Technical parameters of note-based dyeing for one-time OK (dyeing factory practice - recommended reading)

In order to ensure the correct dyeing of the rope overflow Knitted Fabric at one time, this paper analyzes the dyeing time, temperature, dye reproducibility, dyeing system, fabric cloth, laboratory formulation, equipment operation stability, and fixed water level. , put forward a one-time accurate dyeing OK focus is to strengthen the accuracy of the fixed water level to determine the dye cylinder level, improve the reproducibility of staining. It is also recommended to use flow method to set the water level and to enhance the influence of conductivity and SG value on the dyeing.

1 Introduction
1. In the face of fierce market competition at home and abroad, and the rapid development of low-cost dyeing technology at home and abroad, the low-cost dyeing technology is in turmoil. This forced the traditional dyeing processing and management methods to be changed, and the development of the one-time dyeing OK direction. How can I do a one-time dye OK? One-time fabric dyeing is a complex and systematic project with very influencing factors. According to statistics, there are more than 100 [1]. Analyze the technical and management level of the company from a large aspect, the overall quality of bleaching and dyeing engineers and the level of equipment and equipment are the key factors. Scientific management techniques and advanced equipment can integrate various factors, avoid weaknesses, establish a scientific and strict guarantee system, and ensure one-time accurate dyeing OK.
2.1 Dyeing time
In general, the length of time has a great influence on the depth of color. However, it is not difficult to implement accurate control at this point. As long as we have a good grasp of the SEFR value of the active material, we believe that each dyeing plant can control it well.
2.2 Dyeing temperature
From the current temperature control technology point of view, the dyeing temperature can basically be more accurately controlled, but there is the problem of whether the overall liquid temperature is average, because the current dyeing generally has a "cost pressure"; so the general 500P cylinder will be When the temperature rises to about 100°C in 20 minutes, the heating rate is so fast. However, heat transfer takes a certain amount of time to complete. Based on this problem, it is easy to grasp in theory and practice. Therefore, in the design of dyeing equipment, the contradiction is Can be solved.
2.3 The degree of stability of the dye (ie, the reproducibility is good or bad)
For this problem, we must consider when doing dye through, it is an important reference factor for our successful one-time dyeing, but we only use the dye as a reference to reproduce the performance is good or bad, this can be solved by the dye company research, here No detailed explanation will be given.
2.4 color system
When the active material is dyed, there are a large number of electrolytes, alkali agents, various types of surfactants, and other additives in the dyeing system. The SG value (density value) and the conductivity of the various dyeing systems in the dyeing system have a success rate for one-time dyeing. great influence. However, the quality of various additives has been monitored at the time of receipt. As long as the stability of the additive quality is kept in check, other matters should be handled by the additive supplier.
2.5 Cloth floor
That is to say, a control problem of the stability of the pretreatment process. We will have many questions about pre-processing. For example, yarn lot, cloth lot, etc. However, we emphasize here that the difference between the cloth's gross effect and the whiteness value of each pre-treatment should not exceed 5%. If it exceeds 5%, it is very difficult for one-off dyeing to succeed.
2.6 Test Availability and Formulation Are Reasonable
Because the lab is a small sample test, Labdip hit 5g, 10g, mostly by constantly trying to call out the closest to the customer to identify the color formula. In order to find a production formula that is close to the customer to distinguish colors. However, due to the laboratory's pipette accuracy only two digits, so it can only be said to be close to the formula to be found; and the laboratory cloth weight 5g and mass production 8000P (3900 × 103) is almost a difference of 106 times, as long as there is a little error, It will be one millionth difference. Even if the first and most sophisticated equipment is provided (there are differences in the dyeing equipment), it is difficult for the dye to be dyed successfully from the laboratory directly to the dyeing department. Therefore, it is very necessary to do a sample test before production. This will usually further rationalize the data of the recipe and also provide important data for large-scale production of one-time OK.
2.7 Is the operation of the equipment stable?
That is, we should pay attention to the effect of mechanical wear on dyeing, and we must always pay attention to the delicate parts and do maintenance work. This point can be completely solved by the machinery manufacturer, but we must do a good job of registering machinery and equipment failures so that we can report problems to manufacturers. The manufacturer is only responsible for manufacturing, and the user always touches the equipment first. If the two can be combined, I believe we can achieve a win-win goal.
2.8 Technical Research to Improve Accurate Water Level
This point is the direction that we must focus on, and it is also the key point for us to research whether the one-time dyeing is successful.
As we have already mentioned before, one-time dyeing should be successful. We must study the dyeing system. If the water level can not be determined, then some of the research knowledge in the dyeing system will be used to guide the success of a one-time staining will be greatly reduced, and even lead to dyeing failure.
Why do you say this way? In the entire dyeing system, the average density of the electrolyte, we can monitor the SG value instrument, PH value monitoring with a PH meter, these two points have accurate data description. However, the water level, we only reflect the water level gauge next to the dyeing tank to reflect whether the water level meets our requirements. The error is relatively large. We cannot completely obtain the data.
Because, in our common sense, the error value of 100ml measuring cylinder is ±1ml, the measuring cylinder error of 1000ml is ±10ml, and so on, the instrument error of 10,000 liters of capacity should be about 100 liters, which requires the dye cylinder to be made Measuring the shape of the cylinder can reduce the error to such a low level. However, it is actually very difficult to do. The error condition is also calculated from the cross-sectional area of ​​the volumetric device. If the cross-sectional area to height ratio is 1:1, then the error will be around 10%. That means if Into 10,000 liters of water, sometimes 9,000 liters and sometimes 11,000. This is to say that our dye tank water level does not have a definite data to explain its accuracy and error range. Therefore, with regard to water level issues, there is experience in watching Master's success rate in setting the water level. However, his experience also has his limit. Therefore, we must scientifically study the water level and use the data to indicate the level of the water level problem. Because the cross-sectional area and height ratio of the dyeing tank is too large. Therefore, in printing and dyeing, I do not agree with the calibration method to measure the water level. It is more accurate to determine the water than to determine the available flow method or weighing method, but the weighing method is not practical for the large vat. The statutory water level of the flow can be achieved and it is worth further investigation. This is the direction that I would like to focus on.
Regarding the dyeing system, in addition to the several quantifiable parameters that I mentioned earlier: the SG value, the pH value, the electrical conductivity, etc., the dyeing kinetics problem is also involved.
For example, in the entire dyeing system, we dyed 1000 kg of cloth in a ratio of 1:10 water. In theory, the water should have a total of 10,000 liters. If we enter the vat with the exact number of 10,000 liters of water, we can accurately place it in accordance with our sample. The error of the entire dyeing condition is controlled within 4%, and the problem of successful dyeing once is not significant. However, if we put 1,000 liters of water or put 1,000 liters less, what will happen?
If we are accurate, we can add more water to reduce the error as much as possible when measuring SG. However, in the dyeing process, salt is rarely added to the dyeing system all at once. (If this is the case, we can also go through the electrolyte to control the water level.) If the sample is dyed, when the water ratio is set at 1:10, the material is accurately weighed on all sides and the dyeing power is ∑ = ×, the dye concentration The average concentration in water is C = Y, and the diffusion adsorption force is F = Z. Then in the water with less than 1000 liters, several parameters become:
∑=×+ C=Y+ F=Z+ The color will come out
So little more 1000 liters of water
∑=×- C=Y - F=Z- The color will be shallow
According to my personal observation, the department responsible for the sample injection is based on the sample formula provided by the workshop and uses the method of weighing and setting water. The one-time success rate is very high.
3. Conclusion
Therefore, it is very important for us to study the continuous determination of the water level, and it is very important for us to study the one-off dyeing OK. If the water level has not been determined, our previous efforts in management and technology will be distorted. At the same time, we must also strengthen the simulation study of SG value and conductivity standard sampling. For one-off staining and staining success, these two points deserve further study.

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