A process of continuous dyeing in which the fabric in open width is padded with dyestuff and is then steamed.

Is an ideal machine for Reactive dyeing. Light, pale and medium shades can be dyed in this machine. Continuous roller steamer is used for diffusion of reactive, vat, sulphur and direct dyes into cellulosic fibers in an atmosphere of heat and moisture that is created by saturated steam injected into the steamer.

1. It can be used as a pad batch for reactive dyeing in which batch is left for 12-18 hours for the completion of the reaction. For time saving the fabric passes through the steamer for 1 minute and the reaction is completed. 2. It can also be used for reduction clearance (RC) in which we treat PC fabric with caustic and sod. Hydrosulphide to remove the disperse dye from cotton. 3. Stripping of the fabric can also be done on this machine that is, colour can be removed completely by adding higher amount of caustic and sod.hydrosulphide. 4. It can be used for the development of Vat dyes. 5. The dyed fabric can be washed in this machine.

Inlet Section. Padding Section. Steamer. Washer. Dryers. Outlet Section.

Reactive dyeing Pad batch dyeing Reduction Clearing Stripping Vat Development/vat dyeing Washing (Hot + Cold) Pad steam Wet chemical pad

Inlet consists on following parts.

1. 2. 3. 4.

Plaiter/batcher Tensioner rollers Free guide roller Stationary rollers.

 Padders use for padding. The pressure of the padders are 1.5-2 bar. Two types of pressure used in Kuster padders hydraulic and neumatic. The central pressure is hydraulic and sides pressure is neumatic. we can adjust the pressure of the padders ,prevent the listing problem . Liquor is picked in the fabric; afterwards the excessive liquor is squeezed out by means of padders at predetermined pickup% set by applying pressure on the padders.

Uniform squeezing pressure over the entire working width independent of fabric width(no selvedge pressure). No side-to-center shading, due to smooth treatment of the selvedges

 Uniform liquor application over the whole fabric width.  Different liquor application in the range of side-centerside zone is possible.  Attractive price.  Easily operation  Reliable and economical padder.

 Here in steamer temperature required for the fixation is given to the fabric. This temperature is achieved by saturated steam. The purpose of using saturated steam is that the chemicals used for developing should not dry on the surface of fabric preventing fabric from stains. Here roof temperature is given to avoid water dropping that causes spotty dyeing. Here water is not given at the entry of steamer because to prevent developing chemicals that just applied before going into steamer so water lock is given at the end of steamer.

 Steamer Temperature Fabrics dwell time Roof temperature Fabric capacity Water lock

102-105C 1minute. 107C-109C 75meter fabric 1 (at the end)

The functions of the water lock: To stable steam to come out from the steamer. To avoid thermal shocks and also To avoid dyes to be diluted its temperature kept about 4045C The temp here is 40-45C and it serves the following purposes: 1 to cool the fabric 2 Remove excess dye from surface. 3 It condenses the steam that comes along the fabric

 Washing is carried out in order to remove unfixed dyes. After steamer fabric flows from 7 to 8 washers Most commonly first to four washers are used for washing of salt or chemicals which are being applied in trough of pad steamer. In 5th, 6th washer, oxidation is done if required. If oxidation is not required then soaping is done in 5th, 6th washers. Neutralization is done in 7th washer by using acetic acid. There are 8 chambers counter flow system is used.

The chambers are used for number of process a/c to the requirement of dyes by showering of different type of chemicals.

   

Light and hard soaping. Washing. RC. Vat develop. Neutralizing.

There are 9 washing tanks.  Washing #1,2, 8 and 9 contains fresh water where as the others is fed from these tanks.  The capacity of each washing tank is about 950-1300liters.


 NORMAL WASH:  MERCERIZED WASH:  DYED WASH:

This wash is for printed fabrics the temp is kept at 50-60C.

In this only hot washing is done. The temp in washing 1 is 50 C and from washing 2 8 is 98C and last one has 70C.

This is used for dyed fabrics and in this we add soap (RSK), dispergator, Cibapon R for washing. For light shades only soap is added where as for dark shades soda ash is also added with soap which decreases the depth of color and improve rubbing fastness. The temp in 1st and 2nd tank is room temp and from 3rd 8th is 98C where as in the last one is 50C. The tem-p in washing tanks is controlled by a PT temp sensor.

 In the last of the pad steam machine, there are three groups of drying cylinder for dry the fabric. Each group has 12 hot cylinders but last one has 10 hot and 2 cool cylinders. All the cylinders are Teflon coated. Their purpose is to remove water molecules from fabric.

 The fabric from drying cylinders passes through some tension rolls and also from anti static rods which absorbs the charge from the fabric. This rod has 5 KV voltages and 1800-18000A of current after passing through this fabric is winded on the batcher.

 Pad steam is suitable for achieving lighter shades.

pad Thermosol is best for achieving dark and medium shades. that is not in pad Thermosol.

There is water dropping problem in pad steam. Pad steam is best for the dyeing of cellulose. There is MAHLO present in pad steam.

pad Thermosol is best for polyester dyeing. but its not in pad Thermosol

 Wet treatment processes can be carried out on pad steam. on pad steam padding, drying, steaming and then drying again.

cant be on pad Thermosol.

In pad Thermosol drying and then curing takes place

Pad Thermosol is used for the topping of reactive or pigment dyes.

RECIPE:
Dye = 10 g/l Glaubar salt =10 g /l Soda ash = 15 g/l Reduction inhibitor = 10 g/l

PROCEDURE:
Pad the fabric in dye bath at 6070 % pick up. Then steam the fabric for 1- 2 min

WASHING:
(1) (2) (3) (4) (5) Cold wash 30 40 C Warm wash 50 60 C Soaping with detergent 2 g/l detergent at 90 -100 C Warm wash at 50- 60 C Cold wash 30-40 C