continous dyeing and four parts

The whole process of cotton continue-dye generally refers to: from the beginning of the grey fabric to singeing, desizing, mercerizing, pre-shrinking, dyeing, drying, fixing, and high temperature setting, all the links of the entire set of cotton production process are indispensable. There are four main processes: pre-treatment, dyeing, finishing, and finished product inspection.

(1) Pre-processing part:

When turning the seam, pay attention to the hemming of the cloth joints, because the subsequent processes are basically continue-dye production.The consequence of not hemming is that if the cloth joints are broken in the steamer during the production process, that is a very troublesome thing.

Desizing is to remove the slurry on the warp yarns when weaving, and thin fabrics can be directly removed by the desizing machine.The cold-batch desizing method is best for the back weight and stretch fabrics, and the enzyme desizing will be more thorough.

Singeing and cotton cloth need to be singed to remove the hairs of different lengths on the yarn count. Thin cloth singeing is enough. For thick yarn cards such as 7*7, you need to add iron plates (also called cylinders) to burn. The refreshing.

Forming: pre-treatment and setting are only for stretch fabrics, and the width of the door after singing and desizing is different, and the width of the door can be set if it is smaller than the width of the finished product. The setting of the pre-treatment should not be larger than the width of the finished product, preferably close to and equal to the width of the finished product. .

Bleaching, as long as you pay attention to the uniformity of whiteness, cotton cloth is generally bleached with hydrogen peroxide, also called oxygen bleaching.

Mercerizing, mercerizing should pay attention to the width of the door. The door width is too small when it is mercerized. If it is not opened, the finishing cannot be opened. It will shrink a little at time, and the finishing is stretched out, and the pre-shrinking is just controlled. (Note: The pre-treatment of dyed and vulcanized cloth cannot be mercerized, because there is alkali in mercerizing, and dyeing and vulcanization will cause cloth surface blooming)

After mercerizing, if there is a requirement for sanding, then sanding, and the pre-treatment is over.

Pay attention to the points: thin and sparse cloth, check the weft, curling, etc., pay attention to the direction of the flame when singing large lattices, and do not burn through, that is, the flame shall not be perpendicular to the cloth surface to avoid strong damage. The finished product is For black ones, pay attention to the foreign fibers after singeing. The finished width should be close to and equal to the finished width.

Bleaching, as long as you pay attention to the uniformity of whiteness, cotton cloth is generally bleached with hydrogen peroxide, also called oxygen bleaching.

Mercerizing, mercerizing should pay attention to the width of the door. The door width is too small when it is mercerized. If it is not opened, the finishing cannot be opened. It will shrink a little at time, and the finishing is stretched out, and the pre-shrinking is just controlled. (Note: the pre-treatment of dyed and vulcanized cloth cannot be mercerized, because the mercerizing contains alkali, and dyeing and vulcanization will cause the cloth surface to bloom)

(2) Dyeing part:

The dyeing of cotton fabrics is now dominated by continuous pad dyeing of long cars, and the vat dyeing is no longer the mainstream, so I will not introduce it here.

Dyeing is a simple process, because it only needs to pass through a padding car, but it is also the most difficult process, because the color control of dyeing is not only known, but there are many unknown things in it, such as dyes at different temperatures. The stability of the bottom, the control of the steam, the control of the pressure of the rolling car, etc., are very delicate activities.

The dyed long car is divided into two parts, the front car is dyed, and the rear car is fixed. The dyeing method varies according to the different types of dyes selected. The dyes are generally reactive, Shilin, vulcanized, and paint. They have their own advantages and disadvantages, generally Under the circumstances, it depends on the color of the guest and cannot be replaced with each other. Among them, Shilin has the best color fastness, but it is expensive, not suitable for dark colors, and light colors are not bright enough. Except that dyeing dark colors will increase the cost. In addition, it is difficult to control the dyeing of dark colors relative to reactive dyes, and it is prone to phenomena such as cloth flowers. The active color fastness is worse than Shilin, but light colors are more gorgeous, dark colors are easier to control, and the cost is correspondingly less. The vulcanization is the worst, the color fastness is not very good, the ban on AZO is not up to the standard, but now there is a liquid vulcanization (also called water vulcanization) that bans AZO can meet the standard, but the price is close to Shilin, and the dyeing is not easy to control and cannot be popularized. A few people pursue its fading effect and adopt it. The paint is not comparable, and its fading is very serious.

It is the best choice for the pursuit of fading effect after washing clothes. It can be used with Shilin, active and flexible to obtain different washing effects (general Shilin or active primer, paint overcoat, which can solve the white spot problem of single-dye coatings. The cost increases accordingly).

The reactivity, Shilin and vulcanized dyeing front car is basically the same, to say the difference is that the infrared pre-baked one group, two groups or not. The rear car is completely different. The active one uses salt and soda ash to fix the color, and the Shilin adopts Hydrogen peroxide reduces color fixation (so Shihlin is also called vat dye), and vulcanized requires high-temperature cooking and fixation, and the water temperature must be above 95 degrees.

After the paint is dyed, it is determined whether to bake and fix the color according to the fading requirements of the color fastness. The bake temperature is about 195-210 degrees.

Dyeing is impossible to be 100% good. Color repair and peeling are inevitable. Minor adjustments such as lighter coats and darker washes with soda ash.

(3) Finishing part:

Because the cotton fabric has passed a lot of time during the pre-treatment and dyeing, the warp direction is stretched, the weft direction is contracted, and the hand feel is relatively rough. The finishing is to solve these problems.

Softness and tentering, if there is no setting machine, softness and tentering should be carried out separately. First, soften to improve the hand feel. In the tentering. Pull the shrinking weft direction apart. With a setting machine, you can do it in one go. But the stretch fabric is best to be shaped Craftsmanship.

Pre-shrinking, pre-shrinking the stretched part of the production process through the rubber blanket of the pre-shrinking machine, the principle of thermal expansion and contraction shrinks the cloth to the allowable range of clothing cutting, and the elastic cloth is controlled at 3% warp and 5% weft. The non-elastic control is 3% in warp and 3% in weft.

Finishing According to the requirements of customers, whether the twill needs to be drawn and whether the weft of the plain weave is up to the standard (generally the weft of the plain cloth should be controlled within 3%, and the grid should be controlled, preferably close to 0). Weft straightening.

The factory can also use its own equipment, and can also air-soften the fabric and so on. Of course, there is an additional cost.

(4) Finished product inspection part:

The fabric after finishing has been tested, shrinkage rate, color fastness, and other internal indicators required by customers, and the color indicators are qualified, and the finished product can be inspected. Generally, customers agree with the American four-point standard inspection (the Chinese national standard is similar, But the defects are too fine to be memorized and used), and the qualified products can be packaged. At this point, the dyeing process is over, and the fabric can be sent to the garment factory.

Mr Jack(GM)

We woven fabrics manufacturer from china over 16 years

We weave/dye/print ourselves.

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