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Dye House Automation System
An interconnected automation system is now an integral feature of any well equipped modern dye house. The process starts with the automation of dyeing machines through the system. and futher goes on to automatic transport and even to weighing systems of dyestuffs and chemicals. The automation system carries out systemetically the overall management as well as the organization of the dyehouse. A Dye house system can integrate all the products, PC-control systems or host-computers. This integrated approach also includes in itself order handling system, recipe formulation system for the all with the aim to maximize the dyehouse processes. This way the network of all the individual components within a dyehouse ensures a continuous and flawless data flow along with a clear cut structure and full flexibility in production.

Under the umbrella of a common operating surface, that operates on state-of-the-art latest compuer packages the system transmits process programs. These transmission is done strictly according to the pre- arranged pre-defined sequence of the control unit of a dyeing machine. Subsequently production recipes are transmitted to (a) weighing station, (b)solving station i.e. ADS, (c)chemical dispensing unit (CHD).

Ready signals and request needs of any sort also gets exchanged automatically between the color kitchen components and dyeing machines. It is from the dyeing machine control units that all the set, actual values and disturbances get transmitted back into control station. It is important here to note that all the machines from other departments also get directly connected only through a control system. Lastly this method also allows, all the data to be signalled back into the central EDP.

Features of Dye House Automation System

  • It is from a single central point, that inputs for the production data originates. A good integration of different systems ensures that the information to be received is at the right time and place.

  • The recipe formulation system enables the production recipes along with the process-specific data.

  • An additional feature is added by the batch documentation along with analysis of cost and weak points.

  • Optimal utilization of the dyeing machines enabled by the processes of batch overlapping, priority control and process optimisation.

  • Order management, this includes among other
    • Managing of order, acquiring partial orders
    • Planning the release of materials that is based on the configurable working step (optional)
    • Batch generation

  • Batch management, this includes among others
    • An user enabled machine-related visualization of the batches (job list)
    • Optimization of the request processing with clear cut indication stating the maximum optimization time
    • Batches starting automatically

  • Recipe administraiton/Program management, this includes among others
    • Dynamic programming
    • Integrating batch values from the material planning

  • Import/Export of programmes

  • Statistic/reports

  • External interfaces

Functions of a Dye House Automation System

The major functions performed by the Dye House are shown in the form of a diagram.

Benchmark of dye houseBenchmark of dye houseBenchmark of dye house

Advantanges of a Dye House Automation System

The central network system of a dye house offers the following advantages.

Exact dosing- This is characterised by a better reproducibility and reliable dyeing quality.

Simplified operations- It simplifies operational processes and in case of any problems allows a fast remote diagnosis.

Flexibilty and openness- Advanced network concepts ensures openness and flexibility, so that partial solutions are also a distinct possibilty.

For example a free CHD chemical supply is a possibility

Total integration of systems- All the control units along with color kitchen components perform in tandem with standard interfaces.

Savings in time


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