Interpretation of the process flow of dyeing treatment in fuel workshop

1) The blank yarn for the sample should be the same manufacturer, the same ratio, the same number and the same batch number as the large production yarn.

2) Selection of dyes. Dyes are required to have excellent leveling and reproducibility, low sensitivity to changes in dyeing process parameters, excellent washability, and good color fastness. In the three primary colors of color matching, the compatibility of each dye is better, the dyeing curve and the fixing curve are similar, and the color fastness is basically the same. The formula uses three primary colors as much as possible to reduce the mutual interference between the dyes to ensure uniform and stable coloring.

3) Fully and reasonably use the computer color matching system to quickly and accurately determine the sample formula. Although each factory has a large number of color samples and corresponding recipes, some colors can be used to make the required formulas easier and faster by means of the computer color matching system. Through the sample color measurement data, the system can calculate a plurality of recipes, each of which is listed under a variety of light sources and the color difference, shade, depth, etc. of the standard sample, and can be selected to meet the requirements of the customer. Meet the formula of large production. If the customer orders the color on the Internet in the form of data, there is no computer measurement color system can not accept such an order. The computer color matching system is not affected by external light sources, avoiding human visual differences, and finding the most reasonable and economical dyeing formula in a short period of time, making color management and quality testing more scientific, objective and modern.

4) The operation should be standardized when sampling, and the measurement should be accurate. The preparation of the standard solution, the suction of the dyeing solution, the weighing of the proofing yarn, the suction of various additives, and the control of the bath ratio are strictly regulated. It is preferable to use an automatic liquid dispensing and dripping system for the preparation and absorption of the dyeing liquid. The proofing water, pre-treatment process and dyeing process are unified and clear, ensuring that the imitation will not be easy for people, easy to use, and reproducible when re-mixing.

5) After the sample is confirmed by the customer, it needs to be re-sampled before entering the workshop. The duplicate sample should be arranged according to the large production plan, the dyes and additives used in the large-scale production, and the large-scale production reproduction sample should be imitated as much as possible in the laboratory. s color. If the color does not match, you need to find out the cause, and then adjust it until you confirm that the color difference reaches 4 to 5 before you can transfer to the production process, which ensures the correct reliability of the prescription for entering the large production.

For orders with large dosage or high color requirements, the production department and the proofing room should be combined for stakeout before mass production. At the time of stakeout, the relevant technicians in the proofing room and the production department must all be present, track the whole process, record the relevant data, master the first-hand information, and fully understand the color and light deviation between the large and small samples. According to the color of the stakeout, analyze the cause of the difference and make appropriate adjustments to the prescription before mass production. If the color of the stakeout is significantly different from the sample, after finding out the cause, you need to stake it out again if necessary. Through lofting, you can accumulate a lot of data, and long-term accumulation will form an experience that can be borrowed, so that you can better grasp the color and light direction of the large and small, thus reducing the stakeout and making large-scale production faster and better.

Stable production

To improve the success rate of dyeing, it is necessary to establish a “zero defect” management system, the operation standard of each process, the inspection of the dyeing process, the online management and recording of dyeing parameters, the verification method of the auxiliaries for the stencil and dyeing, Quality control methods for dyed products. Under the perfect management system, all production links can be smoothly and orderly, and the whole production can be operated stably and continuously. Only when the production is stable, the success rate of dyeing can be guaranteed. For the large-scale production of mercerized wool yarn, the following four aspects must be clearly defined in management:

1 Each production process must have detailed work instructions. The operators and relevant management personnel must be proficient in the production and strictly follow the operation instructions to ensure the normal and accurate operation of the on-site production personnel and the normal operation of the equipment.

2 pre-dye treatment process, pH value of dyeing, temperature of dyeing, dye bath ratio, time of adding dye, auxiliary agent, temperature, quantity, speed, dyeing temperature rise, heat preservation curve, post-treatment process, etc. Every step of the dyeing process should be recorded and can be viewed at any time to ensure that the dyeing process is monitored throughout. Once an abnormality is found, take timely measures to prevent the problem from expanding.

3 Inspection and verification of blank yarns, dyes, various additives and dyeing water should be carried out constantly. The inspection of the purchase of the blank yarn should be perfect, mainly including strength, strip, count, twist, resurgence, pH, yellow and white, and hand feeling. Problems arising during use, such as broken ends, yarn knots, poor forming, etc., should be reported in a timely manner. Dyes and auxiliaries should be tested for batch numbers, and the dye auxiliaries used in the production process should be checked regularly. The hardness, color and impurity content of the dyeing water are recorded daily. Each user in the process of using the yarn and dye additives must carefully check the inspection and strictly follow the production subpoena to ensure accuracy.

4 quality control of dyed products. The dyeing defects caused by problems in the pre-treatment process and the dyeing stage account for a large proportion, so the key processes related to dyeing must be strictly controlled. The pretreatment should be sufficiently reasonable, and the pH value of the semi-finished product after pretreatment should be checked; the pH value of the dyeing and the temperature of the dyeing should be strictly tested and controlled, otherwise the quality of the finished product cannot be guaranteed. The quality control of the finished yarn yarn is mainly: color difference, color fastness, color flower, hand feeling and weaving performance. The five aspects must be strictly checked and indispensable.

Correct profiling and stable production are two steps that are necessary to improve the success rate of mercerized yarn dyeing. If there is no correct imitation, it will not be stable in production. Without stable production, it is difficult to make a correct copy. Only the correct and fast copy to ensure the stability of production, the RFT dyed by the mercerized yarn can be steadily improved. After improving the dyed RFT, the dyeing enterprise can fully meet the customer's demand on the basis of maximizing profits, obtain more business opportunities, and remain invincible in the market competition.

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