In the dyeing process, reproducibility is a very important topic and has important implications for dyeing. Below we will understand the issue of reproducibility.
Let's look at the meaning of good reproducibility:
Dyeing at different times, dyeing in laboratories today and tomorrow, dyeing in workshops (field) tomorrow; staining in different occasions, formulating samples from labs to the workshop (site), .... all the same results - very small color difference .
The following are the factors of control in terms of reproducibility (look at the examples of disperse dyeing.) Knowing which aspects are poorly controlled leads to reproducibility problems.
1) The dilution ratio of the mother liquor in the laboratory is not good, and the manual pipette operation is not proper. This is related to the operator's work attitude, proficiency and other factors. It should be through intensive training to allow operators to develop good work habits.
2) Laboratory electronics have been used for a long time and their accuracy is not high , including the use of electronic scales for dye bins, and no related corrections have been made. Electronic products are prone to errors in accuracy. Standardized management should be implemented and electronic calibrations should be conducted on time to ensure that everything is safe.
3) There are some sedimentary dyes in the laboratory that are not in place.
4) Improper management of mother liquor life in laboratory.
5) The compatibility problem of laboratory color testing machines.
6) Cleaning problem : The residual dye was adhered to the wall of the dyeing (cup) and was not cleaned.
7) The appearance of the whiteness of the yarn or the lot of the cloth (yarn) varies greatly. If there is a change in the raw materials and there is no compound, then direct dyeing will generally not achieve the desired color.
8) Improper control of the pH value of the dye solution (pH). This is often overlooked by many dyeing factories.
9) Consistent staining curves, temperature deviations, and floating problems.
10) The dye dynamite dosage workshop (site) is in poor synchronization with the laboratory. Even the inconsistency of materials used in the field and in the laboratory. This is a strict issue of control.
11) The reduction and washing of the color samples in the laboratory and smooth and soft processing are quite different from the scene.
12) Different dye batches are used between laboratory and field (workshop) ; Some factory dye warehouse storage environment control is not in place, including temperature and humidity control issues. In particular, in some factories with poor management, the dye warehouses often open doors and windows and are directly connected with the outside world. If you encounter rainy weather, the question of the moisture content of dyes can be imagined.
13) Water management. Water management is often overlooked. But is actually using groundwater, river water or tap water? The reproducibility of dyeing is very large.
Of course, whether dyes with good compatibility are used in the production process, whether the operators are skilled, whether the mobility of personnel is too great, and whether or not standardized management is performed will have an important impact on reproducibility. And reproducibility (reproducibility), we should regard it as a matter of management level, and it is often necessary to correct control to achieve perfection. The mismanagement of almost every point listed above will have a major impact on reproducibility, and it should be given enough attention in dyeing and finishing operations.
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