??

In the dyeing industry, the air-flow dyeing machine achieves low consumption due to its low bath ratio, and is known as an environmentally-friendly and energy-saving dyeing machine in the industry. However, because each dyeing factory is closed to its own dyeing process, dyeing companies have not yet found the essentials of operation, and valuable equipment has become a decoration.

的 Features of airflow dyeing machine

It is mainly reflected in:

⒈It has a high degree of automation, on the one hand, it is convenient for daily production management, and it is not very demanding for the operation of employees; on the other hand, because of the high degree of automation, the flexibility of the production process is very small. The difference will be small and the reproducibility is better;

⒉The production bath ratio is small (up to l: 4 or less), and the energy saving is more obvious. Compared with the conventional overflow dyeing machine, it can save more than 50% of water, reduce the water consumption per ton of cloth to 50 to 80 tons, and save dyes. 5-10%, additive saving 30-60%;

⒊The operation of the fabric in the machine is driven by the air flow generated by the blower, which blows the gray fabric to make the fabric foam, and the gray fabric continuously changes the folded position, so that the gray fabric is not easy to wrinkle and wrinkle during the dyeing process;

廣 A wide range of dyeable fabrics, which can dye gray fabrics of 60-600g / m2. Dyeing cotton / lycra stretch fabrics can be evenly and thoroughly dyed without stitching, which is the most ideal equipment for dyeing rack fabrics.

⒌ No foaming during the dyeing process, no need to use defoamer, which saves costs and avoids defoamer spots.

Dyeing principle

The reason why the air dyeing machine does not work well is that the work idea is inaccurate and the directions are not correct. No matter how many work or methods are done in vain, the dyeing principle and process of the overflow dyeing machine cannot be used to dye in the air dyeing machine. Will go farther and farther, and never find the essentials to develop a dyeing process that can only be used for airflow dyeing machines.

基本 The basic principle of airflow dyeing machine is:

The airflow passes through the fan, and it is continuously blown to the nozzle, which is sprayed toward the fabric in the same direction as the fabric, which drives the fabric to run. At the place where the fabric is running and folded, the air pressure changes sharply, so that the fabric is bubbled to eliminate wrinkles. The dye is sent to the nozzle by the feeding motor, and meets the air at the nozzle, which causes the dyeing liquid to be atomized in a powerful air flow, and diffuses to the high-speed running cloth through the nozzle.

At this time, the various dyeing properties of the dye are slightly different from those of the overflow dyeing. In the flow dyeing, the slow dyeing and migration of the dye are mainly reflected, and the dye migration is reduced because of the cloth-liquid separation in the air dyeing. Dyeability is mainly reflected in slow dyeing and diffusivity, and the process of dye diffusion and adsorption from dye liquor to fabric.

Because the grey cloth has not been immersed in water during the dyeing process, the migration of the dye added is very difficult (this is also an important factor that will not cause color blooming). All dyeing materials must rely on this process of adsorption (or fixation), In addition, the proportion of dyes on the gray cloth must be continuously and evenly increased to finally achieve the purpose of dyeing. The dye diffuses to the fabric and diffuses evenly to achieve uniform dye adsorption and ultimately uniform color fixation.

In this diffusion-adsorption process, in order to make the dye liquor evenly diffuse, the wool effect of the grey cloth is very important. The permeability of the grey cloth helps the dye liquor to be uniform and adsorbed, and finally the dye is fixed uniformly.

The choice of vat dyes

During the dyeing process, the cloth and the dye solution are separated. Only when the grey cloth passes through the nozzle, the nozzle is fully wetted and the dye solution is diffused. Generally, the cloth is circulated for about one minute.

After the dye is added to the dyeing machine, because there is no water flow between the grey cloths, it is very difficult for the dye to migrate after being adsorbed on the grey cloth. Because of this, as long as we add uniformly, there will be no cause of blooming, so the dye is adsorbed on the cloth. In the future, the same dye on the cloth is not much different for the jet dyeing machine. What we want to control is the speed at which the dye is absorbed from the dyeing solution onto the grey cloth.

So the air dyeing machine has high requirements on the compatibility of the dyes. If the dyeing and fixing are not synchronized, it is equivalent to the secondary dyeing of different dyes, which is not conducive to leveling, and it is easy to produce step difference and yin and yang color difference.

Therefore, when using the air dyeing machine to select dyes, using compatible dyes is more conducive to leveling and shortening the dyeing time.

The dual-reactive dyes we use now are very suitable for use. In order to facilitate leveling, we must use the same type of dye in the same dye mix combination (according to the addition of salt and alkali when dyeing dyes, the affinity to the gray cloth). The effects are divided into salt-controlling and alkali-controlling dyes), otherwise we can only change the jC process to extend the dyeing, which is not conducive to the smooth surface of the cloth.

On the other hand, in order to improve the primary success rate of dyeing, when choosing a dye, choosing a dye with a close fixation rate or a close up rate is close to the dye, which can reduce the hue change caused by inconsistent bath ratios of small samples and large goods. In addition, the stability of the dye is also very important. When you feed, choose a better-branded dyer as your own supplier, especially as a ternary component dye. When testing the dyeing material, you must not only detect each batch. The difference in strength and strength should also pay attention to the differences between different packages of the same batch and the differences between the upper and lower layers of the same package. And urge suppliers to provide stable dyes, so that it is conducive to poor stability of the dyeing tank.

調(diào)整 Adjustment of process formula

The small bath ratio dyeing machine is dyed with a bath ratio of 1: 4 or less, and cannot be proofed 1: 4 when making a sample. So we use a 1: 8 proofing formula to formulate a formula adjustment factor based on the dye exhaustion rate. Watch, to adjust the formula of the lower tank, we have always done this. The 1: 4 airflow dyeing machine is a highly reproducible dyeing machine. The correction coefficient from small samples to large goods is also fixed. As long as the accuracy of the proofing is controlled, the formula is directly lowered into the tank, and the success rate is 95%. The above is not a problem, and we have always done it.

Why do I say "air-flow dyeing machine is a highly reproducible dyeing machine", because when we are in production, as long as the dyeing material is not wrong and dyeing: if the process is fixed and the weight of each fabric is the same, each fabric The colors are the same, there is basically no cylinder difference, which means that if the formula is properly adjusted, the color will be good.

Due to the correction coefficient, it is mainly adjusted based on operating experience:

1.According to the exhaustion rate of the dye: the exhaustion rate is reduced or not reduced, and the exhaustion rate is appropriately reduced.

2. When dyeing cotton with polyester-cotton grey fabric, according to the composition ratio of the grey fabric: the cotton proportion is higher or lower (whole cotton), and the cotton proportion is lower.

3. The proportion of other Yuanming powder, oxygen bleaching additives, etc. is reduced according to the reduction of the overflow dyeing machine bath ratio, and the reduction ratio of soda ash is between the dye and the auxiliaries.

編制 Compilation and optimization of dyeing process

The dyeing process of the air dyeing machine is based on the dyeing characteristics of the dye, so you must know the characteristics of the dye used before programming. The addition of each additive must take into account the effect of the addition of this additive on the affinity of the dye and the gray fabric to determine the addition of this additive, mainly based on the addition of salt and alkali to the gray fabric during dyeing Affinity and Immediate Influence. Each dye has a specific dyeing process, so the dyeing process of the air jet dyeing machine must be tailored to the dye characteristics. In short, as long as you know each dye well, you can develop a fast and good dyeing process.

According to the different characteristics of dyes, they can be divided into the following categories:

1. Some dyes will increase the affinity between the dye and the grey cloth after the Yuanming powder is added. We call it a salt-controlling dye. You must control the rate of the Yuanming powder, and the alkali can be added faster.

2. Some dyes will increase the affinity between the dye and the grey cloth after the soda ash is added. We call these dyes as alkali-controlling dyes. The speed of adding soda ash must be controlled during production. Canadian dollar powder can be faster, or Add it under reflux before adding dyes, such as vinyl sulfones such as KN-B black, KN-R blue, navy blue, and Ciba's S series.

3. If the two types of fruit salt-controlling and alkali-controlling dyes are mixed together, the compatibility will be extremely poor, which is equivalent to two dyeings. At this time, if the speed of Canadian dollar powder and soda ash is controlled, Very slow, on the one hand, the dyeing process will take a long time, on the other hand, it may not be done well. However, in many cases, in order to consider the cost or the burning problem, a combination of dyes with poor compatibility is also used. For example, KN-R blue (or KN-B black) and 3BS spell a bright purple. The former is not sensitive to Yuanming powder, but the reaction speed is very fast after adding alkaline agent, while the latter has certain dependence on Yuanming powder. However, after adding an alkaline agent, the reaction is still very slow even at 60 ° C. For this poorly compatible dye combination, we can use the pre-add soda ash process. The so-called pre-addition of alkali is to add a small amount of alkali before the dye is added. It can make a part of the dye have an elimination reaction and have liveliness without over-ionizing the fiber. The amount of pre-added alkali is generally about 5% of the total alkali (depending on the proportion of the alkali-controlling dye).

4. Emerald series dyeing process, most of the dyeing factories are currently at a loss for airflow dyeing machine. Easy to produce color flowers and color spots.

Add dye

In principle, the airflow machine is not allowed to add color (easy to spend), but sometimes it needs to be added in order to solve the problem of the color difference of the head cylinder. In order to avoid the generation of color flowers, reduce the temperature to below 50 degrees and add for about 30-40 minutes before feeding. Otherwise, it is easy to produce color flowers. After the addition is completed, increase the temperature to the original temperature for heat preservation and fixing.

重要 Control of several important parameters during dyeing

1. The cloth capacity of the dyeing machine is controlled. The air dyeing is generally similar to that of Germany. The size is basically the same. The capacity of the dyeing cloth is generally controlled around 200kg / tube, not less than 160kg / tube, and not More than 220kg / tube. The bath ratio will be smaller if the cloth is more, and the bath ratio will be larger if the cloth is less. The change of the bath ratio will affect the color change. Therefore, to control the cylinder difference, we must first control the weight of each cylinder in the same plan of gray cloth. In addition, too much weight or too light can cause blooms.

2, the speed of the damper and the cloth lifting wheel and the fabric cycle time: The air dyeing machine relies on the speed of the damper and the cloth lifting wheel to adjust the speed of the gray fabric. The air dyeing cannot be like the overflow dyeing, and the speed is not as fast as possible. The wind is too small, and the cloth guide wheel travels too fast will cause scratches and clogging. In general, the size of the wind force can be increased when the cloth is not blocked. If it is too large, it will waste electricity; The speed of the wheel is determined by the cycle of the gray cloth. Generally, it is appropriate to control the cycle of the gray cloth for about 160-180 seconds. The time is too short or too long, which will cause color bloom. Too little time (less than 130 seconds) will also cause hair on the cloth. This point should be paid special attention. Many friends mistakenly believe that the faster the speed, the more difficult it is to prevent color blooming. Blindly adjusting the speed of the cloth guide causes hair on the cloth. Then I mistakenly thought that this was the reason for the equipment, and this was also a major reason why many friends were afraid to use and not use the airflow dyeing machine.

Quantitative feeding system

The reasonable setting of the quantitative feeding system is an important part of the preparation of the entire dyeing process. The quantitative feeding system mainly needs to set the time and the measuring line. The values of the time and the measuring curve are determined according to the degree of influence of such additives on the dyeing, and the value of the measuring curve is determined according to the degree of increasing feeding. Choose from 0 to 99. The larger the value, the greater the degree of increase. Generally, the maximum value is between 0 and 70.

However, there are also many shortcomings in the actual use of airflow dyeing machines. We should also carefully avoid them when we do it, and prevent the quality problems that can be avoided in parallel, such as:

l. When the thickness of the knitted fabric of the same cylinder is very different (sometimes the main material is very thick and the auxiliary material is very thin), it is easy to produce difference and color difference. At this time, we should double-dye the slender gray fabric to make the thickness of the gray fabric. Don't double the gap.

2. Dark color fastness of polyester dyeing is not as good as that of high temperature overflow dyeing machine. Here we need to increase the amount of water to increase the dyeing bath ratio or add a dispersion leveling agent that resists agglomeration to reduce this fastness caused by agglomeration of dyes. Good phenomenon, and also pay attention to the phenomenon that the dyeing of polyester will be dark.

3. It is easy to make cylinder difference when the weight difference of each cylinder is too large. At this time, we should control the amount of cylinder capacity of each cylinder to reduce the cylinder difference. In addition, when the weight is too light, the dyeing liquid will pass through the nozzle. Insufficient exchange amount of dyeing solution is easy to cause color blooming.

4. When the weight of the slender island is too small, it is easy to press the lithium car, and it will easily cause segmental discoloration, especially the cotton spandex cloth. This is a defect existing in THEN dyeing machines and imitation machines, which should be solved by rebuilding the equipment.

5. Nozzle is easy to be blocked, and it is easy to produce pipe difference and poor. We should check the pipe difference frequently to find out whether the nozzle is blocked.

6. Air-flow dyeing machine is not easy to wash the tank, it is best to produce the same color series, you should pay attention to staining when changing the cylinder and color.

7. The amount of post-treatment plus softening is not easy to be too large, and it is easy to cause soft spots. It is best to add softening in the softening machine instead of softening in the air flow machine.