

 Dyeing Faults Causes and Remedies Dyeing Faults: Major dyeing faults in dyeing process is mentioned as follows. Uneven Dyeing Batch to Batch Shade Variation Patchy Dyeing Effect Roll to Roll Variation or Meter to Meter Variation Crease Mark Dye Spot Wrinkle Mark Softener Mark Uneven Dyeing: Fig: Uneven Dyeing Causes: When uneven pretreatment occurs (i.e. uneven scouring and bleaching) Improper color dosing in the dye tank When high fixation dyes uses In case of synthetic fibers, uneven heat setting Lack of maintenance of dyeing machine Remedies: Ensure even pretreatment Ensure even heat-setting in the case of synthetic fibers Proper dosing of dyes and chemicals Proper controlling of dyeing machine. Batch to Batch Shade Variation Fig: Batch to Batch Shade Variation Causes Temperature fluctuation Dyes and chemicals improper dosing time Dyes and chemicals batch-to-batch weight variation  Variation of dyes lot Improper liquor ratio, reel speed, pump speed Improper pretreatment  Remedies:

Dyes Used in Textile Industry Textile Dyes Dyes are colored organic compounds that impart color to various substrates including paper, leather, fur, hair, drugs, cosmetics and waxes, and textile materials. Dyes are normally used in solution, which is capable of being fixed to a fabric. According to the Application Form Classification of Dyes: 1. Ready-made Dyes A.Water Soluble Dyes Direct (Cotton) Acid (Wool, Silk) Basic (Jute, Acrylic) Reactive  B. Water Insoluble Dyes Vat (Denim) Sulphur (Umbrella Cloth) Disperse (Polyester) 2. Ingrain Dyes Azoic  Oxidation Color Mineral Color Suitability of Various Dye-Classes for Textile Fibers: Cellulosic (Cotton/viscose) - Direct, reactive, vat, sulfur, oxidative, azoic, etc.   Cellulosic (Jute) - Basic dyes are widely used. Protein (Wool, Silk, Nylon) - Acid dyes are mainly used Polyester, cellulose, acetate - disperse dyes are mainly used Ways of Coloration: Direct dyeing, in which the dye from the solution in contact with the textile material

 Types of Knitting Machines Knitting Machine The knitting machine frame is normally free-standing and either circular or rectilinear according to the needle bed shape providing the support for the machine mechanisms. The machine control and drive system coordinate the power for the drive of the devices.  The yarn supply consists of the yarn packages or beam accommodation, tensioning device, yarn feed control, and yarn feed guides. The knitting system includes the knitting elements, their housing, drive, and control, as well as associated pattern selection, and garment length control device The fabric takeaway mechanism includes the fabric tensioning, wind up, and accommodation mechanism. The quality control system includes stop motion fault detectors, automatic oilers, and wind removal system Types of Weft Knitting Machines There are mainly two types of weft knitting machines. 1. Flat Knitting Machine V-bed Rib Machine (collar and cuff) Flatbed purl or Links Machine 2. Circular Knittin

  Textile Dyeing Process Flow Chart Dyeing Process Dyeing is the process of applying colors to a textile material in loose fiber, yarn, cloth, or garment form by treatment with a dye. It is also the coloring process of textile material by immersing them in an aqueous solution of dye, called dye liquor. Normally the dye liquor consists of the dye, liquor, and the auxiliary. To increase the dyeing effectiveness, heat is applied to the dye liquor. Woven Fabric Dyeing Process Flow Chart Grey Fabric Singeing Desizing Scouring Bleaching Mercerization Dyeing Washing/ Drying Heat Setting Inspection Printing Steaming Washing Drying Heat Setting Finishing Finished Fabric Knit Fabric Dyeing Process Flow Chart Grey Fabric Inspection Batching Fabric turning Loading to the machine Pre-treatment (Scouring and bleaching) Dyeing Dewatering Drying Compacting & Calendering Final Inspection & Packing Hard Water The hardness of Water can be defined as the presence of soluble salt of Ca and Mg ions