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Dye House

Essential components of a Dye House

Dye House SystemDye House System - Used for a complete automation, administration and efficient organization of a dye house.

Control SystemControl System- Control and remote monitors all the necessary sensors and actuators of a dyeing machine.

Color KitchenColor Kitchen- For administration, optimizing and a total control of the color kitchen.

Chemical Dispensing SystemChemical Dispensing System- A innovative system for transportation of liquids and automatic metering.

Weighing StationWeighing Station- Comes in different sizes along with monitor controlled formula processing system.

Automatic Dissolving StationAutomatic Dissolving Station- For a quick and efficient dissolving of the powdered dyestuff.

Dye Bath- Critical process for a perfect dyeing operation.
In today's competetive world it has become very important for a dye house to have a thoroughly consistent system. This development is an absolute necessity now for improving quality and fast turn arounds. Without the proper integration of dyeing equipment into a sound organized network, it is quite obvious that the dyehouses can give away its valuable resources very cheaply.

A fully integrated dye house network comprises of a vast range of automated system components properly syncronized to each other. Machines that are capable of performing a number of operations like dyeing, heat setting, compacting, stentering, hydro-extraction, brushing and washing etc. A typical Dye house network functions like this. It supplies the dyeing machines with dyestuff, chemicals and along with it if the need be, hot water. Another vital task is the control of the system. Although every single device from the color kitchen to dyeing machines these days are PC-controlled, however modern dye houses prefer to employ a Dyehouse automation system. This system ensures that the machines are able to synchronize with each other and can optimise their capacities. Apart from this the automation system facilitates linking of the order management with the necessary machine control units. This helps to complete a fully integrated dyehouse network. The diagram that follows next gives a perfect example of Dye house that is complete in every respect. Most modern dye houses are today following the concept of totally networked Dye House.

Dyehouse Automation

Benchmarks of a Dye House

If the dyehouse does not meet with the following criteria, then perhaps it is necessary to rethink and go in for a new dye house:

Quality- In today's fiercely competetive market, if a manufacturer doesn't have a consistent quality, probably they just can't stay put in business. Therefore a manufacturer must insist on receiving only quality and genuine products from suppliers. Infact adhering to different International quality standards that has written down procedures and manuals is now more than just a norm. There are now various information technology companies that are into the field of operations management. If they are called for and allowed to work on a program at a dye house and follows up it through the completion, then a dye house will be equipped with a totally integrated data base system. This will offer solutions in every sphere of operations like manufacturing, production, financial, forecasting, planning, scheduling and delivery.

Challenges of globalisation- Over the years the supply of material has changed. Today suppliers are challenged from across globe with products of superior quality, and low cost. For example yarn suppliers continues to search for non-branded suppliers of polyester and acrylic for replacing more costlier brand names. Today's mantra is innovate or perish.

Savings in energy- Saving in energy, chemicals and water is now vital for survival of any dye house. Machine vendors are now constantly redesigning dye machines that has the lowest liquid to goods ratio. For example a high pressure dyeing machine consumes much less water for processing. The liquid to goods ratio being 1:5 (i.e. to process 1 kilogram of fabric, five litres of water are used) now compare this to traditional units that are fitted with conventional winches whose water to liquid ratio is in the range of 1:15 or even sometimes 1:20. Survival for such dye houses is impossible.

Package preparation- To be succeesful, dyers must go for latest stainless steel spacer for holding the shape of package ends. This allows for smooth unwinding. Though backwinding to paper cones along with intermediate lubrication is more in vogue, but that costs money and time. Dyers must master new ways to bypass the idea of backwinding.

Package preparation

Package handling- Increasingly the dye houses are insisting on the technology of robotic package handling. Use of Robotics demands uniformity. Robots need the packages to be placed in a specific location.

Modern laboratories- New formulas are first dyed in the lab before it is implemented in production. If there is closer liquor ratio agreement between the production and laboratory, better would be the final result.

Maintenance-It is a general tendency to view maintenance time as an opportunity lost to manufacture dyed sales yarn. Preventive maintenance is clearly less expensive than unscheduled halt and a spoiled dyeing.

Computer aided Dyeing system- By implementing a Computer aided Dyeing system it has been possible to cut down on both costs and time. For example it has been found that by using the system there has been reduction in the acrylic dyeing batch time by at least 30 percent.


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