Now You Know Study on Different Laboratory Equipments of a Modern Dye House

Study on Different Laboratory Equipments of a Modern Dye House

Rofiquzzaman Raju
Chittagong Textile Engineering College
Contact: 01714419781
Email: rtextile.finance@gmail.com

Introduction:

Satisfaction of customer demands is the quality of a product. It is the extent of excellence of a product that indicates that whether it meets the customer ultimate demand or not. As textiles, an integrated word is related to different segments and each segment is responsible to meet up the requirements of subsequent segments and finally the ultimate user. Dyeing, the process of coloring textile materials with some medium. It is the section in which raw fabrics are dyed with coloring materials i.e. dyes in some medium i.e. water along with several chemicals. Fabrics are colored as per the buyer requirements. Before going to the bulk production, a sample fabric is dyed in the dyeing lab. If the desired shade is produced here then it is go for bulk production at large amount. However, primary recipe to develop particular shade is prepared here and then finally implemented in the production section. A standard quality lab provides all opportunities to produce particular shade without any disturbance. Besides, the different tests are done in the physical lab to evaluate the different parameters of dyed fabric. Tests conducted in the physical lab basically based on the buyer requirements. During testing, different types of testing method are followed which is varied from buyer to buyer. To learn this, an observation was done at ECHO-TEX LIMITED; an export oriented apparel industry produces all types of knitting garments. In this article, discussion will be done on dyeing lab of that factory.

Objects:

To know the different chemicals and equipments used in the dyeing lab.
To understand about the different test carried out in the physical lab.
To know the responsibility of different managerial designation in the dyeing lab.
Understanding the function of different machineries used in dyeing lab.

Factory Agenda:-

Name of the Project: ECHOTEX LTD.
Location: Chandra pallibidyut, Kaliakoir, Gazipur.
Established year: 2003
Status:100% Export Oriented Knit composite
Project cost : TK. 2500 crore
Production capacity: 2100000 pcs/month
Man power: 7000 people

Layout of the Dyeing lab:-

Study on Different Laboratory Equipments of a Modern Dye House Now You Know Study on Different Laboratory Equipments of a Modern Dye House

Figure: Layout of Dyeing lab of ECHO-TEX Limited
(Click on image for large size)

Management structure and their responsibility of the dyeing lab:

Management structure and their responsibility of the dyeing lab
(Click on image for large size)

Types of Dyeing lab:-

Types of Dyeing lab

Name of the Machine Used in Chemical Lab:

Machine No.01 and 02

Specification of the machine:

Name: Sample dyeing machine
Brand Name: Datacolor AHIBA IRTM
Origin : U S A
No. of pot: 19
Heating system: Infrared
Sample wt. =5gm

Fig: Sample dyeing machine

Function: To dye lab dip based on buyer requirements.

Machine No. 03

Specification of the machine:

Name: Sample dyeing machine
Brand Name: Mathis LABOMAT
Origin: Switzerland
No.of pot: 23
Heating system: Infrared
Sample wt. =10gm

Fig: Sample dyeing machine

Function: To dye lab dip.

Machine No.04

Specification of the machine:

Name: Rotawash machine:
Brand: SDL International
Model: M228
Origin: England
No. of pot: 8

Fig: Rota wash machine

Function: Treating the fabric sample with water to determine color fastness to washing.

Machine No.05

Specification of the machine:

Name: Sun test CPS+ machine
Brand: SDL International
Origin: England
Lamp capacity=500W

Fig: Sun test CPS+ machine

Function: Exposing the fabric sample to determine color fastness to light.

Machine No.06

Specification of the machine:

Name: Oven dryer machine
Specification:
Brand: XIEMAN Rapid
Origin: China

Fig: Oven dryer machine.

Function: To dry fabric sample at required sample.

Machine No.07

Specification of the machine:

Name: Washing machine
Brand: SIEMENS
Origin: Germany
Capacity: 5.5 kg
Speed: 1000rpm

Fig: Washing machine

Function: To wash the fabric sample at particular temperature.

Machine No.08

Specification of the machine:

Name: Quick wash plus machine:
Specification:
Brand: SDLATLAS
Origin: UK

Fig: Quick wash plus washing machine

Function: To wash the fabric sample very quick manner with respect to normal washing.

Machine No.09

Specification of the machine

Name: Shaker machine
Specification:
Brand: Rapid
Origin: China

Fig: Shaker machine

Function: After dyeing soaping is done by this machine.

Machine No.10

Specification of the machine:

Name: Robolab machine

Fig: Rob lab machine

Function: To prepare dye solution based on recipe amount for dyeing.

Machine No.11

Specification of the machine:

Name: Spectrophotometer machine
Model: 650
Origin: USA

Fig: Spectrophometer machine

Function:

Recipe develop from standard sample
Check CMC value of Sample to evaluate it.

Name of the Machine used in Physical Lab:-

Tests done in Physical lab are:

Dimensional stability.

Shrinkage

Spirality

Angular spacing

Pilling test
Rubbing Test
GSM
Color fastness to light
Color fastness to water
Color fastness to washing
Color fastness to perspiration ( Acid & Alkali Solution)
Color fastness to SALIVA
Color fastness Phenolic Uline

Machine No.01

Specification of the machine:

Name: Pilling tester
Brand: SDL ATLAS
Origin: UK

Fig: Pilling tester machine

Function: Treating the fabric sample to create pile on the sample fabric surface.

Testing parameters:

Sample size: (12.5 x 12.5) cm,Method: ISO 12945-1:2001
Tube size: (14 x 2.6) cm,Revolution: 14400
Speed: 60 rpm,Test sample: 4 pcs
Course wise: 2 pcs and Wales wise: 2 pcs

Machine No.02

Specification of the machine:

Name: Crockmeter
Test parameters:

Sample size: Dyed fabric – (14 x5) cm
White Test Cloth - 5 cm ´ 5 cm
Method: ISO 105x2L: 2002
Revolution: 10cycle/10sec
Weight: 9N

Figure: Crockmeter

Function: Rubbing the fabric sample to measure color fastness properties.

Machine No.03

Specification of the machine:

Name: Overlock sewing machine
Brand: Juki
Origin: Japan

Fig: Over lock sewing machine.

Function: To sew the fabric for dimensional stability measurement test.

Measurement of Dimensional stability:
Dimensional stability: This is the test by which dimensional stability of fabric (i.e.: shrinkage & spirality) are measured. For this test, fabric has to be washed per care label code.

Test specimen & Equipment:

Sample size: outside = (50x50) cm and Inside = (35x35) cm
Method: ISO 6330: 2001 2A/5A
Equipment used: washing machine (Rota wash)
Washing at 400C X 41’, As per care label code.

Procedure:

Conditioning: Put the sample in table for 4 hrs for conditioning before starting test.
Cut the sample 50x50 cm & benchmark should be 35x35 cm.
Stitch the sample (3 sides) by over lock sewing machine.
Put sample in washing machine and run according to buyer’s choice.

Shrinkage calculation:
31.5 + 31 + 30.8
After test: Inside measurement= ........................... = 31.1cm

3

Before wash - After wash

Shrinkage = ........................................... X 100%
Before wash

35 - 31.5

= ................ X 100 =11.14 %
35

Figure: Measuring template

Spirality Calculation:

Figure: Spirality measurement dimension

Total distance = 47 cm.
Average spiral distance = (2+3)/2 = 2.5 cm

Average spiral distance

Spirality = ..................................... x 100% = (2.5×100)/47 = 5.32 %

Total distance

Conclusion:

The dyeing lab machineries are varied from factory to factory. The Devine Fabrics dyeing lab is well equipped with different machineries along with necessary chemicals by which various types of lab dip can be developed and a number of tests are done in the physical lab with assured quality. All the equipments are sufficiently enough to meet the buyer requirements successfully. But all the tests cannot be conducted here.

You can also like: