Factors affecting the success rate of dyeing once


The dyeing success rate (Do It Right The First Time), or DIRFT for short, has a direct impact on the efficiency, quality and cost of a dyeing company and is an important reflection of a dyeing factory's technology and management level. 

In this paper, we discuss the factors that affect the success rate of dyeing in the laboratory, and discuss the ways to improve the success rate of dyeing:

From the management point of view, the various conditions of the laboratory proofing strive to achieve the same as the workshop production, the laboratory proofing work is to serve the workshop, not to ask the workshop to produce according to the laboratory conditions, but the laboratory should strive to imitate the workshop conditions when proofing. Laboratory do more precision, can not effectively provide data and process support for the workshop, then the value of the laboratory can not be reflected.

I. Temperature:

As one of the three elements of dyeing (temperature, time, water), the temperature of the laboratory in the control of temperature, expressed in the impact on the production of large goods, mainly the following points:

1. Unification and correction of the temperature table of small sample machine and the temperature table of large production in the workshop

The temperature table of small sample machine is generally to resistance sensor type, and the temperature table of workshop dyeing machine is generally bimetal thermometer, because the manufacturers of small sample machine and workshop dyeing machine are different, it is necessary to unify and correct the thermometer of laboratory and workshop, which is the premise of consistency of laboratory and workshop imitation sample. The specific correction method is not repeated in this paper.

2. Temperature control of soap boiling, reduction cleaning, etc. should be imitated in the workshop

Many dyeing factory laboratory sampling, dyeing is certainly a small sample machine control, and soap cooking, reduction cleaning and many other operations are operated on the electric or induction furnace, many laboratory sampling staff in the soap cooking will have the habit of boiling water, that boiling is soap cooking, the author believes that this is wrong, the workshop in the soap cooking or reduction cleaning, the temperature is generally set to 95 ℃, while the laboratory boiling operation, the water temperature is close to 100 ℃, then soap cooking conditions are different, the color obtained must be different. For example, reactive dyestuff dyeing light color, according to the laboratory process put samples down, the workshop is always dyed deep, and can not be boiled down, many process supervisors will figure out a parameter, under the large goods process, down 10-20% of the dye, and not to trace the cause of the upper cylinder dyed deep.

Factories with conditions, it is recommended that soap cooking, reduction cleaning, etc., also operate in a separate small sample machine, in order to achieve the temperature unification of small and large samples.

Second, the consistency of the dyed material

1、The blanks for sampling in the laboratory must be consistent with the blanks to be dyed in the workshop, there must be differences in the coloring of different batches of blanks.

2、The pre-treatment of the blank for sampling should be brought out in the workshop as much as possible before the processing of the big goods. It is difficult to do the same with the workshop when the laboratory does the pre-treatment by insulation and moisture evaporation, therefore, the simple way is to do the pre-treatment in the workshop and then take samples for sampling.

3, consider the weight loss and moisture regain of the blank fabric and other factors.