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A successful dyeing cannot rely solely on management, the key is cooperation!



Abstract: The requirements for “first-time success” pursued in dyeing and finishing production are analyzed from various relevant links and aspects, as well as technology, management, raw materials,…

Abstract: The requirements for “first-time success” pursued in dyeing and finishing production are analyzed from various relevant links and aspects, as well as technology, management, raw materials, equipment and other aspects. Discussed the prerequisites and foundations for “first-time success” of dyeing and finishing production, and the relationship, role and significance of upstream and downstream related industries including auxiliaries for “first-time success” of dyeing and finishing production, as well as the importance of auxiliaries Reasonable positioning and other issues.

Common quality problems in dyeing and finishing production and the meaning of “first time success”

Due to the deep processing of textile dyeing and finishing, There are many before and after links and a wide range of aspects involved, so there are many factors that affect the dyeing and finishing results. Therefore, in actual production operations, quality problems of one kind or another are encountered almost every day. And if we can achieve “first-time success”, we must prevent the occurrence or emergence of any kind of quality problems.

According to their phenomena and attributes, dyeing and finishing defects can basically be divided into the following categories: a. Related to color quality are: color difference, color unevenness (color flowers, color spots, color stains, color spots, etc.), color fastness, etc. b. Related to intrinsic quality are: fiber damage, loss of elasticity, dense roads, substandard finishing, shrinkage, g/m2, door width, etc. c. Things related to appearance quality include: finishing agent stains, pilling, crepe printing, warp and weft bias, etc. d. In addition, there are certain quality problems specific to certain types of products, such as cracks in long polyester low-density fabrics, sticking reactions in wool yarns, etc.

“First-time success” means that the production of the product comes to an end smoothly during the entire production process, without any interruption of the set process route. Additional remedial phenomena such as extra repairs.

Since “first-time success” can not only give full play to and reflect labor production efficiency, but also directly affect the maximum utilization of raw materials, energy, water and other resources, so “first-time success” is also based on technology. The maximum savings that are reasonable and effective within the allowable scope. Therefore, enterprises regard “first-time success” not only as an important means to improve efficiency, but also to understand and pay attention to it from a deeper level such as conserving natural resources, saving energy and reducing emissions, and improving economic benefits.

Because all-round “first-time success” is related to the maximization of enterprise production efficiency and economic benefits; and for the modern market’s small batches, multiple varieties, and fast delivery, it is also in the fashion stage. In terms of the market characteristics of extremely rapid role change, it is also critical and important, so it is what every company has been striving to pursue.

Some major aspects that affect and hinder “first-time success”

1. In terms of dyeing samples, getting the color right the first time when enlarging the sample is the prerequisite for “first-time success” in all aspects. If the color cannot be accurate once the sample is enlarged, then there is no need to talk about “first-time success”. One-time accurate lofting technology, that is, whether the problem of lofting color difference is overcome is the focus of the “first-time success” system engineering, and is also a key technical issue in printing and dyeing production.

First of all, small prototypes and large computers have different types and categories, so there is also a matching problem between small prototypes and large computers.

Because there are differences or intermediate changes between the two in the working mode and the four major process conditions (bath ratio, temperature, time, working bath pH value), the various process conditions are The actual parameters and intermediate change parameters need to be included in the basic work content that must be checked in advance, and then the performance and characteristics of the two are strictly compared, the proximity and gap of each parameter, as well as the scope and limitations of the variety. After waiting for the individual situation, carefully make the appropriate choice (if necessary, a prototype may be equipped for additional assistance).

2. In terms of dyes and chemical materials, different origins, production batches, and batch numbers of dyes and chemical materials have differences in the content of their active ingredients, so it is necessary to carry out precision testing of chemical raw materials such as dyes and chemicals. Detection, especially for dyes, has the greatest impact on color difference, and color difference is the number one quality issue in printing and dyeing production.

Therefore, precision testing must be carried out before use to make precision improvements. For this reason, it must be re-tested with modern testing instruments; the same is true for additives and other chemical raw materials.

The above situation has also brought about the supporting special dye and chemical material management system due to this problem. It is necessary to set up a special dye and chemical material application management account to ensure that untested dye and chemical materials After entering the factory, it is not allowed to be used directly in the workshop. This is required for technical management.

There are a few dye varieties that will undergo heat-sensitive discoloration after being processed under high-temperature conditions such as drying or finishing. Some types of fixatives and softeners will also cause some changes in color. Although it can still pass under general quality standards, when it comes to production contracts with particularly strict quality standards, you must be vigilant and select dyeing materials in advance.

However, this type of color fixing agent often has a special ability to improve color fastness. When used in dyeing and finishing, it is suitable for some deep colors that are not bright colors (such as coffee, navy blue, black, etc. ), then its influence on color and light can be completely ignored.

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The multi-faceted nature of dyeing and finishing production also determines the multi-faceted nature and complexity of the solution and processing work. For example, regarding the color fastness problem, we should first pay attention to the nature of the dye. Although improvements can be made with additives, there are certain limits. It is impossible to use fixing agents to raise direct dyes to the level of reactive dyes; similarly, it is also impossible to fix reactive dyes to reach the level of vat dyes.

The problem of uneven dyeing is not only caused by the dye, but also affected by various factors such as the quality and nature of the textile yarn and its fiber raw materials, or the characteristics of the weaving structure design. about. Auxiliaries can help improve dyeing levelness in a targeted manner, but they are not omnipotent. If there is a large difference in the dyeing rate between the various varieties of color-matching dyes, you must carefully choose varieties with good compatibility. This is also an important reason why dye factories provide various types of three primary color series that are divided into different application processes such as high temperature, medium temperature, and low temperature.

The problem of color unevenness affected by dyeing machinery is easily overlooked. There are also many types of dyeing machinery, and they are constantly being updated. Therefore, how to make good use of new types of machinery and equipment in dyeing and finishing production is also a topic that requires efforts.

Different types of dyeing machines adapt to different types of textiles, and the resulting color unevenness also has different manifestations. For example, normal-pressure jig dyeing machines are prone to overlapping prints and left-right color differences, high-temperature and high-pressure jig dyeing machines are prone to color spot defects, and semi-filled liquid jet dyeing machines are prone to color bloom problems.

From the perspective of dyes, disperse dyes with low water solubility are prone to color spots and stains, while reactive dyes and acid dyes with good water solubility are less likely to have this phenomenon; for acidic dyes As for dyes, weakly acidic dyes are more likely to cause blooming than strong acidic dyes; dyes with larger molecular weights have higher color yields than the same type of dyes with smaller molecular weights, but are also relatively prone to blooming problems.

For some problems caused by the way the dyeing machine operates during dyeing and the individual characteristics of dyes, the participation of different targeted auxiliary varieties is essential and becomes an integral part of the dyeing quality maintenance system. and its vital and reliable pillars.

Production requirements for highly standardized stability between batches of auxiliaries

Once the dyeing and finishing enterprise recognizes and determines the auxiliaries, Certain varieties of pharmaceutical companies generally will not make changes easily after being selected into their raw material purchase orders for “first-time success” production. If changes are to be made, it will require a lot of R&D effort, a lengthy testing process, and the decision can only be made after being confirmed by mass production (unless it is a new product, or new quality requirements, or new style characteristics requirements and other special needs).

At this time, additive companies must strictly and conscientiously achieve a high degree of stability and uniformity of various quality indicators between each production batch for these varieties. The error of each indicator between batches must be at least plus or minus less than 1%, and strive to reach 100% (this is also the “first-time success” of dyeing and finishing production, and the allowable value requirement for the inter-batch error of the dye strength indicator ).

If the suppliers of chemical raw materials such as dyes and auxiliaries cannot reach this level, the dyeing and finishing companies will be forced to carry out precise re-testing on their own (it should be said that this is actually the production of dyes and chemicals) business matters). Therefore, dyeing and finishing companies will have a problem of selecting the best suppliers of dyes and chemical materials. Suppliers that cannot reach this level will inevitably be eliminated. Whether an auxiliary company can reach the level required by dyeing and finishing companies depends on the company’s “internal strength” (technology, management, overall quality of all employees, etc.), as well as the level of equipment and other aspects.

In fact, for auxiliary companies, there is also a “first-time success” issue in production; this is the same as the “first-time success” production requirements pursued by dyeing and finishing companies. The nature and meaning of “are just different in the industry category and the products produced.”

Dyeing and finishing auxiliaries maintain the smooth progress of the production process during dyeing production. They also contribute to the functional expansion and quality improvement of textiles, as well as to social benefits such as reducing water consumption and energy consumption. Responsibility requirements and other aspects have obvious roles and important status. If dyeing and finishing production does not involve the participation of various supporting auxiliaries, it will be unimaginable to safely and reliably carry out deep processing of textiles under the requirements of continuously improving modern standards. However, although auxiliaries are very important and indispensable in dyeing and finishing production, they ultimately present a relationship between green leaves and safflowers, and are auxiliary in nature, so they are truly named “auxiliaries”.

The leading role in dyeing and finishing production is undoubtedly the professional technology and professional management of the dyeing and finishing project. Especially for the requirement of “first time success”, because it involves both broad and deep aspects, it requires that no mistakes are allowed to occur in every relevant link and major and auxiliary position in the dyeing and finishing production; and it also includes upstream and downstream Active cooperation and collaboration among all related industries, in addition to providing highly stable product quality, must also keep up with the development of the dyeing and finishing industry and continuously make improvements and upgrades in order to achieve the ideal level of “first-time success”.

References:

[1] Zhou Liangxian et al. Dyeing and Finishing Analysis of common quality problems in production [J]. Knitting Industry, 2011.11.

[2] Wu Zhenyi et al. Discussion on the basis for achieving first-time success and related issues, 28th (2015 Year) Proceedings of the National Academic Symposium on Knitting Dyeing and Finishing.

The development of the entire industry requires continuous improvement and upgrading efforts to achieve the ideal level of “first-time success”.

References:

[1] Zhou Liangxian et al. Dyeing and Finishing Analysis of common quality problems in production [J]. Knitting Industry, 2011.11.

[2] Wu Zhenyi et al. Discussion on the basis for achieving first-time success and related issues, 28th (2015 Year) Proceedings of the National Academic Symposium on Knitting Dyeing and Finishing.

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