With the trial on 1kg sample machine ALLFIT-1 and 2,000kg bulk production machine ECO-38, it shows that ALLFIT-1 is an optimal solution to get accurate recipe and process for the bulk production, and the cost of color correction of the first batch on the bulk machine can be reduced significantly.

Key words: piece dyeing; first batch; color reproducibility; color correction; costs

1. Foreword

Before the launch of ALLFIT-1 small batch dyeing machine, dyehouses can hardly apply the same recipe and process for both small sample batch and bulk production. The variances always exist between dosing time, dosing curve, heating/cooling rate, holding temperature curve, liquor ratio, rinsing mode and system error in production etc, which results in color difference between sample batch and bulk production. The difference between sample and bulk production recipes requires adjustment (or modification) by skillful workers according to factors like: customer order (e.g. color quality requirement and test method), main kier capability (e.g. heating rate and controlling temperature range), dyestuff compounding (distinguish main dyestuff and hypo-dyestuff), dyestuff exhaustion character, sensitivity condition of individual dyestuff, liquor ratio, water quality, after-treatment condition and auxiliaries, etc. Therefore, the first batch dyeing is a hard nut to crack at all the dyehouses nowadays.

Usually after the sample batch dyeing is finished in lab, dyeing technicians should adjust the sample dyeing recipe for bulk production according to their experience and expertise, which is rarely successful by one shot and thus increases costs  incurred in color correction for the first batch on the bulk machine. 

The Fong's innovative product, ALLFIT-1 Small Batch Fabric Dyeing Machine, can prepare sample fabric as little as 1 kg, which helps to get accurate recipe for bulk production from lab trial recipe and save production cost significantly by avoiding unnecessary color correction.

2. ALLFIT-1 Features

Main kier, indirect heating/cooling exchanger, fresh water measuring cylinder, service tank, dosing control, FC-28 computerized controller, nozzle, lifter reel, roller

2.1  Indirect heating/cooling exchanger
 Highly efficient exchanger
2.2  Fresh water measuring cylinder
Preparing fresh water for next step
2.3  Service tank
 Adding dyestuff and auxiliaries
2.4  Dosing control
 Dosing control of dyestuff and auxiliaries
2.5  FC-28 program controller
Providing a user-friendly human-machine interface, and a platform of dyeing automation process. FC28 is able to execute the whole dyeing process automatically according to batch parameters setting and corresponding dyeing program to record actual time, temperature and dosing etc.
2.6  Nozzle
 Special design
2.7  Lifter reel
 Special design that is made of stainless steel
2.8  Roller
 Special design to adjust fabric movement in the machine

3. Trial dyeing on ALLFIT-1 and ECO-38

3.1. Trail method
 ALLFIT-1: After scouring and bleaching in bulk production dyeing machine, dry the sample fabric for dyeing. (*,5% loss of fabric weight in scouring and bleaching process should be counted out)
ECO-38: Weigh the gray fabric, and go through the process of scouring, bleaching rinsing, neutralizing and deoxygenizing. If all the figures are within the controllable range, go on for dyeing.  >> Click to learn more  Download