Package Dyeing

Yarn Packages
Yarn wound onto small plastic or metal centres

Package length (Standard): 14,5 - 17 cm

Cheese Dyeing - Dyehouse
 Processing Steps in the Dyehouse

Drying

Hydro-
Pretreatment extraction
and Dyeing
Yarn Dyeing – Package Dyeing Machine
Package Cheese Dyeing – Flow of Liquor

FLOW RATE FLOW RATE

METER METER

PUMP PUMP

IN - OUT OUT - IN
Package Dyeing – Flow of Liquor

FLOW RATE FLOW RATE

METER METER

PUMP PUMP

IN -OUT OUT -IN

Package Cheese Dyeing – Half Liquor

Note :
- In-out flow only
- Half Liquor -> Save water

FLOW RATE
METER

PUMP
 Liquor Flow Through Package

Differences in flow rate through different parts of the package.

Pale edges
 Liquor Flow through Packages

Flow rate : high low

Liquor velocity : high low

Distribution : poor good
 Differential Pressure

The Differential pressure is the pressure-difference between the Inside and Outside of the
package during the dyeing process. This is a function of the package formation

Typical values;
Inside to Outside = 0,6 - 0,8 bar
Outside to Inside = 0,4 - 0,6 bar

Outside Inside
 Liquor Circulation
• Liquor flow is typically reversed at regular intervals
in the following manner:
– 6 Minutes from Inside to Outside and
– 4 Minutes from Outside to Inside
• In partly-flooded machines - the liquor circulation
can only be Inside to Outside.

4 min

6 min
Well wound is half dyed!
Winding Machines
 Tubes (Selection)

Cylindrical Conical

Di-fix Di-flex Thermo-flex

Column Formation and Liquor Flow through Packages
Conical packages Cylindrical packages
 Packages / Advantages of package forms
Conical bobbins Reason:
Unwinding Easier unwinding, particularly with large packages.

Cylindrical bobbins
Winding More precise with constant radius.
Rounding off Edges Not necessary as winding is more precise.
Spacer No spacers needed for insertion systems;
better sealing; up to 30 % higher loading possible.
Loading the Simpler; no spacers;
dyeing machine Supply from winding department in blocks of 6.
Pressing packages Better utilisation of available space and better seal
between packages.
Flow Smaller edge to middle difference;
better seal between packages.
Packages / Winding density
A Function of Yarn Thickness & Type
Substrate Density Yarn thickness

Cotton  340 -400 g/l Nm 40/1

Cotton  320 -350 g/l Nm 100/1
Linen  250 -350 g/l
Viscose  300 -350 g/l
Wool / Acrylic  340 -380 g/l
PES  340 -380 g/l
PES/Cotton  340 -380 g/l
PES/Wool  320 -360 g/l
 Packages / Winding density calculation (WD)

Cylindrical Conical r
Packages d Packages rH

h h

RH
D R
3,14
V1 = • h • ( RH2 + rH • RH +rH2 )
3,14 3
V = • ( D2 - d2 ) • h
4 3,14
V2 = • h • ( R2 + r • R + r 2 ) - V 1
Yarn weight 3
WD = [ g/l ]
V WD = Yarn weight [ g/l ]
V2
Preparation of Compressed Packages
Before compressing
15 - 25 %

After compressing

 compression gives higher machine loading

Packages / Properties of compressed packages
Winding thickness (WT)

= Tube diameter (TD)

Density uncompressed = 330 g/l

WT
(Example) TD 20 % compressed  400 g/l

Package diameter Indanthren dyes: 200 mm *

Reactive dyes: 220 mm *
200-220 mm

Package weight Indanthren dyes:  1 300 g (Tube 100 g) *

Reactive dyes:  1 500 g (Tube 100 g) *

* maximum diameter if all other parameters are optimal.

Machine Loading - Cross-wound Cylindrical Packages
Machine Loading - Cross-wound Conical Packages
De-watering
Centrifuge
Centrifuge - for Individual Packages
High Frequency (HF) - Drier
Pressure Drier
Potential Problems
 Water quality
The process water for textile mills must meet the following minimum standard:

 Colourless / clear
 Free from vegetable and mineral impurities
 Free from iron and manganese compounds
 Soft
pH: 6-8
Hardness: max. 5 °dH
Suspended matter: < 1 mg/l
Organic load: < 20 mg/l
Residue on ignition: < 50 mg/l
Iron: < 0,1 mg/l
Manganese: < 0,05 mg/l
Copper: < 0,01 mg/l
Nitrate: < 50 mg/l
Nitrite: < 5 mg/l
Free CO2 0 if possible (risk of corrosion)
 Potential problems with Water hardness
• Lower colour yield
• Poor reproducibility of the dyeings
• Dusting of the yarn, particularly when rewinding onto another bobbin
• Poor fastness properties
• Harsh handle
• Poor wettability
• Deposits on the machines
• Poor levelling-out properties, particularly with wound packages
• Formation of spots
These problems can be avoided by
• good pretreatment of the fabric
• the use of sequestering and complexing agents in the dyeing process
 Rubbing fastness

Factors that affect the rubbing fastness :

• Substrate
• Dye concentration
• Water hardness
• Improper finishing of the dyeing
• Inadequate liquor flow rate
 Package dyeing Possible problems and causes
Potential problems
 Unlevelness
 Inner - Middle - Outer variations
 Poor penetration
 Surface deposition
 Filtration

Possible causes
 Poor package winding
 Wrong or poor quality ancillary equipment (e. g. pumps)
 Problems due to poor dyeing machine performance
 Sub-optimised dyeing process
 Incorrect dye selection
 Auxiliaries
 Inefficient pretreatment
 Package dyeing - Potential Problems
Problems caused by the package :
 Incorrect winding density
 Variable winding density
- within a package
- from package to package
 Different package diameters within a batch
 Package diameter too large (package moves on the yarn carrier)
 Over-wound centres
 Perforations
 Damaged centres
 Package shoulders not formed or poorly formed
 Incorrect compression of packages
Over-wound Package
 Potential Problems due to Mixed Yarn Merges
Dyed Yarn (Polyacrylonitrile) Grey Yarn (Cotton)
 Package dye - Potential Problems
Caused by ancillary equipment
 Incorrect spacers
 Faulty spacers
 Faulty spindle locking caps
 Faulty springs on the locking caps
 Incorrect top/bottom plates
 Dye carrier incorrectly positioned
 Faulty dyeing tubes in dyeing cylindrical packages on
triangular spindles
 Contaminated spacers, beams, carriers or column seals.
Leakage - due to the Spacer
 Package dyeing - Potential Problems

Caused by the dyeing machine

 Poor liquor circulation
 Pump performance
Too high pressure results in;
- deposition on the out-in cycle, or package deformation
- channeling
Too low pressure results in;
- unlevelness due to insufficient liquor flow
 Poor temperature control
 Contaminated addition tanks or dyeing equipment (dyestuff, optical
brightener, softeners, oligomer)
 Flooded seals at reduced liquor levels
 Package dyeing – Reactive Dyes

Potential Problems in Dyeing with Reactive dyes

 Inefficient pretreatment.
 Inefficient rinsing after pretreatment.
 Inappropriate cycle times for the dyes used.
 Inefficient rinsing after dyeing.
 Unlevel application of cationic products to the yarn (especially in paler shades).
 Inappropriate dye selection for down-stream processes (eg., post-bleach, post-merc.).
 Package dyeing – Disperse Dyes

Potential Problems in Polyester Dyeing

 Lack of heat-setting of Yarn or fabric leads to
- shrinkage on dyeing
 Unevenly heat set substrate
 Poor temperature control
- dispersion stability problems
- unlevel dyeing
- ring dyeing and poor fastness
 Incorrect dye selection
 Insufficient dispersing agent with highly concentrated dyestuffs
 Too much auxiliary (less is better)
 residual size on the fabric (beam dyeing)
 Waxes, oils, hydrocarbons on the yarn or piece goods
 Application Technology - Machinery
Yarn Dyeing - Hank Form

Hank Carriers

Schematic showing liquor flow

Slide 36
Application Technology - Machinery
Yarn Dyeing - Hank Dyeing Cabinets

Slide 35
Hank Dyeing Machines
PES Sewing Thread – Dyes Selection
MEDIUM & DARK
1. Lumacron Yellow S4G
2. Lumacron Orange SC Conc*
3. Lumacron Red S3BS
4. Lumacron Scarlet SR 150%
5. Lumacron Rubine SGL Conc*
6. Lumacron Turquoise Blue SGL
7. Lumacron Navy S2GLL*
8. Lumacron Black SKLE
Package Dyeing : Apa Yang bisa ditawarkan …?

1. Kualitas air :
Syarat air untuk proses package dyeing lebih ketat daripada
pencelupan kain, terutama kandungan Suspended Solid.
Apakah Chelating agent bisa ( Eskalet DA-APC ) ?
2. Dispersing agent :
Pada pencelupan zw Disperse, Dispersing agent lebih penting dari
Levelling agent - Eskaplus DA-D
3. Lubricating agent :