farjana dyeing presentation

8/6/2019 FARJANA Dyeing Presentation

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Presented byFarzana khan

Sharifa akhter

Md .kamrul hasan

Mr .Solaiman



15ft 20ft 20ft 4ft 4ft 12ft 14ft 18ft 4ft 4ft 9ft 9ft 19ft 24ft 22ft 5ft 18ft 39ft 20ft 24ft 4.5ft 4.5ft

S = Sample Dyeing Machine

D = Dyeing Machine

Sub Chemical Store = Pillar

= Electric Line = Drain

Table = Water Line

Table = Compressed Air

= Steam

= Gas

S

Office Total Length of dyeing floor= 422 ft

Total Width of dyeing floor= 35 ft E W

Total Area of Dyeing Floor= 422*35

= 14770 ft2 N

D1 D2

D3 S S D4 D5 D6 S S D7 D8 D9 D10 D11 S D12 D13 D14 D15 S S



Machine no DistanceBulk dyeing m/c no 1 to bulk dyeing m/c no 2 4ft

Bulk dyeing m/c no 2 to bulk dyeing m/c no 3 5ft

Bulk dyeing m/c no 3 to sample dyeing m/c no 1 4ft

Sample dyeing m/c 1 to sample dyeing m/c 2 3ft

Sample dyeing m/c 2 to bulk dyeing m/c 4 3ft

Bulk dyeing m/c 4 to bulk dyeing m/c 5 3ft


Bulk dyeing m/c 6 to sample dyeing m/c 3 8ft

Sample dyeing m/c 3 to sample dyeing m/c 4 3ft



Machine no Distance



Bulk dyeing m/c 8 to bulk dyeing m/c 9 6 ft



Bulk dyeing m/c 11 to sample dyeing m/c 5 3 ft




Machine no Distance

Bulk dyeing m/c 12 to bulk dyeing m/c 13 3 ft


Bulk dyeing m/c 14 to bulk dyeing m/c 15 8.3ft

Bulk dyeing machine machine 15 to sampledyeing machine 6

3ft

Sample dyeing m/c 6 to sample dyeing m/c 7 2 ft



AT A TIME MACHINE LOADING CAPACITY 11.360 TONS (100%)

AT A TIME MACHINE LOADING CAPACITY 9.088TONS (80%)

PR ODUCTION PER DAY (9.088*2.5)=22.72 TONS CONSIDERING 2.5 BATCH IN 3 SHIFT



MACHINE NO CAPACITY IN K G

MACHINE NO- 1 500

MACHINE NO -2 1000

MACHINE NO -3 1000

MACHINE NO -4 250

MACHINE NO -5 500MACHINE NO -6 750

MACHINE NO -7 200

MACHINE NO -8 250

MACHINE NO -9 750

MACHINE NO -10 1120

MACHINE NO -11 840

MACHINE NO -12 560

MACHINE NO -13 1680

MACHINE NO -14 840

MACHINE NO -15 1120



Single jersey Fleece (2 thread)/terry

Fleece (3 thread)

CVC fleece

Cotton fleece

Cotton single jersey

Situmi

Single lacost

Double lacost

PK

Lycra single jersey

Double jersey Normal/rib(1*1 R ib)

2*2 rib

Mesh

Flat back rib

Interlock

Design



The dye which reacts with the fibreschemically and makes covalent bondwith the fibres & become an integralpart of it,is called reactive dyes.Reactive dyes contain reactive

group & the covalent bond is formedbetween dye molecules & theterminal ²OH group of cellulosicfibres respectively.

D-SO2-C2H 4-OSO3Na + OH-Cell

D-SO2-C2H 4-O-Cell + NaHSO3

Here D=Dye part

Cell=Cellulose polymer

A reactive dye may be representedby

R-B-X



Dyeing with reactive dye generally threeways-

�Exhausted of dye in presence ofelectrolyte or dye absorption.

�Fixation of dye under the influence ofalkali.

�Washing off the unfixed dye electrolyteand alkali from material.



Usually the dyeing with reactive dye begings in neutralsolution in presence of electrolyte that is salt.

Here the salt act to promote the exhaustion of the dyeonto the fibre.

The electrolyte neutraliyed the negative charge forced inthe fibre surface and put extra energy to increase dyeabsorption.

During this period dye just only migrate into the fibresurface but not react with fibre.

Generally the higher shade % is ensure by higher migrationof the dye into fibre,which is only possible by maintaininghigher salt% in the dye bath.

Dye migration can be accelerated by temperaturegradually raising.



In this stage by the reaction of the reactive group of the

dye and the fibre,a covalent bond that is a dye-fibre

bond will formed.

After running the exhausted change for few times,anappropiate alkali is added to the dye bath to increace its

PH

The hydroxyl group of the cellulose is slightly acedic

and due to the hydroxide ion of the alkali,cellulosate

ions is formed.

cell-OH+OH Ø cell-OØ+H2O

cellulosate ion

And this cellulosate ion performs fixation by two way



Heterocyclic ring bearing halogeno substituentsgenerally performs necleophilic Substitution. Thehetaro atoms in the aryl ring activate the systemby their electro-negativity,and the cellulosate ionattack the ring in the following way-

If the nucleophilic becomes the OHÚof water then we

will get a hydrolysed product of dye.

Dye-NH-N

NN

+ O-Cell-

Cl

Cl

Dye-NH-N

NN

Cl

Cl

O-Cell

Transient species

-Cl-

Dye-NH-N

NN

Cl

O-Cell

-

Dyed Fibre



Generally remazol dyes based on sulphone or realted speciesfollows this mechanism.

In vinylsulphone carbon-carbon double bond polarised bypowerful electra attacting sulphone group favouring thenucleophilic addition of the cellulosate ion(dyed fibreproduced) or OH¯(dye hydrolysed)

D-SO2-C2H 4-OSO3Na NaOH D-SO2 ²CH=CH 2 +Na2SO4 + H 2O

D-SO2 ±CH=CH 2 + cell-OH D-SO

2 ±CH

2-CH

2-O-cell

Efficiency of this fixation process depends on reactivittyratio,sustantivity ration,diffusion coefficient liquorratio,sarface area of substrate available for dye absorption.



The application of

colour producing

agents to

materials usuallyfibrous or flim ,in order

to impart a degree of

colour permanence

demanded by theprojected end use.



Grey fabric recive from knitting section

Batching

Selection machine no

Fabric loading

Select production programe

Pretreatment

Select recipe for dyeing

R ecipe conferm by DGM/S.E

Dyeing

Post treatment

unload



level in(pt)

anticreasing agent+

wetting agent+

peroxide stabilizer Fabric load NaOH(65c)

10min

70c

Hydrogen peroxide

1c/min

105c-30minsph 10.5-11

cooling80cScouring and Bleaching Curve:

peroxide killing:

60c

60c

aceticacid peroxide killer

80c 10mins

check residualperoxide

BD

10mins

overflowrinse

10mins

BD

level in(PT-MT)

10mins

overflowrinse

5mins



Biopolishing:

acetic acidph 4.5-5

Enzyme

55c

Run 60mins

sample check

90c 10mins

sequesteringagent

BD

overflow rinse

10mins



Level in(P.T to M.T) 60°C

Wetting agent .7g/l

Peroxide stabilizer .5g/l

Anticreasing agent.75g/l

Fabric load(10)

Caustic dosing (65 *10 )

run 5

H2O2

dosing 70 *10



Temperature rise to 105 C

run 105 C*30PH=10.5Ù11

Cooling to 78 C

Drain

Overflow rinse 10

Drain

Level in(P.T to M.T)

Acid 50 C Ù60 C*10



Peroxide killing injection 80

C*10

check the residual peroxide

Drain

Overflow rinse 5

Acid .7g/l to maintain PH 4.5 5

Biopolishing agent 1.5g/l 55ºc*(45-60´)

Sequestering agent( A.T to M.T)

hot at 90 C*10

Overflow rinse 10



Dyeingprocess

Isothermaldyeing

Migrationdyeing



L

evelling at 60C

Colour dosing 60ÛC * 35( linear dosing)

Run time 60ÛC* 15

Salt dissolving 15 (recirculation process)

Run 15

Soda 50( 70% progressive)

Check the sample 10



Levelling 60 C

Colour dosing 35

Run time 10

Salt dissolving 15

Run time 10

Temperature rise at 80 C



Run time 20

Temperature drop at 60 C

Soda dosing 50

Sample check after 10

Bath drain



Light Medium

Dark White



In case of 0-1.0%(light)shade colour is dosedfirst then salt dissolvingis performed.

In case of 1-2.5%

(medium)shade salt isdissolved at first thencolour is dosing.

In case of 3 &

above%(dark) shade saltis dissolved at first thencolour is dosing.



Overflow Rinse /MIR15-20

(cold rinse)

Normal hot wash70 C *10

Overflow Rinse / MIR 70ÝC*15

Neutralisation with acetic acid PH-7,45° C*10-15´

Enzyme wash



wash off at 95C*15

( soaping agent 1-1.5 g/l)

Overflow Rinse/MIR 50ÝC * 15´

Acid 0.35 g/l

Softening treatment 45 C* 20

Rinse 15

unload



U-tube Heat Exchanger



Theory of Application

� Two fluids, of different starting temperatures, flow through

the heat exchanger.

� One flows through the tubes (the tube side) and the otherflows outside the tubes but inside the shell (the shell side).

� Heat is transferred from one fluid to the other through thetube walls, either from tube side to shell side or vice versa.

� The fluids can be either liquid or gases on either the shell orthe tube side. In order to transfer heat efficiently, a large heattransfer area should be used, so there are many tubes. In thisway, waste heat can be put to use. This is a great way toconserve energy.



TYPES OF MACHINE ACCORDING TO TEMP

HIGH TEMPET ATURE MACHINE

ATMOSPHERIC MACHINE



� Variable Loading (VL) storage

chamber design gives extra capacityto carry loading up to 280 kg pertube

� Heat Exchanger of extremeefficiency gives the largest heatingrate with minimum heat loss to theenvironment

� Multi Saving R insing System (MSR )shortens the dye cycle and reducesthe water consumption

� Advanced Intelligent R insingSystem (MIR ) controls the rinsingwater consumption and shortens therinsing process

� Highly optimised machine structurereaches the lowest possible liquorratio of 1:4.5 to run the machine .

� Variable loading chamber forcontrolling loading.

� Dissolution pump for propercirculation of liquor.

farjana dyeing presentation

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