Denim Manufacturing - Yarn Process Warping

 

The production process of denim given in the following link gives the general idea of the process, the series of blogs like this give the brief explanation of the process and machines. Here in this blog we will go forward to next and important step, which is Warping Process:

https://bindaprocess.blogspot.com/2022/02/denim-production-process.html 

Warping 

It is the process of transferring  multiple yarns, each on a separate yarn  package into a single collecting package.

Ball Warping

In rope dyeing as explained in https://bindaprocess.blogspot.com/2022/03/denim-yarn-dyeing.html

This package of yarns is  referred to as a ball warp. The  individual yarns are brought together  and formed into a rope. The rope is then  wound onto a cylindrical barrel  sometimes called the log, it got its name  from when they were originally made from  solid pieces of wood. Today logs are made  from metal and covered with rubber. The  log does not have any flanges, the yarn collecting package is referred to as a  beam.

When the yarns are laid in sheet  form onto a cylindrical barrel with side  flanges and yarn ends lying parallel to  one another in either case, the supply  yarn packages are placed on spindles  which are located in a framework called  a creel. Traveling package creels are:

V- Shaped Creels

With the current  packages of yarn that are being used to  make the beam or log, placed on the  outside of the V. The replacement yarn  packages for the next warper set are  placed on the inside of the V. When the  running packages are depleted the empty  yarn packages on the creel are rotated, so that the spent packages then move to  the inside of the V and the previously  stored full packages moved to the  outside of the V, ready to be processed  into the next warp.This system  eliminates time lost in creeling up new  yarn packages.

Continuous Magazine Creels

These are straight-line creels with  enough package holders. So that each end  running has a reserve yarn package place  beside it. The tail end of the running  package is tied to the beginning end of  the reserve package. Once the running  package is depleted the yarn transfers  over to the reserve package and the  warper continues to run. This is a random  method of creeling yarn packages and is  most effective by Mills running beams  and balls.With a standardized number of  ends yarn types or yarn counts on them.

Truck Creels

It describe a system where  one creel is running yarn packages while  a second creel  being loaded. Once the current set of  packages is exhausted, the creel is moved  out of the way and the second creel is  moved into the running position.The yarn  hands from the second creel must be  pulled forward and threaded through the  appropriate guides in ball warping  anywhere from 250 to 400 yarns or ends  are pulled from the creel.

These yarns  then pass through a comb like device  sometimes called a hack or Reid which  keeps each warp yarn separate and  parallel to its neighboring ends. Every  one to two thousand yards a least string  is interlaced through the warp yarns at  the hack the string aids the yarn  separation into sheet form during the  subsequent redeeming operation.

After  dyeing the yarns then go through a  funnel shaped device called a trumpet  which condenses the sheets of yarns , interrupts form the trumpet is located  at the base of the warper head and moves  back and forth guiding the rope of yarns  onto the log.

Once the yarns have been  wound under the log this package is  known as a ball warp and is ready to be  delivered to the indigo rope dye range.

Beam Warping

During beam warping, yarns from the creel  are in a sheet form and are wound  parallel to each other onto a flanged  beam. These yarns will not go through the  indigo rope tie range but can be either  slasher died or left natural.

If left  natural the resulting fabric could then  be piece dyed or used as a natural denim  which could even later be garment dyed. If desired another option could be to  beam dye the yarns using something other  than indigo dye.

The complete warping process describe in this blog can be viewed here:

https://youtu.be/425GgktN5I0

 

Denim / Yarn Dyeing

The production process of denim given in the following link gives the general idea of the process, the series of blogs like this give the brief explanation of the process and machines. Here in this blog we will go forward to next and important step, which is Dyeing Process:

https://bindaprocess.blogspot.com/2022/02/denim-production-process.html 

Introduction

With the warp yarns dyed using blue indigo dyes and the filling yarns being left undyed for the special denim appearence.

There are a number of alternatives for denim dyeing that are routinely used to obtain specific fabric appearance or performance with the advent of denim garment washing techniques, the construction and dyeing.

Techniques used are of utmost importance, the selection of yarn the consistencies of the indigo dyeing process and its modifications have become crucially important in determining the quality and performance of indigo denim products.

The properties of the Indigo dyes account for the wide variety of color designs that are available on denim products. Indigo is unique as a major textile dye because the indigo dyeing process is naturally ring dyes the cotton yarns, unlike almost all other commercially successful dye stuffs.

The Indigo dye concentrates in the outer layers of the yarn,during the dyeing process this produces an intense ring of color around a white core in the yarn. Thus the name ring dyeing occurs.It's considered a dyeing defect also indigo dye an intense blue is insoluble in water and will not dye cotton fiber in order to dye cotton yarn the Indigo must first be converted into a water-soluble leuco form and then applied. This chemical process is known as a reduction.

Reducing solutions containing sodium hydrosulfide and sodium hydroxide chemically change the indigo dye into its soluble form this process also converts the dye from its intense blue color to a very pale greenish yellow color. The outer layers of the yarn readily absorbed this leuco form of indigo. once dyed the yarn the Indigo is returned to the insoluble form by oxidation.

During oxidation the ropes of yarn passed through the air in a process called skying. The oxygen in the air converts the dye back to its original insoluble form and it's blue color returns in traditional rope.

Steps in Dyeing

The following steps are involved in processing Scouring,  Indigo dye application, Rinsing and drying. For substantial dyeing, process are defined here:

https://bindaprocess.blogspot.com/2022/02/textile-sustainable-denim-dyeing.html

The ropes are first fed into one or more scouring baths which consists of wetting agents and detergents. The purpose of these baths is to remove naturally-occurring impurities found on the cotton fiber such as dirt , minerals , ash and pectin. Additionally the waxy layer on the fiber which repels water is also remove.

It is very important to remove these materials to guarantee uniform wetting and dyeing.The ropes are subsequently fed into two or more water rinsing baths the key to this process is the dyeing segment. where the Indigo dye is added in layers to the outer surfaces of the yarn in rope.

The yarn is passed into a vat of soluble indigo dye that exhausts on the surface of the yarn and is then oxidized this results in a small amount of dye being deposited on the surface yielding only a light blue dyed yarn. In order to obtain a deeper blue indigo shade the dye must be built in layers by multiple passes of the Rope of yarn into the subsequent vats of soluble dye and then into the air for oxidation.

Each of these cycles is called a dip. Normally this process is repeated from three to nine dips in order to build up a rich deep blue color. If even darker shades are desired a sulphur black or sulfur Navy dye can be applied to the yarn prior to the Indigo dyeing this is known as a sulfur bottom.

If the sulphur dye is applied after the indigo it's known as a Sulfur Topping. 

Here 3 in 1 box or bottoming box plays roles that are defined here for effective dyeing:

https://bindaprocess.blogspot.com/2022/02/denim-rope-dyeing-automation-2022.html

when a sulfur bottom is required the scoured ropes of yarn are then fed into a bath of a reduced sulfur black dye similar to indigo sulphur dyes are water insoluble, they must be reduced to a water-soluble form prior to application. 

Unlike indigo , the sulphur dye can penetrate into the core of the cotton fiber thus darkening the overall color shade. Once the reduced sulfur dye is applied to the ropes of yarn the dye is allowed to oxidized to its normal water insoluble form.

The ropes are then fed into one or more water rinse paths these baths remove any unfixed sulphur dye that might contaminate the indigo dyeing process.

Dyeing range for application of the Indigo dye typically 12 to 36 individual ropes of yarn are simultaneously fed side-by-side into the range. The ropes are kept separate from each other throughout the various parts of the derange.  

The ropes  are then fed into the reduced indigo dye baths once reduced the indigo dye takes on a pale greenish yellow shade the yarns are then skyed as much as 30 to 40 feet into the air to allow the oxygen in the air to convert the indigo back to its normal water insoluble blue shade.

As the yarns oxidize they change from a light greenish yellow shade through various darkening shades of blue green until they become the deep blue indigo shade.

Denim shades require as few as three or as many as nine to tweleve dips and skying processes. The ropes are then rinsed in several water baths to remove any unfixed or surface dye deposits another.

Option would be to add a sulfur top after the indigo dye has been applied. The sulphur dyes still migrates toward the core of the fiber but the sulfur top uses a different type of color performance. Especially in garment washing procedures the sulfur top process is followed by one or more water rinses to remove any unfixed dye , after rinsing the yarn. Ropes pass through squeezed rolls to mechanically extract water from the yarns, are then dried and coiled into large tubs.

The typical drying apparatus is multiple stacks of drying cans these metal cylinders are filled with pressurized steam. Care must be taken not to over dry the yarn or the dye will excessively migrate to the surface of the yarn increasing the tendency of the color to crock.

Additionally if the surface of the drying can is too hot the yarn can be overstressed producing an undesirable shiny or ironed appearance. 

Coiling takes place after drying the ropes, exit the drying cans and are lifted high into the air and then coiled into large trucks or tubs. Each individual rope is placed into a separate truck, after drying, the color of the yarn is checked either visually or instrumentally.

with many indigo dye ranges the color of the yarn is continuously monitored by a color spectrophotometer which is electronically linked to the controls of the indigo dye baths. This type of control system can automatically adjust the dynamics of the process to obtain the most consistent color from the beginning to the end of the many thousands of yards of yarn contained within a single dye lot.

Once the warp yarns are rope tied it's then necessary to change the yarn alignment from rope form to sheet form prior to entering the next process. which is slashing or sizing beaming or Rebeaming. Which involves pulling the dyed ropes of yarn out of storage tubs and moving them upward to a guiding device sometimes called a satelliete.This upward travel allows the ropes to untangle before reaching the Beamer head. Once the ropes come down from the guiding device they go through tensioning rollers to help further separate the yarns prior to going through a comb at the warper. For subsequent process in sizing and weaving.

The complete dyeing process describe in the blog is also available in video at this link:

https://youtu.be/qp2Z_pYsRGM

Denim Spinning

 

The production process of denim given in the following link gives the general idea of the process, the series of blogs like this give the brief explanation of the process and machines. Here in this blog we will go forward to second step, which is spinning:

https://bindaprocess.blogspot.com/2022/02/denim-production-process.html 

The manufacturing of yarn starts with the transfer of the cotton bales chosen by a special software from the warehouse to the feeder of the blowing room which is the starting point of the yarn spinning halt.

From this point onwards the cotton undergoes many processes such as

cleaning opening and blending with the contents of other bales it is during this process that fibers which are too short are extracted. Process are briefly describe here:

https://bindaprocess.blogspot.com/2022/02/blow-room-process.html

CARDING

The cotton fibers are then subjected to a carding operation that ensures that the fibers are parallel to each other at the same time a vigorous and detailed cleaning of the material to be used in the yarn production is carried out in order to radiate to the next phase of manufacturing as a result of these operations the cotton fibers are transformed from the compressed randomly mixed material containing impurities to the sliver which have been neatly stacked into cans ready to the following processes.

Drawing

In the drawing frame process the sliver from different carding machines are joined to form a homogeneous mix and the parallelism of the fibers is further enhanced the bookends that are a part of the fibers nature are straightened out and the fibers are further lengthened. In order to monitor the weight per unit length of the produced sliver. Control highly developed electronic regulation systems are utilized. Sliver from the drawing frame operation with uniform mass per unit length are further drawn out by the roving frame.

Roving 

In this operation single twisted yarn  then wound onto tubes that can be used on the yarn machines. The roving is the final step before yarn is produced, after this operation the rovings are subjected to a further drawing out operation on the ring machines.

Ring Machine 

Ring machines further thinned out the yarn to the final required yarn thickness. During this operation the yarn gravity is subjected to a twist in order to give it the required durability. The ring machine determines the circuit structure and the physical attributes of the yarn being produced. 

Winding Process 

Last phase of yarn production is the winding process here the cops produced by the ring machines are spliced to each other and transformed into a bobbin format of specific lengths,  this splicing process is very important from the point of view of the productivity of subsequent phases. Where the bobbins will be used and the final appearance of the fabric developed. During the winding process the yarns are monitored every millimeter of the way by high technology sensors on the bobbin machines and faulty areas that may affect the texture of the fabric are eliminated.

Finally, color quality and authentic appearance is preliminary for  preparing the yarn for  Rope dyeing system which is the preferred system of denim production. The yarns that will be used in the warping  are stacked in the ball warping machines creel section and are all brought to the front of the machine to be transformed into Rope. The Rope does produced is then wound on two cylindrical shafts ready to be dyed in the indigo machine. following blog help in the understanding of process , how substantial dyeing range can be produced:

https://bindaprocess.blogspot.com/2022/02/textile-sustainable-denim-dyeing.html

 

BLOW ROOM PROCESS

The production process of denim given in the following link gives the general idea of the process, the series of blogs like this give the brief explanation of the process and machines. here in this blog we will get the idea of Blow room Process:

https://bindaprocess.blogspot.com/2022/02/denim-production-process.html 

Overview

Department blow room is the first apartment inside the spinning mill. The m ain objective of blow room is opening, cleaning, Dust removal, Blending (even feed) for the material to the card blower machineries.

Operations

The operations involves loader, it all begins with lay down arrangements, where Bales are collected from Bale go downs based on the properties they possess, length strength micronized reflective

index which is checked through ketch VI instrument, improper lay down which caused variation in yarn.

Pluckers or blend or mat is the first machine in the department. where fibers are opened from bale with opening rollers which acts on bales and opens into fiber flocks. The height of bale pluckers advances during each transfers so that there will be constant opening of fibers. open fibers are transferred for  further fine opening and cleaning, and are  transported with the help of pipeline. condenser plays a vital role in transporting material to next machine. lean opened fibers from bale plucker reach to the unit precisely called Pre cleaner , through duct line. 

This  line eliminate heavy trash like seed particles, stones trash etc. These heavy particles drop down on the grid bar through gravity and suction generated by waste collection chamber these wastes will be collected through waste pipelines and will be stored in waste collection lines. 

Multi Mix pre-cleaned material reaches the multi mixer contains several chambers to collect the material. material will be filled in sequence in all chambers uniformly and it is controlled by a pressure switch. Material from all chambers mix uniformly inside the chamber before they exit, so the property will not very much different in the output fiber this is to avoid variation in yarn properties and this will be reflective in fabric appearance after dyeing.

flexi clean material from multi mixer is then transferred into fine

cleaning flexi clean material. Which  is subjected to fine beating achieved with the help of pin beta or sawtooth beta.

waste particles adhere to fibers will be removed during this

fine beating precisely called controlled beating. So it is very important to maintain the feed from uniform beating.

waste particles are eliminated through suction generated by waste collection chamber. Contamination cleaner particles which cannot be removed by Uni-clean of flexi clean machines like colored contaminations and polypropylene materials, should be transported and are removed through contaminated cleaners. These machines  particularly act upon colored particles and polypropylene materials. Presence of these materials in yarn should cause bad effect on fabric after dyeing.

Material rejected to these machines are later subjected to sorting where waste particles are separated from good fibers. This should reduce the overall fiber loss and improve yarn realization. 

Denim Fabric Stucture & Application

Denim History 

Denim is one of the world's most iconic fabrics. Jeans is popular across national and cultural boundaries and the denim jeans has become a symbol of culture throughout the world over last decades.

What exactly is denim? where did this come from and why has its popularity endured and abated throughout the decades.

We will dive into all these questions and more as we to tell you everything you need to know about denim fabric.

Denim has been used in the united states since the mid 19th century. Denim initially gained popularity in 1873. When Jacob W Davis a tailor from Nevade, manufactured the first pair of rivert rainforest dining pant.

At this time,clothes for western livers such asteam stars surveyors and miners were not very durable.This time denim was too popular among western liberals for its durable properties Levi Strauss and Company was so impressed by the possibilities for profit.

They hired davis to be in charge of the mass

production of denim in San francisco. Nowadays denim is popular across national and cultural boundaries.

Fabric construction 

Denim is made from rugged tightly oven twill. In which the weft yarn passes under two or more wrapped threads. Lengthwise the yarn is dyed with indigo or blue dye.  Horizontal yarns remain white. The yarns have a very strong twist to make them more durable but this also affects the denim's color, the yarns are twisted so tightly that indigo dye usually colors only the surface leaving the center of the yarn white.

The blue turns become the threads that show on the outside of your denim and the white are the ones that make the inside of your denim look.

It causes denim to fade. Properties of denim fabric denim is traditionally woven with hundred percent cotton yarn. However, today it's blended with polyester to control shrinkage, wrinkles and liquid to add stretch. Following Sources explains the process in brief:

https://bindaprocess.blogspot.com/2022/02/denim-production-process.html

https://bindaprocess.blogspot.com/2022/02/textile-sustainable-denim-dyeing.htm

Properties

Denim fabric basically constructed of cotton or blended fabrics, usually in woven in two by one or three by one twelve waves, inserts strength and durability which is very high.

Very high GSM makes it moisture observant  abilities and breathability is very high. Stretachability of denim fabric is low to medium prone to peeling or bubbling.

Use-Ability

Almost no uses of denim fabric in the past it was used by workers as a safety wear. Day by day, its acceptability is increasing among consumers. 

In apperal,  it is used as jeans shirts , lightweight jackets, suits, sportswear ,caps , evening wear and children clothes. It is also used in making protective clothing, ladies handbag school and college bag, travel bag and also for seat covers.

Denim Production Process

RAW MATERIAL/ BLOW ROOM

The  process starts with cotton before yarn is even in the picture. Various cotton varieties from around the world and Turkey are available,  these varieties are blended according to a special blend recipe in an attempt to acquire raw material that meets specific properties. The  aim to use quality cotton and process it to yield high quality yarn.

Once blended cotton arrives at factory, there are certain tests that needs to be performed in order to  determine whether the product is really, what we expected it to be?,  these tests are done to execute an input control before the process begins.

Once the tests are completed cotton can enter the process where the  cleaning and blending has been done, for this  the bales has been stacked  in  blow room unit and  certain procedures are performed  to thoroughly remove stems dirt and dust that occurs naturally in the cotton plant. We focus in achieving sustainable homogeneous quality and optimum performance in our production.

SPINNING

By the time the mixing fluffing phase is finished. The cotton is completely free of foreign matter like dirt and dust and is ready to be spun into yarn, which begins at the combing machines. combing machines create cotton sliver before additional cleaning to remove the nets cotton as well as the remaining dirt and dust.

Subsequently, in the drawing frame process the slivers from different combing machines are joined to form a homogeneous mix and eliminate irregularities. After the drawing process,  an interim step is achieved in  which the roving machine  thin out the strip so it can be fed into the spinning machine.

eventually, this raw material reaches the ring spinning machine,  which is the final stage of spinning the production of yarn by giving twist and draw/ draft. Afterward,  forming of yarn into bobbins has been accomplished , for use in  subsequent process.

Processing

The Indigo unit where we give denim its legendary color , yarn in processed in the form of ball 12/ 24 7 36 ropes at Rope Dyeing Machine. At first pretreatment is done for  dyeing the yarn  in different colors ranging from very light to very dark shades. various dyes substance groups on the bottom and topping can also be done. It is the crucial aspect of indigo for  darkness and lightness of the color, and this is made possible by increasing or decreasing the number of vats/ dye boxes. 

once the dyeing process is complete,  the semi finished product in rope form is redeemed before being transferred to the sizing beam.

Below link mention complete process for sustainable dyeing.

https://bindaprocess.blogspot.com/2022/02/textile-sustainable-denim-dyeing.html

SIZING

warp yarn is prepared in Re-beaming  processes before arriving in  for sizing, this is where yarn is prepared for the subsequent stage. Which is weaving,  unwound warp yarn arrives here on unwinding beams to be coated with chemicals prepared at optimum process conditions. special chemicals are used to increase the resistance of warp yarn against mechanical strain in the weaving stage. In the next stage warp yarn is wound on the weaving beam and stored for subsequent process in  weaving.

WEAVING

It is a process in which warp and weft yarn are interlaced at right angles to form a fabric. The weaving process depends on three basic motions. First is shedding this is the stage where warp yarn is grouped in preparation for the weft insertion process. Second comes weft insertion, this stage involves inserting weft inside the shed. The third motion is Beat up and this is when the weft that has been inserted into the shed is compressed.

FINISHING 

The finishing unit is where we improve the properties hand feel and appearance of the fabric product by means of physical and chemical processes. Our job consists of three main processes Pre-finishing, Coloring and Finishing.

Pre- finishing involves brushing and singeing. Coloring involves dyeing and coating. The finishing phase is where the fabric is given its final properties, this is what defines the fabrics hand feel properties.

QC 

At the quality control department we perform our work with three main control mechanisms are developed. Physical tests, Visual inspection and Shade assessment. Test are done based on the specifications desired by the customer. This link offers the same in depth:

https://bindaprocess.blogspot.com/2022/02/denim-fabric-stucture-application.html

For maximum yeild and great results, engineering automation in current line may be made, below link specify the same in detail:

https://bindaprocess.blogspot.com/2022/02/denim-rope-dyeing-automation-2022.html
 

Textile Sustainable Denim Dyeing

 

Advanced Denim for more Sustainable
Denim Colors and Effects 

Almost 2 billion pairs of jeans are manufactured every year, no item of clothing is more popular then the  starting material is cotton. which passes through numerous processing steps from the cotton field to the finished thread in the textile factory.

The raw cotton is fluffed up cleaned and the single fibers are pressed into loose strands before being spun into yarn.

Since the gold digger era the yarn for jeans has been dyed blue with indigo. With advanced denim ,  now a days a more eco-friendly era of traditional dyeing, in which indigo requires the use of long production lines. Some stretching to more than half a mile in length.

These machines consume enormous amounts of water and energy. Moreover when the color is changed most batches create large amounts of cotton waste, because of the metre dispose off, all the fibres still inside the machine.

After spinning up to 4500 cotton threads of simultaneously pre wedded, decreased with chemicals and cleaned in several preparation lines, now the actual dyeing process begins with an average of 10 % immersed in the first indigo dyeing box.

Indigo in its natural agglomerate state is not soluble in water and in this state cannot penetrate into the fiber material. The molecules have to be separated to make them water-soluble. This is done by reduction of the double bonded oxygen in this reduction process.

The strong reducing agent sodium hydrosulfide causes the indigo to take up negative charges. The molecules repel each other making the indigo soluble in water.

In this process indigo loses its the resulting finely dispersed indigo molecules can L settle on the top layer of the cotton fiber the yarn fibers are then exposed to atmospheric oxygen which removes the negative charges from the indigo molecule causing the oxidant groups to return to the original form in other words they are oxidized the indigo.

molecules turn blue again the dye is no longer water-soluble and adheres to the fiber for intensive and uniform dyeing the cotton has to pass through 6 to 15 consecutive dyeing that's because the fiber absorbs the indigo only very slowly this process not only consumes vast amounts of energy but also an above all .

Large quantities of water in  the next step removes the chemicals previously added for cleaning and reduction as well as the unbound indigo in several washing boxes.

This produces large volumes of coloured waste water contaminated with sulfides which adversely impact the aquatic ecosystem. 

The yarn fibers are now dried and during the sizing process ,same coated with a film of starch to protect them during the stressful weaving process that follows the conventional production process.

According to National Geographic magazine an estimated water consumption of 11,000 litres for each pair of the groundbreaking technology of advanced denim the new pad sizing ups process provides savings of up to 92% water 30% energy and 87% cotton waste during dyeing and sizing and generates absolutely no waste water.

Central to the new process is the more eco-friendly,  concentrated liquid sulfur dyes with a high affinity for cotton just a single dyeing bugs and one sugar base reducing agent are needed to obtain a medium color intensity for the next step is a combined sizing and oxidation box in which the dye is fixed and the protective starch layer is applied all the other working steps are eliminated.

In chemical terms dyeing with sulfur dyes closely resembles the traditional indigo process but sulfur dyes not only have the oxygen groups but also sulfur containing functional groups known as tiles in the first step as with indigo the dye molecule is reduced causing it to dissolve in the water and change color in the oxidation process. That follows the dye is fixed to the fiber by a strong ionic bonds and the final color develops the sulfur groups can cross link with each other and can also bond very strongly to the fiber via the fixing agent this improves the strong color fastness and high abrasion.

Link may be utilized:

https://bindaprocess.blogspot.com/2022/02/denim-rope-dyeing-automation-2022.html

https://bindaprocess.blogspot.com/2022/02/denim-fabric-stucture-application.html

https://bindaprocess.blogspot.com/2022/02/denim-production-process.html

Textile Rope Dyeing Automation/ Troubleshooting

 

TEXTILE ROPE DYEING AUTOMATION / TROUBLESHOOTING

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How to retrofit the current Rope Dyeing  processing line to increase the maximum yield with minimum rejection and maximum efficiency?

This report aims to provide the details of introducing a dosing pump and the hydro feeder in the current 3 in 1 circulation line for getting efficient and uniform (without variation) dyed product, it is observed that the current line lacks the proper feeding system which is disturbing the consistency of shade at some place, in this report three types of designed are given for making an efficient dyeing line to resolve this problem. 

INTRODUCTION

The purpose of the report is to recommend the installation of dosing pump and hydro feeder for minimizing the variations. Because the current line has no such components and for fulfilling their requirements the mobile pumps are used as alternatives  which are not functioning efficiently.

 

PROBLEMS ASSOCIATED WITH CURRENT DESIGN 

•       The mobile pumps didn’t have the proper stirring system which restricts the chemical to mix properly as a result of which the denser chemical settled down at the bottom.

•       They also don’t have the leveling system which increases the chances of making incorrect level.

•       The denser chemicals which settled down are sometime accumulate with in the pipe and as a result of which the pump get choked.

•       Mobile pumps not fulfill the basic requirement of more than 7 liters and also not worked properly at limited feeding of > 1.

•       Whereas for the continual feeding of dye, topping pump is used whose head is at a far distance from the box, which generates the heat for maintaining such a high pressure and might be get stop in the future long production runs. 

RECOMMENDATIONS

The above issues could be resolved by making some alteration in the current line, and for this three type of design are given below that could solve this problem.

 

 DESIGN 1

DESIGN 2

 

 

DESIGN 3

CONCLUSION

By selecting one of the three  above designs the system could be perform better then present, the sedimentation will not occur because of the introduction of  hydro feeding system which is directly attached with the main circulation line of the box. Besides this the installation of dosing pump in the 3 in 1 tank allows the continual flow of dye at constant rate without making any of the high heat loses, because of the low head distance and this pump will also be used for high feeding . Moreover, the topping pump could be used for the caustic feeding to completely eliminate the mobile pump from the line.

This may also be viewed:

https://bindaprocess.blogspot.com/2022/02/textile-sustainable-denim-dyeing.html

https://bindaprocess.blogspot.com/2022/02/denim-fabric-stucture-application.html

https://bindaprocess.blogspot.com/2022/02/denim-production-process.html?m=1