General Requirements for Textile Wet Processing:
Pretreatment:
1.
Control of time, pH, temperature gradient (C/min)
2.
Quality control of raw material, chemical, dyestuff etc.
3.
Control of machinery (speed, fabric flow rate, water flow rate, gradient of
temperature increase (heating) and decrease versus time (cooling down) etc.)
4.
Record of all textile preparation condition
5.
Alarm for worker to have an attention (machine stoppage, in case of emergency,
attention for adding chemicals, attention for designated time)
Dyeing:
1. Control of time, pH, temperature gradient (C/min)
1. Control of time, pH, temperature gradient (C/min)
2.
Quality control of raw material, chemical, dyestuff etc.
3.
Control of machinery (speed, fabric flow rate, water flow rate, gradient of
temperature increase (heating) and decrease versus time (cooling down) etc.)
4.
Record of all textile preparation condition
5.
Alarm for worker to have an attention (machine stoppage, in case of emergency,
attention for adding chemicals, attention for designated time)
Flow
chart of scouring and bleaching
Machine
Start
↓
Level in( water fill from p.t to m.t)
↓
Wetting
agent +antcreasing agent + per oxide stabilizer (inject at 50 ⁰
C.)
↓
Fabric
load (10 min.)
↓
Caustic
dosing (60⁰
C., 10 min.)
↓
Run
10 min.
↓
Hydrogen
per oxide (70⁰ C., 10 min.)
↓
Temp.
raise to 5⁰ C using gradiant 1.5 ⁰
C per min.
↓
Run
30 min.
↓
Cooling
at 78⁰ C using temp. gradient 1.5 ⁰
C per min.
↓
Drain
with rinsing
↓
Level
in
↓
Neutralization
at 60⁰ C
↓
Per
oxide killer 80⁰ C 10 min.
↓
Drain
↓
Check
residual per oxide & absorbency of the fabric
Flow
chart of enzyme treatment
Level
in
↓
Acetic
acid ( 1 Gram per lit. ) 5 min.
↓
PH
Check ( Ph = 4.5 to 5)
↓
Add
enzyme 55 ⁰ C
↓
Run
time (50 -60 min.)
↓
Sequestering
agent ( 0.5 g/L , 90 ⁰ C
↓
Run
time 10 min.
↓
Rinse
10- 15 min.
↓
Drain
Turq.
colour dyeing Sequence
Level
in ( M: L = 1:7)
↓
PH
Check ( PH = 6-6.5)
↓
Levelling
agent + half Sequestering agent (inject.)
↓
Colour
dosing 80 ⁰
C, 45 min.
(
color must be filtered two times and color disserved with levels at high temp.)
↓
Run
time 25 min.
↓
Half
Sequestering agent (inject)
↓
Half
salt dosslving 10min.
↓
Run
25 min
↓
Half
salt dosslving 10min.
↓
Run
25 min
↓
Soda
dosing 50min ( progressive)
↓
Run
10 min
↓
Sample
check
Dark
color dyeing flowchart
After
Enzyme treatment
↓
Levelin
↓
Levelling
agent(.5 g/L) + Anti creasing agent ( 1g/L)
↓
Salt
dissolving ( 60g / L , temp. 60⁰
C pH =7-8 )
↓
Colour
dosing 45 min( linear)
(Color
must be filtered two times; Color must be dissolved with levels at high
temperature.)
↓
Run
10 min.
↓
Soda
dosing(16 g/L, temp. . 60⁰
C, 50 min ,pH = 10—11.5)
↓
Run
time 10 min.
Light
color dyeing flowchart
After
Enzyme treatment
↓
Level
in
↓
Leveling
agent(.5 g/L) + Anti creasing agent ( 1g/L)
↓
Colour
dosing 35 min( linear)
(Color
must be filtered two times; Color must be dissolved with levels at high
temperature.)
↓
Run
20 min.
↓
Salt
dissolving ( 40g / L , temp. 60⁰
C pH =7-8 )
↓
Run
10 min.
↓
Soda
dosing(16 g/L, temp. . 60⁰
C, 50 min ,pH = 10—11.5)
↓
Run
time 10 min.
↓
Check
Sample
After
treatment flow chart
B.D.
Rinse 15 min. 45 ⁰ C
↓
Drain
↓
Level
in
↓
Normal
Hot wash 70 ⁰
C 10 min.
↓
Over
Flow rinse / MIR 45 ⁰ C 10 min
↓
Drain
↓
Level
in
↓
Neutralization
by Acetic Acid at 45 ⁰ C 10 min
↓
Over
flow Rinse MTR 50 ⁰ C 10 min
↓
Hot
wash by soaping agent 90 ⁰ C 10 min
↓
Over
flow Rinse MTR 50 ⁰ C 10 min.
↓
Drain
↓
Level
in Enzymatic wash if required 55 ⁰
C 40 min , PH 4.5-5
↓
Normal
Hot wash 80 ⁰ C 10 min
↓
Drain
Softening
treatment at 45 ⁰ C 15 min, pH 5.5
↓
Rinse
45 ⁰ C 10 min
↓
Unload
Chemical Name
|
Function
|
Wetting agent
|
To wet the fabric and reduce surface tension
|
Anticreasing agent
|
To protect the fabric from creasemark
|
Per Oxide stabilizer
|
Deactivate metallic ion
|
Caustic soda
|
Neutralize acidic material , saponify glycerides(waxes & oils),
solubolizes silicate
|
Hydrogen per Oxide
|
To reduce natural color and produce permanent white effect.
|
Per oxide killer
|
To remove residual Hydrogen per oxide from fabric surface.
|
RELATION BETWEEN YARN COUNT & GSM
Count
|
Fabric
|
|||||
S/J
|
Ly S/J
|
S/Lac
|
Pique /
D
Lac
|
Rib
|
Interlock
|
|
40/1
|
115
|
160 (20D)
|
150
|
190~200
|
||
36/1
|
125
|
160
|
||||
34/1
|
130
|
180 (20D)
|
180
|
220
|
||
32/1
|
135
|
190 (20D)
|
165
|
190
|
||
30/1
|
140
|
200 (20D), 250 (40D)
|
180
|
200
|
240
|
|
28/1
|
150
|
215
|
||||
26/1
|
160
|
180
|
210
|
230
|
||
24/1
|
180
|
205
|
250
|
|||
22/1
|
190
|
|||||
20/1
|
200
|
230~240
|
270
|
|||
16/1
|
220
|
|||||
34/2
|
220
|
|||||
22/2
|
280
|
|||||
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