Process Control in Wet Processing

1.

Introduction The introduction of comprehensive process control techniques in

the textile industry is a comparatively recent phenomenon. The concept of process control measures in the local textile industry is catching up very fast for the two main reasons, namely, growing competition and increasing cost of production. Today, a textile manufacturer is faced

with stiff competition not only from within the country, but also from overseas manufacturers. This, in turn, has offered a wider choice of material to the consumer. Under these circumstances, price and quality become important criteria in the process of purchasing. Process control within the mill has therefore become essential for achieving over all success.

2.

Role of process control. n order to achieve overall profitable results and operate

effectively, certain management tools are needed to control various phases of production. Process control is one such tool. The main

functions of a process control laboratory comprise the following ! ..2. .. 2 ..

 "btaining and maintaining optimum processing conditions #stablishing correct operative procedures $arrying out adequate machinery maintenance $ontrolling Production yield and waste %etting up to testing sequences Providing for through documenting system &ssessing the department's effectiveness Today in the textile industry, increasing costs are a matter of grave concern. (or any product, there is always a minimum cost of production) but, in practice the actual cost is higher than the minimum one due to excessive production of waste, processing, difficulties, incorrect procedures, etc. Thus, in today's context, one of the most important functions of the process control laboratory is to reduce overall cost besides ensuring the production of goods conforming to the standards * specifications laid down.

+.

Approach of process control &s far as the choice of processing conditions for a given product is

concerned, generally, some guidelines are always available. ,owever, -+. .. + ..

the optimum levels of various processing parameters differ from mill to mill for obvious reasons. Thus, mills have to carry out their own n order to

experiments to identify their optimum processing levels.

achieve these levels, it is recommended to adopt the '#volutionary "peration Technique'. n this technique, experiments are carried out by

the process control personnel during the various production stages and small changes are made in the process variables in a systematic manner, till optimum operating levels are reached. #very change in the processing parameters is introduced in such a manner that in case of a failure, the financial losses due to higher re.ects or degradation of product are minimal. t is also important to thoroughly review the results of each

change before deciding upon the next set of experiments. "nce the processing conditions are standardised, it becomes necessary to ensure that these conditions are rigorously followed during the normal course of production and adequate records of the process control chec/s are maintained. 0uring process control rounds, it may not be possible to chec/ all the process parameters in one go and hence separate lists for each process should be prepared for those parameters to be chec/ed regularly and for those to be chec/ed randomly, depending on the bearing of the individual parameter on the effectiveness of the -1. .. 1 ..

process. ,owever, it is important that the selected regular inspection chec/s ensure that the particular process is doing precisely what it is supposed to do.

1.

Process control in wet processing Textile wet processing comprises several unit operations, namely,

desi2ing, scouring, bleaching, dyeing, printing and finishing. 0uring the course of wet processing, the goods are sub.ected to various chemical * mechanical treatments employing widely varying process conditions. %ince most of these operations are carried out in a sequential order, the efficiency of the preceding operation has direct bearing on the success of the following one. (urther, some of the steps involved in wet processing of textiles are not specific and while accomplishing one desired property in the textile material, an undesired effect may also result, if the processing conditions are not rigidly controlled. again, for consistent performance, reduced damages and increased machine efficiency, regular chec/s at each strategic point are absolutely essential. n the wet processing department, process control starts with the inspection of grey cloth meant for processing and follows right upto the final finishing. 3arious important process control measures to be -4. .. 4 ..

implemented at the different stages of processing are discussed with the help of Tables 15.1 6 15.12 which cover in general, all the unit operations. t is important to note that regular chec/ing of all the parameters listed in the Tables is not required. hence the mills should prepare two sets of formats for each unit operation) one of which should cover the chec/s to be carried out regularly and the other should cover the chec/s to be carried out randomly. Table - 10.1 : Process control in gre inspection
%r. 7o. 1. 2. +. 1. 4. @. A. Parameter $onstruction $rey width 8echanical damage 8anufacturing damage Piece length %tain mildew 8ending $hec/ Point ;efore stitching ;efore stitching ;efore stitching ;efore stitching ;efore stitching ;efore stitching ;efore * stitching after 8ethod of chec/ing Pic/ glass 8easurement tape 3isual 3isual 8easurement tape uv lamp 3isual by by %tandard * frequency of chec/ <andom = 1 cm * random during each round > > > "nce a shift > between the > rounds > ? 7o stains * mildew * once in a day 6 7ecessary action9s: %egregate odd pieces %egregate odd pieces %egregate the pieces for full bleached * dyed * printed sorts depending upon the extent of damage %egregate short length piecs mainly in the case of export orders. %pot clean for stains, give damage note for mildew affected goods. Ta/e necessary action for correcting and subsequent segregation of damaged goods. $onvert to full bleached sorts. f any variation is found, then convert to full bleached sort or pigment printed sort $orrect to full bleached or printed sort. #nsure that proper thread is used for stitching. Tear and restitch

B. C.

8ix up of warp yarn ;lend variation

before stitching ;efore stitching

15. 11. 12.

<eediness %election of thread for stitching #nd to end stitching

before stitching ;efore stitching ;efore stitching

%trip dyeing if not done at beam stage %potting with %hirlastation or similar staining agents %trea/ analyser $ount*ply*blend determination 3isual

7o mix up of wrap yarns 7o variation in blend * random 6 6 7o bowing

-@. .. @ ..

Table - 10.! : process control in shearing " cropping

%r. 7o. 1. 2. +. 1. 4. @. A. B. Parameter 8etal detection %eam detection Doose threads &brasion Dong threads $ut * hole formation "verall shearing efficiency 8achine efficiency $hec/ Point 0uring shearing * cropping 0uring shearing * cropping 0uring shearing * cropping 0uring shearing * cropping during shearing * cropping 0uring shearing * cropping &fter shearing * cropping 0uring shearing * cropping 8ethod of chec/ing 8etal detector %eam detector 3isual 3isual 3isual 3isual 3isual assessment Productivity assessment %tandard * frequency of chec/ 7o metallic particles should be present 6 7o loose thread should remain 7o abrasion random chec/ "nce a shift * 7ecessary action9s: #nsure efficient wor/ing of metal detector. #nsure efficient wor/ing of seam detector &d.ust the position of ledger blades and sharpen 9honing: 0isengage emery rolls $hec/ for proper functioning of suction. #nsure proper ad.ustment of brushes and blades #nsure proper wor/ing of the machine 8a/e sure of optimum speed and also assess the feasibility of running two ends to increase production.

7o cuts or holes * random chec/ B5 6 C5E A5 6 A4 E once a day

Table 10.#. : Process control in singeing

%r. 7o. 1. 2. +. 1. 4. @. A. B. C. Parameter %peed (lame height %ooty flame Uneven flame Threading $rease free flow Guenching %ingeing efficiency 8achine efficiency $hec/ Point 0uring singeing 0uring singeing 0uring singeing 0uring singeing 0uring singeing 0uring signeing during signeing &fter drying singeing 6 * 8ethod of chec/ing %peedometer reading 6 3isual 3isual 3isual 3isual 3isual 6 examination of the extinction of spar/s ha2y dyeing pilling test feel visual Production record %tandard * frequency of chec/ C5 6 1+4 m*min as per ma/e * during each round 1 6 A inches as per quality 7o sooty flames * during each round 7o uneven flame * during each round &s per machine construction 7o creases * random chec/ing 7o spar/s <andom A5 6 A4 E once a day 7ecessary action9s: <un the machine optimum speed at

&d.ust the length of the flame 8ix Fas and air property $lean cho/ed up orifices #nsure that both faces of the fabric are signed #nsure proper functioning of expanders #nsure proper quenching #nsure efficient singeing of the goods Ta/e corrective measures

-A.

.. A .. Table - 10.$ : Process control in desi%ing

%r. 7o. 1. 2. Parameter 7ature of si2e Percentage wet pic/ up $hec/ Point Prior to desi2ing 0uring desi2ing 8ethod of chec/ing Daboratory testing of si2ed sample percentage pic/ up determination by laboratory analysis $hec/ recipe Thermometer reeading Thermometer reading p, indicator * p, paper laboratory testing %tandard * frequency of chec/ 6 &bout 115E as per quality * once a shift 7ip pressure during each round &s per requirement +64 sec. &s per nature of the desi2ing agent &s per desi2ing agent characteristics during each round per &s per desi2ing agent characteristics during each round H B4E * once a shift 7ecessary action9s: %elect corresponding desi2ing agent #nsure proper nip expression

+ 1. 4. @. A.

$oncentration of desi2ing agent * salt * wetting agent mpregnation * dwell time Temperature p, 0esi2ing eficiency

0uring desi2ing 0uring 0esi2ing during desi2ing 0uring desi2ing &fter desi2ing

Ta/e corrective measures to ad.ust recipe #nsure optimum penetration and reaction time <egulate steam supply 8aintain the required p, $ontrol process parameters adequately

Table - 10.& : Process control in scouring. A. 'ier

%r. 7o. 1. 2. +. Parameter Iier lining Piling &ir removal $hec/ Point Prior to filing of /ier during filing of the /ier ;efore ta/ing pressure 8ethod of chec/ing 3isual 3isual 3isual %tandard * frequency of chec/ 7o chipping of interior wall * once a wee/ Uniform piling * once a day 7o entrapped air 7ecessary action9s: #nsure proper cementing of the interior wall of the /ier 0o uniform piling #nsure complete removal of air in the /ier by passing steam for some time and then closing the coc/ for pressure build6up #nsure proper cleaning of heat exchanger tubes Ta/e corrective measures &d.ust the concentration <egulate steam supply <egulate steam supply Five optimum dwell time for treatment

1. 4. @. A. B. C. 15.

$irculation <ecipe $oncentration of scouring liquor Temperature %team pressure Time concentration of drain liquor

0uring process ;efore scouring ;efore * 0uring scouring 0uring scouring 0uring scouring 0uring scouring &t the end of scouring

(low rate $hec/ recipe with respect to the amount of cloth to be scoured and quality of cloth Titration Thermometer pressure gauge reading Time record Titration

%mooth circulation &s per quality * once a day &s per quality * once a day &s per quality during each round &s per quality during each round &s per quality * once a day H 15E of original concentration * once a day

-.B.

.. B ..

Table - 10.& :Process control in scouring ( Contd. ) *. + - bo,.

%r. 7o. 1. 2. +. 1. 4. @. A.

Parameter <ecipe chec/ing $oncentration of chemicals in the saturator (low of chemicals in the saturator Pic/6up %team pressure Time Temperature

$hec/ Point Prior to scouring 0uring scouring 0uring scouring 0uring saturation 0uring scouring 0uring scouring 0uring scouring

8ethod of chec/ing $hec/ requisition Titration (low measurements the

%tandard * frequency of chec/ &s per quality * once a day &s per quality * once a shift &s per quality * once a shift &bout 14625E positive pic/ 6 up * once a shift &s per quality * once a shift &s per quality * once a shift &s per quality * once a shift

7ecessary action9s: Ta/e corrective measures #nsure proper concentrate of chemicals in stoc/ tan/ feed liquor * saturator &d.ust flow of chemicals and maintain constant level in the saturator &d.ust nip pressure #nsure proper steam pressure, inform boiler house if necessary Five optimum dwell time <egulate steam supply

rate

laboratory analysis pressure reading gauge

0well time record Thermometer

Table - 10.& : Process control in scouring ( Contd. ) C. +igger

%r. 7o. 1. 2. +. 1. Parameter Time Temperature $oncentration of chemicals <esidual al/ali $hec/ Point 0uring %couring during scouring 0uring scouring &fter scouring 8ethod of chec/ing <ecord time by counting no. of ends Thermometer Titration Titration %tandard * frequency of chec/ &s per quality * once a day &s per requirement * during each round &s per quality once a shift H 15E of chemicals * once a day 7ecessary action9s: #nsure optimum treatment time by giving optimum number of ends <egulate steam supply 8aintain optimum concentration of chemicals 8aintain concentration of seouring liquor

-C.

.. C .. Table - 10.- : Process control in che.ic/ing " perio,ide bleacing

%r. 7o. 1. 2. +. 1. Parameter 8etal contamination <ecipe $oncentration of chemicals Guantity of stoc/ solution Temperature Time p, $oncentration of drain liquor 7a2" ! sio2 ratio for sodium silicate $hec/ Point $hec/ stoc/ solution and while in process Prior to bleaching 0uring process Prior to peroxide bleaching 0uring bleaching 0uring bleaching 0uring bleaching &fter bleaching Prior to preparation of peroxide stoc/ solution 8ethod of chec/ing Daboratory analysis $hec/ requisition slip Titration $omparison of level of stoc/ solution and quantity of cloth to be bleached Thermometer 0well time record p, indicator * paper Titration Daboratory analysis %tandard * frequency of chec/ 7o metal contamination * once a wee/ &s per requirement * once a day &s per requirement * once a shift (ull consumption of prepared stoc/ solution * once a day &s per requirement * during each round &s per quality * once a shift C.4 6 5.4 9chemic/: 15.4611.4 9peroxide: during each round "nce a day 7a2 ! %i"2 ! 1!1 7ecessary action9s: &dd sequestering agent Use (ilters <eplace silicate by metasilicate <esort to souring prior to bleaching Ta/e corrective measures &d.ust concentration of chemicals &d.ust feeding concentration. <egulate flow rate #nsure full consumption of prepared chemicals <egulate steam supply Five adequate treatment time 8aintain required p, #nsure optimum utilisation of peroxide <eplace by metasilicate &dd soda ash * caustic to maintain the ratio

4. @. A. B. C.

Table - 10.0 : Process control in souring " acid desi%ing " neutralisation
%r. 7o. 1. 2. +. 1. 4. @. A. Parameter $oncentration of acid (low rate during feeding Temperature Time Docalised drying p, during washing * neutralisation Pic/ 6 up $hec/ Point Prior to souring 0uring souring 0uring souring 0uring souring 0uring storage &fter treatment acid 8ethod of chec/ing Titration (low meter Thermometer 0well time record 3isual p, indicator paper Daboratory analysis %tandard * frequency of chec/ &s per requirement * once a shift &s per requirement <oom temperature * during each round &s per requirement * once a shift 7o localised drying 7o acidity after washing * once a shift Positive pic/6up 146 25E once a shift 7ecessary action9s: 8aintain the <egulate flow of acid feeding Plug all steam lea/ages #nsure optimum dwell time #nsure proper covering of the acid treated goods during storage Ta/e corrective measures &d.ust nip presure during

0uring souring

-15. .. 15 .. Table - 10.1 : Process control in dr ing ( c linder dr ing )

%r. 7o. 1. 2. +. 1. 4. @. A. Parameter %team pressure Fuide rolls %croll * <olls * expanders 7ip pressure %team traps $leaning cylinders &lignment cylinder Parameter 8oisture content of of $hec/ Point 0uring drying 0uring drying 0uring drying 0uring drying 0uring drying 0uring drying 0uring drying 8ethod of chec/ing Pressure reading 3isual 3isual Daboratory analysis 3isual 3isual 3isual gauge %tandard * frequency of chec/ &s per quality * during each round 6 6 8inimum possible expression * once a day &tleast once a shift <andom chec/ing 6 7ecessary action9s: <egulate steam supply #nsure smooth rotation and alignment of guide rolls #nsure crease free flow of cloth &d.ust nip pressure #nsure no air * water * steam condensate inside the cylinder, prior to ta/ing steam pressure #nsure efficient heat transfer from the surface of the cylinders &d.ust the alignment of cylinders for crease 6 free drying. 7ecessary action9s: 0ry the fabric on a drying range or squee2e the fabric on a padding mangle or a water mangle which is running in tandem with mercerising machine &d.ust the concentration and control the temperature

Table - 12.0 : Process control in .ercerising

%r. 7o. 1. $hec/ Point ;efore mercerisation 8ethod of chec/ing Daboratory testing %tandard * frequency of chec/ #ither dry or with uniform moisture

2.

$austic solution padding

soda at

$oncentration Temperature

Twaddle titration

meter

Thermometer %top watch * speed indicator Pic/6up study

+. 1.

Time of mercerisation Jet pic/ up of caustic soda Jashing <ecuperator

4. @.

mpregnation 2one (abric after last padding with caustic soda solution $oncentration of wash liquor Temperature

&ccording to treatment desired * during each round <oom temperature * during each round 14 6 @5 sec * during each round 12561+4E <andom chec/ing for each quality B615' TJ * during each round 8ore than C55$ 9coloured fabric @55$: * during each round Dess than 1E once a shift p, near neutral * random chec/

&d.ust speed &d.ust nip pressure &d.ust concentration of caustic soda solution &d.ust rate of flow of water &d.ust steam flow

Twaddle meter Thermometer

A. B.

$austic soda left on the fabric %ouring and washing

(abric delivery end &cid addition

at

Daboratory testing Daboratory testing and p, indicator

C.

(abric after washing

$oncentration of feed liquor $oncentration of acid in the tan/ p, of fabric

$hec/ the washing procedure, ta/e necessary action to effect thorough washings &rrange for overhead tan/ and pipe line. &d.ust the concentration of acid &d.ust the rate of flow

p, indicator

&bout A.5 * during each round

&d.ust rate of flow of water

-11. .. 11 .. Table - 10.10 : Process control in d eing A. arn de ing

%r. 7o. 1. 2. +. Parameter Pac/age density %hape of the cheese $hec/ing of angle of winding 3ariation in pac/age Perforation of spindles 8D< Pump pressure $hec/ Point Prior to loading Prior to loading Prior to process 8ethod of chec/ing ; T<& pac/age density meter 3isual 3isual %tandard * frequency of chec/ 5.+g*c*c* 1 or 2 pac/ages at random per shift 6 $ross wound for cheese and parallel for beam random chec/ <andom chec/ <andom chec/ &s per ma/e $hange in pressure after reversal of the cycle should not be more than 11b*in.2 "nce a day once a day &s per class of dyes 0uring each round 6 7o entrapped air 7o lea/age, /eep vigilance * during round <andom chec/ 7ecessary action9s: #nsure uniform pac/age density both within the pac/age and among the pac/ages. Ta/e corrective measures %egregate defective wound goods and rewind them #nsure uniform pac/age si2e #nsure no cho/ing perforation of spindles. #nsure proper 8D< Ta/e necessary action for smooth reversal and cho/ing of pump #nsure conformity with standard recipe #nsure proper dissolution of dyes 8aintain the desired p, <egulate steam supply 8aintain optimum processing time #nsure complete air removal Plug steam lea/ages $orrect pac/age density after drying and rewinding of the

1. 4. @. A.

Prior to loading Prior to mounting on spindles 0uring process 0uring process

&ctual weighing 3isual ;y 0ip6stic/ measurement pressure reading

B. C. 15. 11. 12. 1+. 11. 14.

<ecipe6 colour * chemicals $olour dissolution p, Temperature Time #ntrapped air %team lea/ages 3ariation in pac/age density during process

Prior to dyeing prior to dyeing 0uring process 0uring Process 0uring process Prior to pressure build6up 0uring process &fter dyeing of polyester component of ployester * cellulosic blended goods

%crutinising of colour * chemical issue slips %potting on filter paper p, indicator Thermometer Processing cycle record $hec/ air vent valve 3isual (eel after drying

-12.

.. 12 .. Table - 10.10 : Process control in d eing *. 3.T.3.P. d eing : bea. " 4et d eing
%r. 7o. 1. Parameter (abric pretreatment $hec/ Point ;efore dyeing 8ethod of chec/ing &bsorbency Uniformity treatment. 0egree of setting (eel 3isual 3isual ;y yardage measurement Jater outlet valve Pressure reading guage of heat 6 &s per quality * random chec/ 8inimum B615 layers * random chec/ 6 7o entrapped air 0ifference of K 11b*in2 between reversals * once a shift &s per ma/e <andom chec/ once a day #nsure uniform batching resulting in neither too tight nor too loose a batch 8aintain desired overlap #nsure proper length of wrapper cloth being used for avoiding perforation mar/s <estrict batch si2e as per machine specification <emove entrapped air completely. $hec/ for proper batching and air removals ma/e desired changes &d.ust .et pressure according to quality #nsure conformity with standard %tandard * frequency of chec/ Daboratory analysis * each bleached lot 7ecessary action9s: #nsure good pretreatment of the fabric

2. +. 1. 4. @. A.

Pac/age density "verlap on beam Jrapper cloth length "verloading dye bec/s &ir entrapped (low reversal

0uring batching 0uring batching ;efore batching Prior to during loading ;efore pressure build up 0uring process

B. C. 15.

8D< Let pressure <ecipe

Prior to dyeing 0uring dyeing Prior to dyeing

11. 12.

P, Temperature

0uring dyeing 0uring dyeing

6 Let pressure gauge reading $hec/ing of batch si2e, shade number and corresponding colour * chemical issue slip p, paper * p, meter 0ial thermometer

p, 1.4 6 4.4 &s per requirement * during each round &s per requirement 0uring each round

1+. 11.

0yeing time %team pressure

0uring dyeing 0uring dyeing

Time recording pressure reading gauge

&d.ust concentration of acid buffer solution #nsure uniform heating rate as per standard programme 8aintain uniform steam pressure $hec/ proper wor/ing of thermostat #nsure desired holding time and rate of cooling #nsure optimum steam supply.

-1+. .. 1+ .. Table - 10.10 : Process control in d eing ( Contd. ) C. +igger d eing

%r. 7o. 1. Parameter (abric preparation $hec/ Point Prior to dyeing 8ethod of chec/ing &bsorbency Uniform whiteness p, of cloth ;ody creases * selvedge crease 3isual %tandard * frequency of chec/ Food absorbency Uniform whiteness 7ear neutral 7o creases * each bleached lot <andom chec/ <andom chec/ 7ecessary action9s: #nsure good fabric preparation

2.

;atching

0uring batching

+.

;atch si2e

0uring batching

8easurement yardage

of

1.

8D<

Prior * dyeing

during

$hec/ for water level in .igger $hec/ for weight of fabric loaded

maximum permissible load as per ma/e * random chec/ "nce a shift

Inife edge batching #nsure no slippage while running Proper wor/ing of expander Uniform tension at the time of batching #nsure that .igger is not overloaded

4.

%election end cloth

of

Prior to dyeing

@.

$reasefree wor/ing .iggers <ecipe

0uring dyeing of Prior to dyeing

Dength of the cloth $olour of end cloth should be compatible with the shade to be dyed 3isual

<andom chec/

8aintain constant 8D< for consistent results Jater level mar/ing in .igger must be done in accordance with capacity and not by approximate level 9height: of water in the .igger. Prevent water * steam lea/ages #nsure proper selection and length of the end cloth.

0uring each round

A.

B.

$olour preparation

0uring colour preparation

%crutinising of chemical * colour issue slip with respect to batchsi2e, shade number, sort number 3isual * spotting on filter paper

"nce a day

&d.ust alignment of expanders &d.ust roller alignment <emove crease manually, possible Ta/e corrective measures

if

<andom chec/

C.

$olour chemical addition

0uring 0yeing

3isual

<andom chec/

#nsure proper dissolution of dye %train the colour prior to dyeing nvestigate the method of dissolution #nsure proper vatting of vat dyes use splash board during additions $arry out colour addition in equal parts #ffect proper stirring after colour addition Predissolve all solid chemicals

added

-11. .. 11 ..

%r. 7o. 15.

Parameter $oncentration of chemicals

$hec/ Point 0uringdyeing

8ethod of chec/ing $hec/ hydrose * caustic by using vat yellow * congo red paper The concentration of chemicals should be on volume * depth basis irrespective of batch si2e whereas the dyes should be calculated on the fabric weight basis Thermometer

%tandard * frequency of chec/ 0uring rounds

7ecessary action9s: #nsure proper concentration

11.

Temperature

0uring dyeing

&s per standard dyeing procedure * during each round &s per dyestuff 6 class of

12. 1+. 11.

p, Time &ddition of colour for correction of share &fter treatments

0uring dyeing 0uring dyeing 0uring process

p, paper Time record, number of ends 3isual

<egulate steam supply $arry out heating at the end of turn Prefer dial thermometer to cup type thermometer for precise temperature control Ta/e corrective measures Five adequate time * number of ends #nsure that when additions are made half the liquor containing unexhausted dye is drained so as to maintain 8D< and help in exhaustion $hec/ if the following treatments are given %ulphur blac/6sodium acetate * soda ash treatment or sodium dichromate treatment &2oic 6 thorough soaping with dispersing agent <eactive 6 thorough soaping, dye fixing treatment and ensure no tinting of colour in final wash 0irect 6 dye fixing treatment. 0isperse 6 reduction clearing treatment nvestigate the reasons of for redyeing

Jherever possible

14.

&fter dyeing

Daboratory analysis

&s per class of dye * random chec/

1@.

<edyeing

0uring process

Production records

minimum redyeing * once a day

-14.

.. 14 .. Table - 10.10 : Process control in d eing ( Contd. ) 5. 6e.i continuous " Continuous .ethods of d eing
%r. 7o. 1. Parameter (abric preparation $hec/ Point Prior to dyeing 8ethod of chec/ing Uniform absorbency $rease 6 free cloth #ven width Proper stitching of the end pieces Percentage expression determination ,ardness of bowls $arbon impression 3isual %tandard * frequency of chec/ #ach bleached lot 7ecessary action9s: #nsure good fabric preparation

2.

7ip pressure

padding rolls %quee2e rolls 9soaper: Process ! padding drying soaping 0uring dyeing 0uring dyeing 0uring colour preparation 0uring process 0uring dyeing 0uring dyeing 0uring drying of padded goods 0uring dyeing

"nce a shift

#nsure optimum pic/6up

+.

Threading

"nce a %hift

#nsure optimum pic/6up

1. 4. @. A. B. C. 15. 11.

#xpanders Fuide rolls $olour preparation P, %peed 0well time Temperature in drying 2one Uniform colour concentration in padding trough Temperature of padding liquor (low feeding liquor ;atching

3isual 3isual &s per recipe Proper dissolution %training p, paper %peedometer %top watch 0ial thermometer 3isual

6 6 <andom chec/ &s per class of dye 0uring each round &s per requirement 0uring each round <andom chec/

#nsure smooth wor/ing and crease 6 free run of the material #nsure smooth wor/ing of guide rolls #nsure proper colour preparation 8aintain recommended p, 8aintain required speed &d.ust speed #nsure slow, uniform and progressive drying to avoid migration #nsure continuous circulation of the dye liquor if possible or use shallow padding trough 8aintain desired temperature throughout the padding process &d.ust flow and ensure uniform feeding of dye liquor through out the width of the fabric ma/e proper arrangement for rotation of padded batches to avoid seepage of dye liquor and stoppage mar/s #nsure low padding expression Properly wrap with polythene sheet

12. 1+. 11.

0uring dyeing 0uring dyeing &fter batching

Thermometer (low meter 3isual

&s per the class of dyestuff 6 <andom chec/

14.

$overing of batches 9pad 6 roll*pad batch:

&fter batching

3isual

solate from atmosphere by proper covering * random chec/

-1@. .. 1@ .. Table - 10.11 : Process control in printing A. Actual printing

%r. 7o. 1. Parameter (abric preparation $hec/ Point ;efore printing 8ethod of chec/ing 3isual * laboratory testing %tandard * frequency of chec/ Food absorbency Uniform whiteness $reasefree fabric p, of the cloth Uniform width &ppropriate sort number $orrect face for printing * each bleached lot &s per requirement * once a day &s per standard recipe * once a day 7ecessary action9s: Ta/e corrective measures and batch the material for printing on correct face

2.

Fum preparation $olour preparation

0uring gum preparation 0uring colour preparation

3isual * visocosity measurement 3isual and random chec/ing of issue slips for colours and chemicals 3isual $omparison with s/etch or approval sample 3isual 3isual

+.

1. 4. @. A.

0esign chec/ing %ample chec/ing #xpanders * guide6rolls %quee2ee pressure * design roll pressure ;ac/grey

;efore printing ;efore printing 0uring printing 0uring printing

<andom chec/ "nce a day 6 7o selvedge 6 to 6 selvedge variation * during each round $reasefree feeding of dried bac/grey 0uring each round <andom chec/

#nsure adequate wor/ing time and temperature #nsure the preparation of free flowing gum devoid of lumps 6 #nsure correct p,, 6 &dd ingredients in the desired order only after dissolution and straining Use prefiltered gum and also filter the print paste Ta/e corrective action. Ta/e corrective action #nsure creasefree run of the cloth #nsure uniform pressure throughout the fabric width #nsure proper drying and creasfree feeding of bac/ grey #nsure the use of longer length pieces with minimum stitches Ta/e necessary action and change lapping at regular intervals. #nsure uniform and complete drying #nsure proper wor/ing of fans * alignment and free rotation of guide rolls in the case of hot flue #nrich the print6paste with the required ingredients to ta/e care of depleted strength #nsure proper recording of actual print paste consumption on the machines and effective reutilisation of loft 6 over print paste

B.

0uring printing

3isual

C.

15. 11. 12. 1+.

Dapping of guide rolls on printing machine 0rying $rease drying %tability print paste free of

0uring printing of discharge or resist styles 0uring printing 0uring printing ;efore printing $olour /itchen

3isual

;y feel 3isual %ample printing 3isual chec/s random

0uring each round 0uring each round <andom chec/ once a shift

left over pringt paste

-1A. .. 1A .. Table - 10.11 : Process control in printing ( Contd. ) *. Pol .erising

%r. 7o. 1. 2. +. 1. Parameter Temperature Time #xhaust (ree movement guide rolls $hec/ Point 0uring polymerisation 0uring polymerisation 0uring polymerisation of 0uring polymerisation 8ethod of chec/ing 0ial thermometer * thermopaper %top watch 3isual 3isual %tandard * frequency of chec/ &s per requirement during each round &s per requirement * during each round &s per requirement * once a shift &s epr requirement 7ecessary action9s: #nsure adequate and uniform temperature throughout the width of the machine 8aintain proper speed %ee that all exhaust fans wor/ mainly for pigment printing when /erosene is used #nsure creasefree run of cloth

Table - 10.11 : Process control in Printing ( Contd. ) C. Ageing

%r. 7o. 1. 2. +. 1. 4. @. A. B. Parameter Time Fuide rolls Jater level &cid n.ection %team pressure Dea/age $ondensation 8a/ing off $hec/ Point 0uring ageing 0uring ageing 0uring ageing 0uring ageing 0uring ageing 0uring ageing 0uring ageing &fter ageing 8ethod of chec/ing %top watch 3isual 3isual 3isual Pressure guage 3isual 3isual 3isual %tandard * frequency of chec/ &s per requirement * during each round 7o creases * if possible, during each round &s per style of printing * once a shift "nce a shift &s per requirement * during each round 7o lea/ages, /eep vigilance 7o water dropping * random chec/ 7o mar/ing off * random chec/ 7ecessary action9s: 8aintain speed * holding time #nsure crease 6 free flow of cloth #nsure optimum water level #nsure optimum quantity of acid in.ection <egulate steam supply and correlate with temperature Plug all steam lea/ages #nsure proepr heating of steam .ac/ets * shoes, lid and roof and use of completely dried bac/ grey $hange bac/ grey on pressure ager at desired internally.

-1B. .. 1B .. Table - 10.11 : process control in printing ( Contd. ) 5. Carbonising " 6ilicate padding " 6oaping

%r. 7o. 1. 1.

Parameter $arbonising $hec/ing of concentration of sulphuric acid $oncentration of chemicals 7itrogenous impurities in sulphuric acid 0well time $arbonising neutralising Docal drying %ilicate Padding $oncentration of silicate 7a2" ! %i"2 7ip pressure 0well time

$hec/ Point prior carbonising to

8ethod of chec/ing Twaddel titration meter *

%tandard * frequency of chec/ A5E 9 w*w : once a shift "nce a day (or each lot sulfuric acid of

7ecessary action9s: 8aintain proper concentration of sulfuric acid 8aintain the required concentration of chemicals. &dd urea or sulphamic acid in carbonising bath #nsure optimum dwell time. #nsure optimum carbonising efficiency #nsure complete neutralisation and washing increase acid pic/6up and avoid undue exposure maintain optimum concentration of silicate &dd sodium hydroxide to maintain the ratio #nsure optimum nip pressure and uniform application Five optimum dwell time

2. +. 1. 4. @. A. . 1. 2. +. 1.

Prior to process Prior carbonising 0uring carbonising &fter carbonising &fter carbonising 0uring carbonising Prior to silicate pading Prior to silicate padding 0uring process &fter padding to

%crutinising of the issue slips 0iphenyl amine test * brown ring test %top watch laboratory analysis p, indicator 3isual

&s per quality minimum 14 min. * once a shift CC.AE once a day near neutral * chec/ each lot 7o local drying * random chec/ 152615@ Tw* during each round 1!2 *once a shift <andom chec/ 1@ hr. for cold pad batch and B612 sec. for hot silicate * random chec/ <oom temperature 9cold process: B46 C55$, 9hot process: during each round

Twaddel meter laboratory analysis laboratory analysis %top watch, record Thermometer time

4.

Temperature

0uring process

<egulate steam silicate process

supply

in

hot

-1C. .. 1C .. Table - 10.11 : Process control in printing ( Contd. ) 5. Carbonising " 6ilicate padding " 6oaping
%r. 7o. @. . 1. 2. +. 1. 4. @. A. Parameter Proper covering %oaping Jater .ets Jater supply Threading Fuide rolls %quee2e pressure Temperature $oncentration of chemicals $hec/ Point &fter process 0uring washing 0uring washing Prior to process Prior to * during process Prior to * during process prior to * during process Prior to * during process 8ethod of chec/ing 3isual 3isual 3isual 3isual 3isual 3isual Thermometer ;y /nown test methods for individual chemical for reduction clearing and developing baths %tandard * frequency of chec/ <andom chec/ 7o cho/ing of .ets * once a day <andom chec/ Proper threading * once a day 6 0uring each round &s per treatment * during each round &s per treatment * during each round while reduction clearing 7ecessary action9s: Ta/e necessary action to avoid local drying and exposure to atmosphere #nsure proper functioning of .ets #nsure adequate supply of water for overflow washes Ta/e corrective measures #nsure smooth wor/ing of guide rolls also chec/ for alignment of guide rolls #nsure proper and uniform expression at each nip <egulate steam supply to maintain the temperature 8aintain optimum concentration.

Table - 10.1! :Process control in finishing A. 6tenter

%r. 7o. 1. Parameter 7ip pressure $hec/ Point 0uring process 8ethod of chec/ing Pic/6up study %tandard * frequency of chec/ "nce a shift 7ecessary action9s: &d.ust the compressor valve or weights on lever $hec/ the surface of padding mangle <egulate steam supply <egulate speed #nsure optimum overfeed in the case of heat setting Ta/e corrective measures #nsure proper wor/ing and the direction of fans 8aintain desired width

2. +. 1. 4. @. A.

$hamber temperature 0well time overfed #xpanders uncurlers ;lower Jidth *

0uring process 0uring process 0uring process 0uring Process 0uring process 0uring process

0ial thermometer %top watch measurement 3isual 3isual Tape measurement

&s per requirement * during each round &s per requirement * during each round &s per requirement * during each round 7o crease * during each round Proper air circulation * once a shift &s per requirement *

at delivery end

during each round

-25. .. 25 ..
%r. 7o. B. C. Parameter %team lea/ages $oncentration of chemicals %tability of procondensate in resin finishing Temperature * viscosity of starch paste 0rying eficiency %team pressure <andom inspection of clips * pins $hec/ Point 0uring process Prior * process Prior to finishing during 8ethod of chec/ing 3isual $hec/ing chemical issue slips and actual verification during preparing 3isual %tandard * frequency of chec/ 7o lea/ages, /eep vigilance <andom chec/ 7ecessary action9s: Plug all steam lea/ages 8aintain the required concentration

15.

resin

<andom chec/

#nsure proper stability * selection of resin precondenstates 8aintain optimum temperature * viscosity of starch paste #nsure optimum drying efficiency <egulate steam supply #nsure proper functioning of clips * pins

11. 12. 1+. 11.

Prior * during starch finishing 0uring * after process 0uring process Prior to process

Thermometer viscometer

0uring each round 7o overdrying *.during each round 0uring each round "nce a wee/

Textometer or by feel at stitches pressure gauge reading 3isual

Table - 10.1! : Process control in finishing *. Pre-shrin/ing

%r. 7o. 1. 2. +. 1. 4. @. A. B. Parameter 0amping Temperature Jidth %peed ;elts ;lan/ets %hrin/age * $hec/ Point Prior to Palmer stretcher 0uring pre 6 shrin/ing &fter pre 6 shrin/ing 0uring pre6 shrin/ing Prior to pre 6 shrin/ing &fter pre 6 shrin/ing 0uring pre 6 shrin/ing 0uring pre 6 shrin/ing 8ethod of chec/ing (eel dial 6 thermometer Tape measurement %peedometer 3isual * (eel %hrin/age test 3isual 3isual %tandard * frequency of chec/ 6 0uring each round &s per fabric sort * random chec/ 0uring each round once a wee/ &s epr fabric sort * chec/ for each lot 0uring each round 0uring each round 7ecessary action9s: &d.ust the spray intensity <egulate steam supply &d.ust the dwell percentage shrin/age &d.ust speed regulator time and

$ooling water no22le %tamping

#nsure correct surface of the belts * blan/ets by regular grinding #nsure optimum shrin/age percentage $hec/ the cho/ing of no22le heads #nsure %tamping as per quality $orrect position of stamping &dequate in/ application resulting in clear imprint.

..21. .. 21 .. Table - 10.1! : Process control in finishing A. Calender " 6chriener

%r. 7o. 1. 2. +. 1. 4. @. Parameter 7ip pressure Threading 0amping %peed Jidth <oll surface $hec/ Point Prior * during process Prior * during process Prior to calendering 0uring process 0uring process Prior to process 8ethod of chec/ing 7ip presure reading 3isual (eel %peedometer Tape measurement 3isual %tandard * frequency of chec/ 6 &s per requirement * random chec/ 6 0uring each round &s per sort * during each round 7o grooves * crac/s * holes or surface deposition * once a shift 7ecessary action9s: <egulate the compressor valve or correct the lever arrangement #nsure proper threading &d.ust water spray intensity <egulate speed #nsure desired width at the delivery end #nsure proper maintenance and cleaning of calender bowls.

4.

*enefits of Process control $lariant has been stressing the need for adequate process control

measures in textile wet processing for over a decade.

t has guided its

customers in successfully introducing the concept of process control in process houses. The various advantages that have accrued to the member industry by the implementation of these process control measures recommended by $lariant are as follows !

ncreased production efficiency as a consequence of more stable speeds and in certain cases even higher processing speeds, besides better machine utilisation.

-22. .. 22 .. <educed chemical consumption 9 it is not uncommon to discover that chemicals are not only frequently overused but also under utilised :. <educed energy and water consumption. <educed labour cost per unit of production. mproved consistency of chemical treatments and consequent standardisation of a product's performance particularly in the case of repeat orders. Precise prediction of chemical processing costs for a given product, eliminating the ris/ of undercosting of products by ta/ing hypothetical averages. Predictability in quality of the products. %ignificant reduction in percentage reprocessing.

@.

6u..ing up (rom the foregoing, it can be said that process control is one of the

most effective managerial tools.

ts important and positive role towards

maintaining the quality and increasing the margin between production cost and sales price cannot be undermined. n the past and even today,

in some of the mills, the process control department is considered non

-2+. .. 2+ ..

productive and is hence neglected. "ver the years, $lariant has been helping its member mills in implementing process control measures and the mills have derived considerable advantage in terms of reduced value loss and improved quality. n some of the cases, the mills have been able to reduce processing costs by way of optimising the various unit operations and standardising chemical recipes. The mill have also

succeeded in reducing the extent of reprocessing on account of the vigilance of the process control personnel in maintaining the processing parameters at a desired level. n a nutshell the need of the hour is total

exploitation of the concept of process control.

;efore concluding, it would be worthwhile to mention that the personnel wor/ing in the area of process control must have good rapport with other personnel engaged directly or indirectly in the production line, elicit their co6operation and acquire the confidence of shop6floor personnel. They must also have thorough /nowledge of the process involved and be able to discuss the problems with others in a language that they can understand.