Slasher Dyeing p1kn

SLASHER DYEING The second machine for Dyeing is Slasher Dyeing. This is very old & manual machine. This machine has a capability of handling Ne count form 9/s30/s (OE and Slub both). In this machine there are 2 beam stands to load lots.

Flow Chart of Indigo Dyeing PRE-TREATMENT Tank WASHING

1-Wetting 1-

Tank DYEING

4-

5-Dyeing Tanks WASHING

2-Tanks

DRYING SIZING

2-Tanks

DRYING

PRE-TREATMENT (1 tank): Pre-treatment process includes; • Pre-wetting:

In order to get proper dyeing of the sheet, pre-wetting is carried out with; Wetting Agent Temperature

3-5g/l 20-30ºC

• Mercerization:

If well penetration of the dye is required, then the yarns are treated with strong caustic soda solution, hot wash and cold wash treatment prior to dyeing. Caustic Soda (20 ºBe)

PH 11.8-12

Temperature

Room

Temperature

WASHING (1tank): Cold wash

Room

Temperature

DYEING (Indigo Blue Dye): The dyeing is carried out in 4 to 6 dye box. The dyeing recipe is given by;

Stock Vat: Indigo powder Sodium hydro sulphite Caustic soda (38 ºBe) Dispersing agent Water Total Vetting temperature Vetting time

85gm 70gm 140ml 5gm Xgm 1000ml 50ºC 30mins

Dyeing (4-5 tanks): In each dyeing tank following quantities of stock vat will be required; Requirement per tank Requirement for 6 tanks (Capacity 700L) (Capacity 3500L) Caustic soda (38ºBe) 17.5L Sodium hydro sulphite 5Kg

3.5L 1Kg

Stock vat 31.25L

26.25L

The dipping time of sheet in each tank is about 15secs and airing time or oxidation time is about 90secs.

WASHING (2 tanks): Cold wash at room temperature Hot wash at temperature of 70ºC In each washing tank dipping time is about 12secs.

DRYING: The dyed sheet is dried through drying cylinders, heated with the help of saturated steam at temperature of 150ºC.

ACCUMULATOR: The function of accumulator is to store the yarn sheet in running condition when the size beam is stopped due to any fault so that quality of the dyed sheet in dye box may not damage. Storage capacity 90m Speed of 22m/min Accumulation time 3mins

SIZING (2 tanks): Warp yarns are sized with a protective coating of water soluble, film forming macromolecule and a lubricant. Size paste recipe is given by; Maize starch PVA

75Kg 4Kg

AVRN Softener Water

30Kg 6Kg 700L

DRYING: The dyed sheet is dried through drying cylinders, heated with the help of saturated steam at temperature of 150ºC.

The ropes are also dyed with Indigo + Sulphur dye in order to achieve vast shade range. The Sulphur dye is applied through two ways; 1. Bottoming 2. Topping

1-BOTTOMING: In bottoming the rope is dyed with Sulphur dye first and then with Indigo dye. The process layout is given by;

Flow Chart of Indigo Dyeing And Bottoming with Sulphur Dye PRE-TREATMENT Tank WASHING

1-Wetting 1-

Tank DYEING

1-

Dyeing Tanks OXIDATION DYEING Dyeing Tanks WASHING

1-Tank 4-52-Tanks

DRYING SIZING

2-Tanks

DRYING

PRE-TREATMENT (1 tank): Pre-treatment process includes; • Pre-wetting:

In order to get proper dyeing of the sheet, pre-wetting is carried out with;

Wetting Agent Temperature

3-5g/l 20-30ºC

• Mercerization:

If well penetration of the dye is required, then the yarns are treated with strong caustic soda solution, hot wash and cold wash treatment prior to dyeing. Caustic Soda (20 ºBe) Temperature

PH 11.8-12 Room

Temperature

WASHING (1tank): Cold wash

Room

Temperature

DYEING (Sulphur Black Dye) (1 tank): Dyeing is carried out with recipe of; Sulphur Black powder Sodium Sulphite (Na 2S2O 4) Soda Ash Wetting Agent Temperature Dipping time Pick up

5-10g/l 7.5-10g/l 4-8g/l 3g/l 80ºC 10-20secs 70-80%

OXIDATION (1 tank): Formic Acid H2O2 Water

DYEING (Indigo Blue Dye):

70Kg 20Kg 200gallon

The dyeing is carried out in 4 to 6 dye box. The dyeing recipe is given by;

Stock Vat: Indigo powder Sodium hydro sulphite Caustic soda (38 ºBe) Dispersing agent Water Total Vetting temperature Vetting time

85gm 70gm 140ml 5gm Xgm 1000ml 50ºC 30mins

Dyeing (4-5 tanks): In each dyeing tank following quantities of stock vat will be required; Requirement per tank Requirement for 6 tanks (Capacity 700L) (Capacity 3500L) Caustic soda (38ºBe) 17.5L Sodium hydro sulphite 5Kg Stock vat 31.25L

3.5L 1Kg 26.25L

The dipping time of sheet in each tank is about 15secs and airing time or oxidation time is about 90secs.

WASHING (2 tanks): Cold wash at room temperature Hot wash at temperature of 70ºC In each washing tank dipping time is about 12secs.

DRYING: The dyed sheet is dried through drying cylinders, heated with the help of saturated steam at temperature of 150ºC.

ACCUMULATOR: The function of accumulator is to store the yarn sheet in running condition when the size beam is stopped due to any fault so that quality of the dyed sheet in dye box may not damage. Storage capacity 90m Speed of 22m/min Accumulation time 3mins

SIZING (2 tanks): Warp yarns are sized with a protective coating of water soluble, film forming macromolecule and a lubricant. Size paste recipe is given by; Maize starch PVA AVRN Softener Water

75Kg 4Kg 30Kg 6Kg 700L

DRYING: The dyed sheet is dried through drying cylinders, heated with the help of saturated steam at temperature of 150ºC.

2-TOPPING: In topping the rope is dyed with indigo dye first and then with sulphur dye. The process layout is given by;

Flow Chart of Indigo Dyeing And Bottoming with Sulphur Dye PRE-TREATMENT Tank WASHING

1-Wetting 1-

Tank DYEING Dyeing Tanks

4-5-

DYEING

1-

Dyeing Tanks OXIDATION

1-Tank

WASHING

2-Tanks

DRYING SIZING

2-Tanks

DRYING

PRE-TREATMENT (1 tank): Pre-treatment process includes; • Pre-wetting:

In order to get proper dyeing of the sheet, pre-wetting is carried out with; Wetting Agent Temperature

3-5g/l 20-30ºC

• Mercerization:

If well penetration of the dye is required, then the yarns are treated with strong caustic soda solution, hot wash and cold wash treatment prior to dyeing. Caustic Soda (20 ºBe) Temperature Temperature

PH 11.8-12 Room

WASHING (1tank): Tank#1 Cold wash

Room

Temperature

DYEING (Indigo Blue Dye): The dyeing is carried out in 4 to 6 dye box. The dyeing recipe is given by;

Stock Vat: Indigo powder Sodium hydro sulphite Caustic soda (38 ºBe) Dispersing agent Water Total Vetting temperature Vetting time

85gm 70gm 140ml 5gm Xgm 1000ml 50ºC 30mins

Dyeing (4-5 tanks): In each dyeing tank following quantities of stock vat will be required; Requirement per tank Requirement for 6 tanks (Capacity 700L) (Capacity 3500L) Caustic soda (38ºBe) 17.5L Sodium hydro sulphite 5Kg

3.5L 1Kg

Stock vat 31.25L

26.25L

The dipping time of sheet in each tank is about 15secs and airing time or oxidation time is about 90secs.

DYEING (Sulphur Black Dye) (1 tank): Dyeing is carried out with recipe of; Sulphur Black powder Sodium Sulphite (Na 2S2O 4) Soda Ash Wetting Agent Temperature Dipping time Pick up

5-10g/l 7.5-10g/l 4-8g/l 3g/l 80ºC 10-20secs 70-80%

OXIDATION (1 tank): Formic Acid H2O2 Water

70Kg 20Kg 200gallon

WASHING (2 tanks): Cold wash at room temperature Hot wash at temperature of 70ºC In each washing tank dipping time is about 12secs.

DRYING: The dyed sheet is dried through drying cylinders, heated with the help of saturated steam at temperature of 150ºC.

ACCUMULATOR: The function of accumulator is to store the yarn sheet in running condition when the size beam is stopped due to any fault so that quality of the dyed sheet in dye box may not damage. Storage capacity 90m Speed of 22m/min Accumulation time 3mins

SIZING (2 tanks): Warp yarns are sized with a protective coating of water soluble, film forming macromolecule and a lubricant. Size paste recipe is given by; Maize starch PVA AVRN Softener Water

75Kg 4Kg 30Kg 6Kg 700L

DRYING: The dyed sheet is dried through drying cylinders, heated with the help of saturated steam at temperature of 150ºC.