For a long time, printing and dyeing enterprises in China dyeing of knitted fabric has been followed by a continuous process since the dye bleaching line, because this technology is simple, widely accepted in China and the use of dye. However, continuous process for dyeing bleached white knitted fabric dyeing and finishing of all the processes (boiling, bleaching, washing, dyeing, soaping, hot run, neutralization, washing, fixing, softening) all concentrated in the dyeing machine for an average of one cylinder fabric technology of the time more than 10 hours from start to finish, which is more than 10 hours must use a lot of steam, electricity, water, additives, in the present tense form of energy, this is very scientific, it must be knit dyeing To burn off so much energy, so high costs, our answer is no! environmental protection in recent years with the introduction of new standards, the increase in labor costs, product quality, continuous improvement, continuous process since the dye is gradually drift from the expression out it takes a long time dyeing machine, a cylinder is low, energy consumption, quality control is difficult and other defects, has not well adapted to the needs of social development, it should create the updated scientific knitting dyeing process route instead.
After 8 years I plant exploration and practice, create Chu has a scientific and energy efficiency, and quality of the dyeing process: sub-type dyeing process! It overcomes the drawbacks of white dye bleaching, by using different devices, the use of appropriate technology, the knitted fabric dyeing and finishing of pre-treatment, dyeing and post-processing after separation from the dyeing machine, into pre-treatment, dyeing, after three separate post-processing stage, the specific line is: pre-treatment (cold pad pre-treatment) of a stain (dye into the tank of caustic soda) for a post-processing after dyeing (staining of the tank processing)
1, the specific processes
1.1 Pre-treatment (scouring bleaching)
Pre-processing (scouring and bleaching) use cold pad-batch pre-treatment process, it is not only an economic, environmental, energy saving and simple shortened process (its simple equipment, low energy consumption, low production of Ding Yuan, integrated, low cost, and the reaction mild, less damage to the fiber), but also the release of dyeing machine, to achieve the pre-treatment isolated from the infected machine key. The use of cold rolling heap washing cars and professional equipment, to achieve the pre-treatment of the pile, and washed and washed through strict quality control to ensure good cold pile into the cylinder direct dyeing cloth.
1.2 dyeing fabric dyeing stage requires the reactor directly into the cold cylinder dyeing, dyeing machine dyeing only do simple operations, excess acid, after soaping the cylinder. We selected an advanced, environmentally friendly dyeing process caustic soda instead of soda ash. Use of caustic soda (36. Be), as in dark solid color base agent, chemical materials easy
Using less and low prices, are now some new dye base can not be compared, not only greatly reduces the cost of additives, but also to improve the fastness of reactive dyes; reduce the COD value of residue, greatly reducing the burden and cost of wastewater treatment.
[email protected]### Page ###@=================1.3 treatment
1.3.1 Use special washing equipment washing, wash cloth dyeing operation to achieve. Through practice and analysis, both domestic and imported dyeing machines should not be a pre-treatment and post-processing equipment, because the fabric before and after treatment need to be cleaned thoroughly, regardless of domestic or imported dyeing machines do not have the thorough cleansing advanced features, the overflow dyeing machine for pre-treatment and post-processing, only the use of large amounts of energy, water, steam,
Dyeing fabric on the power of the dilute residue treatment, the same time, gray in the overflow machine is running rope, so the added difficulty of cleaning, so even with a lot of energy and auxiliaries, as on the scientific principle , cleaning the not complete, so the cause of the instability of the quality of dyeing fabric, understand the principles, we believe that special washing equipment is the best pre-treatment, post-treatment washing equipment.
1.3.2 Fixing loose dyeing machine using the fixing operation independently.
1.3.3 Use a soft-style rolling cart storage solution dyed fabric to achieve dehydration softening.
External fixation in the dyeing machine and soft, you can wash cylinder This process is less, thus reducing the number of washing tanks as the outstanding result of quality problems.
For example, take the color fixing agent problems and because the silicone softener emulsion breaking spots and other issues arising; in the reservoir fluid type rolling the car rolling softener, fabric dyeing are dehydrated rolling good, soft is better than the dye machine than the soft, large bath, and when rolling softener can be shallow, medium and dark sequence is conducive to saving additives, and to meet the needs of different quality requirements. According to my factory statistics, can save fixing agent, softening agent nearly half.
2, sectional analysis of the dyeing process
2.1 Sectional dyeing process is a superior technology to use water-saving energy, electricity, steam the cold pad-batch processing, can be compared with the conventional pre-treatment process since the dye bleaching (oxygen bleaching a bath) in the energy (water ,
Electricity, gas) on reducing the consumption of nearly 3 percent or so; the use of advanced caustic soda instead of soda ash in the dyeing process can greatly reduce the use of soda ash,
At the same time the price difference between the two, causing more obvious cost savings; use of professional equipment for washing after washing out the tank than in the dyeing machine
Conducted rope washing washing effect is better, but can be shallow, medium, dark washed order to make full use of water resources and conservation, post-processing aids, fixing agents and the amount of softener can save more than half .
According to the statistical analysis of our plant for many years, for an annual output of 3 000 t of medium-sized enterprises, the dyeing process using sub-type of energy and auxiliaries can save about 1.5 million yuan, equivalent to 1.5 million yuan to improve profits.
2.2 Sectional dyeing process is the product of high quality, high yield guarantee
[email protected]### Page ###@=================Sectional dyeing process can improve the success rate of a dye to improve product quality. Because, as all processes have an independent existence, each process is completed can the quality of their monitoring responsibilities on the job assessment personnel can effectively ensure product quality.
Previous treatment, can effectively strengthen the management and quality control efforts to reduce the confusion caused by the pre-treatment quality, based on production practices, due to confusion caused by pre-treatment quality problems in more than 40%, so good control pre-treatment quality, better control on product quality equal to half the effective quality control process is not only the quality of the former the latter is certainly a quality assurance process. The pre-treatment were isolated from the infected machine can greatly reduce the occupancy rate of dyeing machine to improve its efficiency, without increasing the case of dyeing machines, potentially increasing yield.
2.3 Sectional dyeing process is conducive to the overall arrangement of production, rationalization and flexibility of the production plan can be arranged to do a single production plan to achieve the same unity of plan or similar material handling, pre-treatment of the unity of
Can reduce the degree of difference between white fabric; arrangements depth of color separation staining, washing can reduce the number of cylinders; the workshop production of the relative concentration of products, you can dip the high product quality and reduce defects, improve operator proficiency and reduce production time and improve efficiency.
3 Conclusion In summary, segmental dyeing process is a scientific line of knitted fabric dyeing process is to adapt to social sustainable development, to meet the quality requirements of high-quality market Ka, low consumption of new technology.
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