Practical Textile Dyeing needs consistency in its process for getting accurate results. So the sop of dyeing or standard operating procedure for the dyeing process is so important in the textile industry. Dyeing is a repeating procedure. We need to do the same work several times a day. This is the full dyeing operating process (sop) from knitted gray fabric to finish fabric.
Tried and tested SOPs for dyeing to ensure consistent color quality, minimize defects, reduce rework, and enhance productivity. These SOPs also help in maintaining a safe working environment and are essential for achieving regulatory compliance. In this article, we will discuss the tried and tested SOPs for the dyeing process, which can be implemented in any dyeing unit for achieving consistent results.
The dyeing process sop depends on the type of fabric. That means is it knitted fabric or oven fabric? This is the SOP of the complete knit dyeing process.
SOP Of the dyeing process:
The Batch section receives fabric from the grey fabric store.
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Prepare the batch according to the dyeing machine capacity, color, lot, etc & provide a batch number for further follow-ups up to finishing.
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Batching QC team cross-checks the batching procedure & ensures the batching whether it is done properly or not. They check the quality & quantity of the batch before sending it to the next process.
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Batched fabric is sent for singeing for removing the hairiness of the fabric. Heat setting is done at 190-200 °C temperature.
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The dyeing section receives the fabric & starts the pretreatment process i.e demineralization, scouring, and bleaching for removing the impurities of the fabric at a certain temperature.
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The dyeing machine operator operates the machine & completes the process of dying by dosing dyes & chemicals as per instruction. Dyeing online QA concern randomly checks the parameters of dyeing.
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Unload the batch after treatment
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Complete the whole finishing process with one roll (first roll). If the pass follows the parameter for the whole batch. If not ok then reprocess that roll to correction
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After dyeing, Finishing Section receives the fabric, fabric is opened by a slitting machine following the needle mark.
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Fabric is dried at the center/dryer machine to adjust the dia & GSM of the fabric by giving specific pressure, temperature & overfeed at a specific speed. Softener is added for giving the fabric a smooth hand feel.
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For fleece fabric, the fabric is sent to the brush & peach finish machine. This process is to be done as per buyer requirements.
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For readjustment of dia & GSM after the peach, brush process the fabric is sent to stenter machine as per work instructions.
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Finally, the fabric is finished in the compacting machine by controlling dia & GSM.
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The online quality controller checks all types of process parameters & quality of the fabric during the production process.
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The offline quality controller inspects the finished fabric with 4 point inspection system & checks the Dia and GSM of the fabric. GPQ team gives a decision for offline inspected fabric on the basis of lab test report as per work instruction.
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QC team arranges physical tests (Shrinkage, Spirality, Bursting, Rubbing, Pilling, etc.) and chemical tests (colorfastness, phenolic yellowing, PH, etc.) through the lab & GPQ team to assess the QC & Lab report.
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Pass fabrics are sent to the finished fabric store with a QC pass sticker. The temporarily rejected fabrics are sent for reprocessing & the rejected fabrics are sent to the permanent reject zone.
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End
Why do we need to follow SOP for the dyeing process?
Following Standard Operating Procedures (SOP) is critical in the dyeing process for several reasons. First and foremost, SOP ensures that the dyeing process is consistent and repeatable, which is essential for maintaining the quality of the final product. It also helps to minimize errors and inconsistencies that could lead to defects or customer complaints. Additionally, SOP provides clear guidelines for employees to follow, reducing the likelihood of accidents or injuries in the workplace. Moreover, it enables the efficient use of resources, such as water and energy, which can help to reduce costs and minimize environmental impact. By adhering to established procedures, dyeing operations can be carried out in a safe, efficient, and effective manner, ultimately leading to better products and increased customer satisfaction.
Conclusion
In conclusion, Tried and tested Standard Operating Procedures (SOPs) play a crucial role in the dyeing process of textiles. They provide a set of guidelines and instructions that help to ensure consistency and quality in the final product. By following SOPs, dyeing mills can improve their efficiency, reduce waste, and minimize the risk of errors or accidents. It is essential to regularly review and update these procedures to incorporate new technologies, safety regulations, and industry best practices. Adherence to SOPs is vital for the successful implementation of a dyeing process and can contribute to the overall success of a textile manufacturing operation.
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