Each and every step, all inputs of dyes, chemicals, time and temperature - determines the final shade.
This process control chart has check points for common process route of reactive dyes.
Dyestuff, chemicals and auxiliaries weighment are very much important in getting the right shade as per lab match.
In lab preparations, the timings that would be spent during actual bulk dyeing should be maintained, eg.
- holding time with only auxiliaries at the initial stage
- holding time after salt addition
- holding time after dye solution (addition + holding) in bulk process should be maintained in lab.
NUCHEM
Dyestuffs P Ltd.
Ahmedabad – 382 445
Trial No. PROCESS CONTROL REACTIVE DYEING CHART Trial Date:
S.No | Details | Observation | Remarks |
1 | Customer Name | ||
2 | Address | ||
3 | Contact Person; Mobile No. | ||
Water Quality Details: | |||
1 | Water pH | ||
2 | Water pH after boiling for 5 minutes | ||
3 | Hardness (Total) | ||
4 | Presence of Bicarbonates | ||
5 | TDS of water | ||
Machine Details: | |||
1 | Machine type | ||
2 | Capacity | ||
3 | Automated / Manual dosing /timing | ||
Material Details: | |||
1 | Fabric or yarn Quality | Collect ½ meter sample grey fabric | |
2 | Batch Length or Density of package | RFD Fabric Whiteness Index | |
3 | Batch Weight / GSM | Residual Peroxide Content | |
4 | MLR | Water pH of Starting bath | |
5 | Hardness of Process water | Hardness of 80 gpl salt | |
Dyeing Recipe Used: | |||
1 | Leveling Agent Name & Dosage | ||
2 | Sequest. Agent Name & Dosage | ||
3 | Dye-1 | ||
4 | Dye-2 | ||
5 | Dye-3 | ||
6 |  Salt (Glauber/Common) | ||
7 | Soda ash (Purity - …..%) | ||
8 | Caustic soda | ||
Compatibility Check | |||
1 | Compatibility of Sequestering & Leveling agent : | Check up done using a test tube | |
2 | Compatibility of dyestuffs before adding in to bath | Check up done using a test tube & Filter paper | |
3 | Compatibility of dyestuffs after adding in to dye bath | Check up done using a test tube & Filter paper | |
4 | Compatibility if dyestuffs after adding Salt (full dosage) | Check up done using a test tube & Filter paper | |
5 | Compatibility if dyestuffs after adding Soda (full dosage) | Check up done using a test tube & Filter paper | |
6 | Compatibility if dyestuffs after adding Caustic (full dosage) | Check up done using a test tube & Filter paper | |
7 | Compatibility if dyestuffs at dyeing temperature | Check up done using a test tube & Filter paper | |
Timings: (Check Lab Procedure) | |||
1 | Time running with Auxiliaries | ||
2 | Dosing time of dyes alone | ||
3 | Running time of dyes alone | ||
4 | Salt addition time | ||
5 | Salt running time | ||
6 | Soda addition time | ||
7 | Soda running time | ||
9 | Steam rising time | ||
10 | Running time after steam rise | ||
11 | Sampling time | ||
12 | Caustic addition time | ||
13 | Caustic running time | ||
14 | Draining time | ||
15 | Cold wash 1 running time | ||
16 | Cold wash 2 running time | ||
17 | Neutralizing with Acetic acid – Dosage and time | ||
18 | Cold wash – running time | ||
19 | Hot wash (steam rising time | ||
20 | Hot wash (70°C) running time | ||
22 | Soaping 1 steam rising time | ||
23 | Soaping 1 running time | ||
24 | Soaping 2 steam rising time | ||
25 | Soaping 2 running time | ||
26 | Hot wash (steam rising time | ||
27 | Hot wash (70°C) running time | ||
28 | Cold wash 1 running time | ||
29 | Cold wash 2 running time | ||
30 | Acetic Acid wash (1 gpl) running time | ||
31 | Dye fixing – running time | ||
32 | Softner – running time | ||
Dried Fabric Checkup | |||
1 | Uniformity in dyeing? | ||
2 | Appearance (bright, dull) | ||
3 | GSM after dyeing | ||
4 | Fastness to cold water | Immerse dyed fabric in cold water for 2 hours and check | |
5 | Fastness to washing | Soap at 60°C with 2 gpl soap. | |
6 | Fastness - Rubbing | Dry Rub Wet Rub |
Collect Before dyeing sample – ½ meter
Collect After dyeing sample – ½ meter
