Causes and Remedies of Batch to Batch Shade Variation in Textile Dyeing Floor

Published: 2024-10-12

Shade variation is a common and big problem for the dyeing industries. Lots of reasons are responsible for the variation of shade in dyeing textile industries.

Batch to Batch shade problem is noticed when the fabric is dyed in small batch to fulfill the whole order quantity.

From the thorough investigation it is seen that the most cases, the shade variation occurs due to lack of the concentration and lack of proper duty by the operator of the concerned machine. Most of the time, different dyeing faults like shade variations happens due to lacking’s of responsibility taken by concerned management in the dyeing floor along with some technical issues.

Maintenance is also a burning fact for the shade variation. To keep the machine sound, the maintenance department must be strong enough and effective. Shade variation is a very unwanted and unexpected thing to a Textile Engineer and also for dyeing production floor. It is the duty of responsible authority in the dyeing floor to keep the production away from the shade variation among all the batches of an order along with all the dyeing faults also through performing the duty properly along with maintaining all the Procedures and parameters smooth in the dyeing floor.

Some considerable factors which effect batch to batch shade variation. Batch to batch running shade is a general phenomenon noticed almost everywhere in dye houses. Here are so many factors that affect a particular dyeing operation. By checking this factor eliminates 90 to 100% of the above problem.

1. Excessive Heat setting

2. Lack of control on dyeing m/c

3. Rope length and cycle time

4. Reel speed

5. Running time

6. Drum to Drum Variation/ Dyes lot variation
7. pH

Remedies

• Standard dyes and chemicals need to be used.

• Maintain the same liquor ratio in all the batches of same color in an order.

• Follow the standard pretreatment procedure.

• Maintain the same Reel speed and cycle time.

• Identical dyeing procedure should be followed for the same depth of the Shade.

• Make sure that the operators add the right bulk chemicals at the same time and temperature in the process.

• The pH, water hardness, specific gravity of salt and sodium carbonate content of supply water should be checked regularly.