Pad Batch en

CONTINUOUS PROCESSES,
COLD PAD-BATCH DYEING

PROCESS
AND TAILING PROBLEM
Murat SAHINLI
2005
HUNTSMAN TEXTILE EFFECTS

Boya Vernik Organize Sanayi Bölgesi Doğu Caddesi No:8 TUZLA-ISTANBUL
Tel: (+90 212) 585 30 00 Fax: (+90 212) 585 30 01
Mobile: +90 533 391 77 79

E-mail:murat.sahinli@huntsman.com
TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 1

ABSTRACT
Dyeing cellulose takes great place in textile sector today. Dyeing

cellulose is about %55 in textile sector in the world. The world textile consist of
cellulose dyeing which is more than %50
There are various processes in cellulose in cellulose dyeing. The rates of
applying of this process in the world textile sector are following:
Exhaust: %53, %13 Hot Dyeing 80 °C

%40 Cold Dyeing 60 °C
Pad-Batch: %15
Pad-Dry-Pad-Steam: %8
Other Continue: %3
1-Phase Printing: %15
2-Phase Printing: %6
The most important dyeing process of Europe textile sector about

continue dyeing process is the Pad-Batch. Due to the most common process is
Pad-Batch. The using rate of continue process in Europe are below:
Pad-Batch: %79
Steam Process: %17
Other Continue: %4

The dyeing of Pad-Batch is nearly %39 in continue process in USA, %21
in the Asia.
The rate of Pad-Batch among the continue process is %46 in the world,
the rate of steam process is %46 and other continue process is %8. However
these rates are different in Europe.
We can see the importance of Pad-Batch process in the continue dyeing
from the numbers. With the thought of the importance of Pad-Batch’ I have
searched many problems. The turning point of this study about continues dyeing
is the tailing problem.
The study of project has realized especially in the Ciba Company I’m
working for and Gerede Textile in Gerede/Bolu applying Pad-Batch Dyeing
process.
Short time of later beginning dyeing, the colour difference exists between
the first a hundred meters and the following length of fabric, which is called
Tailing problem. There are several factors are evaluated below:
Adjusting Machines
Process Values
Used Materials
Environment Factor,
Human Factor
During project study, I got some results of tests and experiments, the
factors causing Tailing problem are evaluated.

ACKNOWLEDGEMENT
There is no way to fully acknowledge my depth to the many people

contributing to this dissertation.
I am grateful to Ciba Special Chemicals Co. I am working for to enable

me to work and carry out my studies.
I would like to thank all managers and assistants in Gerede Textile Co.
for their help and support for this research project. I especially would like to
thank to General Manager Verdal HOSTA and Manufacture Manager İrfan
AKKUŞ for their acknowledge and supports.
Finally, I would like to thank all my friends for their support and
encouragement during this dissertation. I apologize for all the time I spent on it
that I could have spent with them.

DEDICATION
DEDICATION
To Ciba
and
The all GEREDE TEXTILE stuff.

CONTENTS
Page
Abstract............................................................................................................2
Acknowledgment..............................................................................................4
Dedication.........................................................................................................5
Contents............................................................................................................6
List of Figures..................................................................................................8
List of Graphs...................................................................................................9
Glossary Of Terms.........................................................................................10
Background.................................................…................................................11
Chapter1: Introduction...................................................................................12
1.1 Definition Of Problem.................................................................................12
1.2 The Utility of This Project..........................................................................13
1.3 The Methodology of The Solving Of Problem............................................13
Chapter 2: Literature Review........................................................................16

2.1 Techniques Of Continue Dyeing..................................….........................16
2.1.1 Pad-Dry-Pad-Steam Process.....................................................................16
2.1.2 Pad (Pad) Steam Process..........................................................................17
2.1.3 Pad-Dry-Steam Process............................................................................18
2.1.4 Pad-Dry E-Control Process.........................................…..........................19
2.1.5 Pad-Batch Process....................................................................................21
2.1.5.1 The Most Important Factors Of Pad Batch Dyeing Process...................25
2.2 Laboratory Clour Studies.........................................................................33
2.3 Dyeing Kitchen and Dyeing Preparations Operations............................36

2.4 Operation of Pre-Treatment.....................................................................38
2.4.1 Operation Of Singeing.…………………..................................................38
2.4.2 Operation Of Bleaching............................................................................40
2.4.2.1 The Control Of Surface of Bleached Fabric...........................................47
2.4.3 Operation Of Mercerize............................................................................50
2.5 Finishing Operations.................................................................................51
2.5.1 The Washing Operations Of Dyed Fabrics................................................51
2.5.2 Drying Operations....................................................................................54
Chapter 3: The Evaluation of Colour Measurement of Tailing………….55
Chapter 4: Suggestions……………………………………………………… 57
REFERANCE………………………………………………………………….5
9
BIBLIOGRAPHY………………………………………………………......…6
0

LIST OF FIGURES Page
Figure 1
Factors To Be Evaluated Solving Problem 15
Figure 2
Pad-Dry-Pad-Steam Process 16
Figure 3
Pad-Steam Process 17
Figure 4
Pad-Dry-Steam Process 18
Figure 5
E-Control Process 19
Figure 6
The Amount Of Using Chemicals In Continue Process 20
Figure 7
The Cooperation Of Cost Of Dyeing In Continue Process 20
Figure 8
Cold Pad-Batch Process 21
Figure 9
The Examples Of Pad-Batch Dyeing 21
Figure 10a
Pressure Paders 21
Figure 10b
Finishing Padders 22
Figure 11a
The Dyeing Padders 22
Figure 11b
Dyeing Trough 22
Figure 12
Trough Samples 23
Figure 13
The Criteria’s Of Pad-Batch Dyeing Process 24
Figure 14
Cooling Padders Of Pad-Batch Entrance 27
Figure 15
Ventilator Of Cooling Fabric 28
Figure 16
Trough Cooling System 30
Figure 17
The Sprinkles Of Dyeing Trough 32
Figure 18
The Sample Of Dye Hydrolyze 34
Figure 19
Dyeing and Alkaline Tanks 39
Figure 20
Singeing and Enzyme Machine 39
Figure 21
The Unit OF Rotation 39
Figure 22
The Sample Of Bleaching Machine 41
Figure 23
The Samples Of Squeezing Padders 44
Figure 24
The Control Of Fabric Surface 47
Figure 26
Washing Of Samples 52
Figure 27
Washing Liquid Samples 53
Figure 26
The Sample Of Open-end Stander Machine 54

LIST OF GRAPHS
Page
Graph 1 Humidity Of Fabric Prepared Dyeing 25
Graph 2 The Temperature Of Fabric Before Cooling Padders 26
Graph 3 The Temperature Of Fabric Before Trough Entrance 27
Graph 4 The Temperature Of Fabric Trough Exist 28
Graph 5 The Temperature Of Fabric Afterward Waiting,
Before Washing 29
Graph 6 The Temperature Of Dye Trough 31
Graph 7 The Measurement Of Dye Trough 32
Graph 8 The Values Of Control Of Bleaching Chemical Pumps 43
Graph 9 The Pressure Values Of Padders 45
Graph 10 The Pressure Values Of Padders Mercerize First 46
Entrance
Graph 11 The Pressure Values Of Padders Bleaching First 46
Entrance
Graph 12 ∆L* Values During Dyeing Process 56
Graph 13 ∆E* Values During Dyeing Process 56

GLOSSARY OF TERMS
Dipsat It is chemical troughs used before steaming unit in

continues bleaching machine.
Dispenser It is an apparatus of automatic dye and chemical dozing
used for laboratory colour studies.
E-Control Process It is the name of continuous dyeing process developed
and carried out by Monforst.
Hydrofilte It is the power of fabric absorption.
Hydrolyze, The operation of excessive dye amount after fixation is
Hydrolyzed called hydrolyzes; this excessive dye is called
hydrolyzed.
Dye Combination The total dye used for obtain colour.
Migration It is the colour waving on the surface of fabric. It is
especially on of the problems often faced to in fabric.
Neutralization The operation made for acidic or basic bath PH 7
The Dye Penetration The operation made for the absorption of dye on surface
and in fibers.
The Tension Of The tightness of winding fabric during winding.
Winding Fabric
Dye Stability It is the appropriateness of dye. It is the appropriateness
of dye in combination or in its own structure.
Sanforization It is a kind of finishing operation to correct the rate of
fabric shrunk and supply regular surface of fabric.

Background:
As known, there are several process and methods in fabric dyeing. There
are several machines and dyeing process resulting from bath the features of
fabric and the aim of using fabric.
The aim of manager is to supply right, rapid, qualified manufacturing so
satisfaction of customer and obtain high quality standards in fabric dyeing. The
highest target is to carry out right manufacturing at first step. In addition to do
it, technological improvement and world necessities lads us to make searches.
We have to take care of required precautions by adjusting improvement,
improving ourselves and following technological improvement.
In textile sector semi fabric dyeing recently taken great importance. In
Europe and Turkey, taken the most important process of semi continue dyeing
is Pad-Batch.
Textile sector faces frequently problems such as other sectors. One of the
most common problems in textile sector is tailing problem.

Chapter 1: INTRODUCTION
1.1 Definition Of Problem:
Tailing problem is frequently faced. Due to Pad-Batch dyeing process is
commonly used; I prefer to search this process Pad-Batch machine and process
conditions, human factor, materials used (Fabric, dye, chemical, water, etc.)
cause problem. When we list the factors causing problem in Cold Pad Batch
Dyeing Process.
The points To Be Cared In Cold Pad Batch Dyeing Process:
Appropriate Fabric Humidity

The Temperature Of Trough Entrance Before Dyeing
The Tensions Of Machine Entrance
The Consistence Of Pre-Treatment
The Feature Of Tube Of Fabric
Pressure Of Trough Squeezing
The Control Of Width In Squeezing
The Time Of Diving Of Fabric Into Trough
The Penetration Of Dyeing On Fabric
The Temperature In Padders
Speed Of Machine
Capacity Of Winding
The Temperature Of Trough Bath
The Cleaning Of Dyeing Trough
The Temperature Of Dye Feed
The Temperature Of Cooling Water
The Temperature Of Winding
The Temperature Of Winding

The Time Of Fabric Rotation After Dyeing
The Temperature Of Management Water
The Capacity Of Roll Of Fabric In Rollers
The smooth Of Seams On Fabric
Used Alkaline
Consistence Of Dye and Recipe
The Right Combination
1.2 Utility Of This Project:
There are several processes that have originated from both the machines
and the materials used.
After the machine starts to produce, a colour difference exists between
the first nearly 100 meters and the following length of fabric. At the same time,
there is a fabric fixation problem owing to that process has been perfectly
applied. The reason of this problem is not understood. Many experiments, tests,
researches have been made by considering the caused effecting this problem
however the main origin of problem has been not found.
That the machine is new and does not have established processes are as
disadvantages. The furthermore, producing rapidly, being less harmful for
environment, ecological and economic dyeing and acceptable quality are some
of the innovations this machine provides.

Tailing problem increases our product cost and other losses. If give
examples,
Time Loss
Energy Loss
Row Material Loss (Fabric, Dyestuff, Alkaline, Water, etc.)
Customer Loss
Stuff Loss
Quality Loss
Competition Loss
Performance Loss
In order to increase manufacturing quality, we must consider our losses

as company and follow improvement in textile sector. I believe this study help
customer and manufacturers relevant to this issue.
1.3 The Methodology Of Solving Of Problem
By considering all possibilities causing problem, we must evaluate the

problem.
In figure 1 below, the factors to be cared are indicated;

MACHINE RELATED HUMAN RELATED
S
•Machine Adjustment
•Machine Condition
Training (Skills) O
Motivation
•Machine Settings Supervision L
-Machine Speed -The Pressure Of Padders Unsystematic Working Time
-The Temperature Of Trough -The Tantion Of Fabric Unacceptable Salary V
-The Temperature Of Rolls -Dye Stuff and Alkaline
-The Temperature Of Winding Adjustment I
and The Tancion of Winding -The Cleaning Of Dyeing Trough
N
G
PROCESS RELATED MATERIAL RELAITED ENVIRONMENT
Wrong Dyeing Method •Uncontrolled Dyestuff and Chemical •Wrong Humudity P
Using Of Wrong Process with •Unappropriate Fabric •Wrong Temperature
Dystuff and Chemical -Unappropriate Fabric Temperature R
Untried process -Unappropriate Hydrofilite,PH,Perokside
Unappropriate Material O
-The Temperature Of Manufacturing
-The Temperature Of Cooling System
B
-The Temperature Of Dye Liquid L
-Unappropriate Of Dye Combination
-Unappropriate Of Chemicals E
-Wrong Recipe
M
Figure 1: The Methodology Of The Solving Of Problem

Chapter 2: LİTERATURE REVIEW
2.1 Techniques Of Continue Dyeing
Generally continue dyeing process can be started as three main topics.
1-PAD-BAKE 2-PAD-STEAM 3-PAD-BATCH
These three continue dyeing process is applied in various types.
2.1.1 Pad-Dry-Pad-Steam Process

Pad-Dry-Pad-Steam Process in continuous dyeing process is the standard
process in steam dyeing. It is generally suggested for long meters of fabric. It is
suitable for fabric more then 500 meters it has a good stability of bath.
Additionally, it is appropriate for bright colour. It has more control parameters.
It is necessary to obtain suitable condition. Pad-Dry-Pad-Steam process is
unproductive for short time lots.
I.R.
pre-dry hot flue dry chemical steam wash-off
pad
pad
Figure 2: Pad-Dry-Pad-Steam Process (Search: Kuesters)

2.1.2 Pad- (Pad)-Steam Process
Cotton weaved fabric is generally dyed by continue process. The criteria

defining which of Pad-Steam or Pad-Jig is prepared, is the feature of fabric such
as the length type.
Long meters heavy mercerize weaved fabric is dyed by the method of
Pad-Steam with distance drying.
Short meters fabric is dyed by the method of Pad-Jig, however the cost
must be cared. Knitting fabric is not dyed by this method.
Dyeing by Pad-Jig methods without any instance drying supplies much
more penetration and suitable. In bath of methods mentioned is prepared
according to the position and feature of machines, but it is not suggested.
Pad-Steam process has more advantages to supply high production due to
it is an easy process. It requires less investment and energy than Pad-Dry-Pad
Steam. It has no possibility of migration. It includes fewer chemicals. It is the
continue dyeing process used in big amount of fabric and viscose fabric. It
includes tailing problem and it has limit to dye choose.
I.R.
pad
pad
Figure 3: Pad -(Pad)- Steam Process (Search: Kuesters)

2.1.3 Pad-Dry-Steam Process
Firstly, right prep operations must be done to realize good dyeing.

In Pad-Dry Steam Process, the satiation of colour is high. The
possibility of colour difference and tailing is low. It does not include salt. It is
more advantages than Pad-Dry-Pad-Steam process.
If fewer chemicals are wanted to be used and migration problem is
faced, this process is prepared. It has the risk of dropping water. The adjustment
of machine is too difficult because steaming and hot drying is close.
I.R.
pad
pad
Figure 4: Pad-Dry Steam Process (Search: Kuesters)

2.1.4 Pad-Dry (E-Control) Process
I.R.
pre-dry hot flue dry wash-off
pad
Figure 5: E-Control Process (Search: Kuesters)
E-Control process is improved by the cooperation of Monforts Company.

It is economical and with using of chemicals. It is rapid and new process
realizing immediately washing after dyeing.
In this process steaming does not exist. With the %25 humidity, at the
110-130 ºC cellulose dyeing at the 210 ºC polyester dyeing is done. It is a
suitable process for people wanting to pass entirely continues from cold Pad-
Batch.
E-Control process is short and includes cost. It is usable with hot air
drying and fixation continue dyeing process it includes less procedures and uses
less chemicals so it has advantages. Its feature of reputability is great. Tailing
problem is again encountered in E-Control process like the other process.

THE COMPERATION OD DIFFIRENT
PROCESS
Chemical Consumbtion/10 billoin meter
520
Paton
d
Dry 308 ton
Chemical Pad 154 ton

Pad
Dry
Steam Pad
Bake
14 ton
Batch
ECONTROL
Figure 6: The Amount Of Using Chemicals of Different Process(Search: Monforts)
Alternatively Process
Relative Costs
Chemical
(Search: Monforts)

Figure 7: The Amount Of Using Chemicals In Continuo Process
2.1. Cold-Pad-Batch Process
Figure 8: Cold Pad Batch Process (Search: Kuesters)
Figure 9: The Samples Of Pad-Batch Dyeing Machines (Search: Monforts)
Cold Pad Batch process is easy and practice process. With good trough
and machine order, it carries out rapid dyeing operation. As we understand from
its name, depending on type of dye we wait for dyeing fixation nearly 4-24

hours. It is advantages for concerning chemicals and using dye. It requires less
energy. Control of machine is easier than steam dyeing. The adjustment of
machines in Cold-Pad-Batch dyeing is easy, it does not like much time to start
dyeing.
There are many factors to be controlled in Cold-Pad-Batch dyeing. In
order to realize qualified dyeing, the all controls must be done well. When we
through this process with detail; the whole Cold-Pad-Batch dyeing systems
looks like each other. There are three pressures padders in continue process.
1-The Pressure Padders 2-Finishing Padders
(Search: Kuesters)
Figure 10a: Pressure Padders Figure 10b: Finishing Padders

3-Dyeing Padders
(Search: Kuesters) (Search: Monforts)

Figure 11a: The Dyeing Padders Figure 11b: Dyeing Trough
Basically there are 3 samples for Dyeing Troughs;
1 2 3
Figure 12: Trough Samples (Search: Kuesters)
In through example 1 and example 3, because the time of fabric diving is

long, the fabric becomes wet. The way of diving is a distance from the first
point of fabric touching bath to squeezing padders. Depending on the

hydrofility of fabric, the time of diving at each 2-4 is to be considered. Since
renewal of bath at more volume through takes much time, risk of tailing
problem occurs. The passing speed changes 25-60 minutes depending on the
volume, weight and hydrofility of fabric.
The mixing of fresh dye bath coming from the tank of prep dye and the
bath flowing from padders is easier in 1 and 3 through examples. Because of
this fact, these two dye bath are mixed with the help of pomp in through in
some systems. The fabric having such as velvet, knitting and towel is dyed by
the method of through diving without exception.
When we look through the criteria’s in Cold-Pad-Batch dyeing Process;
6a 7a 1 4 8 6c 5 3 2 7b 6b 6d
Figure 13: The Criteria’s Of Pad-Batch Dyeing Process (Search: Kuesters)

1-The Humudity Of Fabric 6a- Cooling Of Fabric
2-The Mixing Of Dye Liquid 6b- Cooling Of Dye Liquid
3-The Colour Measurement Of 6c- Cooling Of Dye Tanks
Dye Liquid 6d- Cooloing Of Dye Trough
4-Fast and Good Cleaning System 7a+b-The Capacity Of Winding
5-Colour Kitchen 7a- The Tantion Of Entrence
6-The Cooling System: 7b- The Tantion Of Ending
(On the fabric, in dye 8- The Control Of Pressures
trough,etc.)
2.1.5.1 The Most Important Factors Of Cold Pad Batch Dyeing
Suitable Fabric Humidity
The temperature and humidity of fabric taken dyeing is important. The
preparation, drying operation has to be done and particular temperature value
and humidity must be included. The standard humidity of cellulose type fibers
is %7 and the temperature of fabric 25 ºC. Namely, before dyeing the humidity
of % 100 cotton fabric is %7, the temperature 25 ºC. According to the results of
test in company, the value of humidity %100 cotton fabrics ready for dyeing is
below.
HUMUDITY OF FABRIC PREPERED DYEING
AVARAGE.
9
5,687
% FABRIC HUMUDITY
8
7
6
5
4
3
2
1
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
NUMBER OF MEASUREMENT
Graph 1: Humidity Of Fabric Prepared Dyeing

The Temperature Of Fabric Before Cooling Padders
Before dyeing, the temperature of fabric must be in standard temperature.
Because, the temperature resulted from fabric will increase the temperature of
dye solution, before and after dyeing the temperature will increase and this will
tailing problem.
When we look over the values realized in company; as indicated in graph
2, the average temperature is 26,481 ºC. This value is close to desired average
value 20-25 ºC. But it is compulsory to supply 20-25 ºC. Cooling padders
supply fabric cooling and combination before dyeing.
THE TEMPERATURES OF FABRIC BEFORE COOLING
PADDERS AVARAGE
26,481
35
30
TEMPERATURES
25
FABRIC
20
R
15
10
5
0
11
13
15
17
19
21
23
25
27
29
31
33
35
37
1
3
5
7
9
Graph2: The Temperatures Of Fabric Before Cooling Padders

The Temperature Of Fabric Before Trough Entrance
According to the results, the temperature of fabric declines after cooling
padders.
THE TEMPERATURES OF FABRIC BEFORE TROUGH ENTRANCE

AVARAGE
23.00 19,629 'C
22.00
TEMPERATURES ('C)
21.00
THE FABRIC
20.00
19.00
18.00
17.00
16.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
NUMBER OF MEASUREMENTS
Graph 3: The Temperatures Of Fabric Before Trough Entrance
Figure 14: Cooling Padders Of Pad-Batch Entrance

In the increase of temperature in summers, cooling ventilators can be
used to cool and prevent flies putting on fabric so it prevents stain. (See
figure15)
Figure 15: Ventilator Of Cooling
The Temperature Of Fabric At The End Of Trough After Dyeing

One of the important temperatures of fabric is the temperature of fabric at
end of trough. The changing of temperature caused by bath dye solution and the
temperature of manufacture water affects fabric temperature. The value
temperature from dyeing is below:
THE TEMPERATURES OF FABRIC TROUGH EXIST
AVARAGE
29.00 27,184 'C

FABRIC TEMPERATURES ('C)
28.50
28.00
27.50
27.00
26.50
26.00
25.50
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
NUMBER OF MEASUREMENTS
Graph 4: The Temperatures Of Fabric Trough Exist

The Temperature Of Fabric At The Entrance Of Washing After Waiting
(Rotation)
The all factors likely to affect colour after and before dyeing have to be
cared and necessary precations must be taken. As it is known, in the Pad-Batch
Process winded fabric rollers after dyed must be waited in the conditions of
manufacture. (4-24 hours, depending on kind of fabric and dyestuff) This
waiting temperature is vital since our waiting conditions normal atmosphere
conditions; it differs depending on winter and summer over country and region.
In winter, manufacture temperature 0 ºC; in summer it is 35 ºC. So it is
inevitable to be different colours. Therefore, this problem resulted from
changing must be not neglected. In some companies, dyed part is conditioned
by condition equipment so the same humidity and temperature are supplied.
In the result of expereriments made in April, when the average
manufacture temperature is 15-16 ºC, the measurement of temperature of fabric
is;
THE TEMPERATURES OF FABRIC AFTERWORD WAITING,BEFORE
WASHING AVARAGE
25.00
19,028 'C
20.00
TEMPERATURES('C)
15.00
FABRIC
10.00
5.00
0.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Graph 5: The Temperatures Of Fabric Afterward Waiting, Before Washing

The Measurement Of Temperature in Dyeing Trough:
Since the excessive and insufficient temperature resulted from fabric bath
manufacture water and cooling water and cooling water influence dyeing
through, the temperature in dyeing through is suitable to be fix and 20-25 ºC. In
summer at the 35-40 ºC, the temperature of dyeing through will be excess. At
the same time, the temperature coming from manufacture water and fabric will
change. Since this kind of the excess of temperature exist. It is right to cool
dyeing through by cooling systems and it enables to get good trough
temperature.
Thanks to cooling system likely to supply cold water circulation around
through, the bath temperature is supplied not to be over 25 ºC. 25 ºC is desired
value. According to the experiments, the measurement of Pad-Batch dyeing
trough bath temperatures is below;
As it is seen in graph 6, much excessive increase does not occur, the
temperature after the beginning of dyeing gradually increases. The dye started
with the temperature 21.5 ºC results 25.5ºC. The values do not cause great
changes by the effect of bath cooling padders and the cooling system in the
trough bath.
The Cooling
System Dye
Trough
Figure 16: The Cooling System Dye Trough (Search: Gerede Textile)

THE TEMPERATURE OF DYE TROUGH
26.00
TEMPERATURE ('C)
25.00
24.00
23.00
22.00
21.00
20.00
19.00
1 2 3 4 5 6 7 8 9 10
Graph 6: The Temperature Of Dye Trough (The measurements are made

during period from beginning dyeing to end of dyeing)
The Measurement Of PH at the Trough Bath
From the period of the beginning of dyeing to the end, PH in dyeing

bath must be fix and desired value. If we realize dye by different PH bath, the
effect of dye on fabric will be different, that is tailing problem will occur.
Therefore, PH in trough has to be checked periodically. In the pipeline, between
pomp and dyeing trough time to time there is water and the remains inherited
previous dyeing. So the dye solution at the beginning of dyeing and dye
solution at the end of renew and changed dyed are different. Due to it, some
manufacturer empty fist dye bath and take new dye into trough. In some
manufactures, this operation is carried out automatically. First bath is fulled up
by flowing and the setting free pipe is leaved open 1-2 minutes. When we think
about the renewal of the bath per 2 minutes, first bath is sent to setting free and

this bath enables to clean water and dye remain from pipe and trough before
dye.
In addition the PH of bath of manufacture water and water used in
laboratory must be 6,5-7.
THE PH OF DYE TROUGH
13,65
13,60
13,55
13,50
PH
13,45
13,40
13,35
13,30
1 2 3 4 5 6 7 8 9 10
THE MEASUREMENT OF PH
Graph
7: The Measurement Of Dye Trough
Dye Sprinklers in Dyeing Trough
There are sprinklers pipes supplying to disperse dye equally on the
surface of trough. (See Fig.17) This sprinklers cause to stopped up so entirely
cleaning cannot be done. Particularly after dark colour dyeing. This leds to mix
dark colour and light colour during dyeing later. Therefore different sprinklers
pipes must be used for light and dark colour and the cleaning of pipes must be
done.
Figure 17: The Sprinkles Of Dyeing Trough (Search: Gerede Textile)
The Pipes
Of
Sprinkles

2.2 The Study Of Laboratory
In the study of laboratory colour is one of the important issue in manufacturing.

Whether this study on laboratory is right reflects manufacture. Therefore, the
study in laboratory must be done well and correctly.
Great investments are recently done in textile sectors. Electronically
apparatus must be prepared. (e.g.) Dispenser dye solution maker,colour
measurement apparatus.
The work conditions in laboratory and manufacture must be
continuously controlled.
When We Look Trough The Necessary Matters Cared In Pad-Batch
Dyeing Laboratory;
Dye Bath Temperature
The temperature of the dye bath to be dyed in laboratory and the temperature of
trough must be supplied to be equal (20-25 ºC desired)
Pick-Up
The rate of pick up in sample of padder and the rate of pick up in manufacture
must be equal or manufacture laboratory colour equality must be supplied.. (The
ideal pick-up is 65-70 %)
The Time Of Diving
The time of fabric diving into dyeing trough and dyeing diving in manufacture
must be same. (2-4 seconds is desired in the time of diving)
The Time Of Waiting
The time of waiting the sample of dyed fabric must be the same with the time
suggested (4-24 hours depending on the kind of dye)

The Temperature Of Waiting
The waiting temperature of sample dye must be equal with the dyed fabric in
manufacture. The sample to be waited has been cared to be winded with nylon.
(Desired waiting temperature is 20- 25 °C)
The Appropriateness Of Used Fabric
The sample fabric used in laboratory and the fabric to be dyed in manufacture
must be cared to be some and the appropriateness (The control of hydrofoils,
PH, Peroxide, Sizing must be done)
The Appropriateness Of Dye Solution
The dye solution prepared for sample dyeing is to be prepared in suitable
temperature (20-25 °C ), the mixture of alkaline must be done before dyeing
operation. The dye solution mixed with alkaline must not certainly waited.
Waited mixture solution is hydrolyzed. (See Fig.18)
1 2 3 4 5 6 7
Figure 18: The Sample Of Hydrolyzed Dye

1: Unwaited Done The Sample Of Dye Solution,
2: The sample Of Dye Solution waiting a min.
3: The sample Of Dye Solution waiting 3 mins.

The Speed Of Passing Fabric

The speed of sample dyeing machine in lab and the machine in manufacture
must be adjustment in appropriate with colour.
Constant and Right Washing
The washing of dyed samples done carefully. Depending on the kind of fabric,
the temperature of drying must be determined and drying must be realized at the
high temperature. 60 °C is suitable temperature for drying. However depending
a kind of fabric, the short time drying. This temperature can up 100 °C.
The Operation Of Drying
Depending on the kind of fabric, the temperature of drying must be determined
and drying must be realized at the high temperature. 60 °C is suitable
temperature for drying. However depending a kind of fabric, the short time
drying. This temperature can up 100 °C.
Right Combination
The dye combination to be used must be noticed to be same with suggested
combination by manufacture; suggested dye combination must be used.
Right Alkaline
The feature of used alkaline must be same with the alkaline used in
manufacture.
The Appropriateness Of Used Water
The temperature of water used for preparation solution must be 20-25 °C. More
ever, while preparing solution, hot water not obviously used.

2.3 Dye Kitchen and The Operations Of Preparing
After the laboratory works, the dye for the fabric to be prepared for
dyeing is prepared in dye kitchen. Prepared recipe is essentially considered; the
recipe is prepared in appropriate with the kind and amount of fabric. The
amount of alkaline changes according to the compares. The main principle
about rate of dye is 4, rate of 1. (800 liters dye, 200 liters alkaline)
The operation of preparing dye must be carefully made. The dye solution
must be at the temperature of 20-25 °C. It is compulsory to solue dye well. The
urea can be used to make easy solution on dark turquoise colours. While
preparing dye solution, mixture must be used for mixing.
The amount of dye must be prepared carefully; the level of water in
trough must be controlled. Moreover, this indicator to be digital and automatic
is beneficial.
Excess or less solution especially in light colours leds colour difference
problem.
Degree of Caustic and silicate Bome as used alkaline must be controlled.
Alkaline must be taken into manufacture by controlling. Caustic used for dyeing
must be 38 °C. Generally 50 °C Caustic is taken to manufacture and this is
declined 38 °C. It must be controlled whether it is at this degree. This degree for
dyeing is suitable. Additionally silicate to be used must be 40 °C. This fact is
beneficial to control.
Dye and alkaline solution are got together at the pomp before dyeing and
this pumps to the pumps to the dyeing trough. After starting to pump, the
dyeing operation must be start, dyeing must be started not be hydrolyzed.

The
Tank Of
Dyestuff
The
Tank Of
Alkaline
Figure 19: The Tanks Of Alkaline and Dyestuff (Search: Gerede Textile)

2.4 Operation Of Pre-Treatment
Pre-treatment of fibers in cellulose type must be done before dyeing. The

Pre-treatment of fabric is vital. Therefore, pre-treatment operations must be
done well and the elements affecting quality must be under control. Pre
treatment operations of fabric in cellulose type essentially look like each other.
2.4.1 Operation Of Singeing
As it has been known, in order to remove the feather on the surface of

fabric and supply the smoothness of fabric, the singeing operation is realized.
By waiting for a while the sizing in cellulose must be ripped open. The sizing is
used for supplying the sewing cotton being good and to weave.
Singeing are used such as starch singeing, PVA (Poly-Vinyl -Alcohol)
and these singeing must be for away by pre treatment operations. Afterwards
singeing operation, fabric passed the bath of singeing ripping open is waited in
time of rotation units. (This time changes according to the chemicals used, but
approximately 10 hours)
Before and after singeing

Enysime Trough
60°C, PH:5,5-6
Wetting (arbitrary)
Row Material The Unit Of Singeing To approve of ion
Remover Enyzme
Destroy to air(arbitrary)
A.Acit(PH settings)
Figure 20: Singeing and Enzyme Machine (Search: Goller)
Figure 21: The Unit Of Rotation (For Singeing)

2.4.2 Operation Of Bleaching
One of the most operations in fabric dyeing is bleaching operations.

Bleaching operations must be done well and correct fully to get regular and
qualified dyeing. Bleaching operations depend on the kind of fabric. Hot
steaming carries out bleaching operations of the fabric in cellulose type.
Bleaching operation is essentially to get while fabric. The fabric ripped open
singeing subjects to bleaching operation to whiten.
There are several factors to be considered during bleaching operations. First
one or two troughs are hot washing trough in bleaching operation. E.g.
Afterwards previous washing the bath is alone via the chemical called dipsat.
(See figure 22). Fabric subjects to operations by chemicals such as caustic,
hydrogen peroxide, to approve of ion, stabilazator making white and opening the
fibers of fabric, increasing the absorption of fabric. Afterwards these chemicals,
fabrics in cellulose type are applied the operation of steaming at 100°C in steam
units. In this unit, depending on kind of fabric, the fabric is waited 10-20
minutes to realize fabric white in some kinds of fabric; the steaming operation
cannot be done.
Steaming units are the units where the bleaching operations are realized
and it is sensitive operation. Therefore waiting units must be continuously
controlled. Because dropping risk originated from steam and waiting causes
trace problem due to fabric waited in high temperature exist.
After steaming operation, washing baths exist. There are 3,4,5 washing
cabins and these cabins are designed in different shape after bleaching washed
fabric must be neutralization well. Because fabric passed from the chemicals
affecting dyeing such as caustic, peroxide, by washing after bleaching and
neutralization, fabric is removed from these chemicals. The PH of last bath in

bleaching must be adjusted as 5,5-6. Otherwise, fabric having caustic and
peroxide remains causes problems during dyeing. In figure 22, we see the
general view of bleaching operation.
2)Dipsat,
Chemical
Reaction 5) Drying
Units
3) Steaming 1 and 2
1) 4)Wash-Of
Washing
Cabin
(1 or 2 )
Figure22: The Sample Of Bleaching Machine (Search: Goller)
Good bleaching operation enables good dyeing. While applying

bleaching operations, the criteria’s to be controlled are;
The Speed Of Machine:
The speed has taken great importance. In some manufactures the speed is
fixed unlike other manufactures. Some manufactures adjust the different speed
according to the type of fabric. Speed must be some from the beginning of fabric
to end; the machine must not be slow or stopped. Since slow operation and
waited fabric surface trace and whiten problem.

The Period Of Waiting Bleaching Steam Unit and The Regularity Of Fabric
The period of waiting in bleaching steam unit must be adjusted carefully.

The period of waiting is calculated by considering the whiteness of fabric and
thee operation of whiten coming true period. 13-15 minutes are sufficient for the
moss waiting in waiting unit in good conditions. The extension of waiting
depends on the type of fabric. According to the type of fabric, the bleaching
operation without pilling up is realized. Waiting trace and broken problem must
be cared. The dropping from steam and the effect of chemicals consisting foam
via high temperature have to be considered. The bolt attached fabric sides and
preventing broken must be chosen well not to make trace on fabric.
The Sleekness Of The Pumping Amounts Of Chemicals Pumped To Dipsat
One of the most important issues in bleaching operation is to pumping

chemicals in regular and equal way. This point must be continuously controlled.
The desired values are essentially registered icon the panel of bleaching machine
and these values are pumped to the dipsat by pumps that is it is pumped by
mixing the bath before the steaming unit. The results of approximate test values
made through 1 year are in graphs below.

THE VALUES OF CONTROL OF BLEACHING CHEMICAL
POMPS
30.00
OUT OFF STANDARDS AS %
20.00
10.00
0.00
15
22
29
36
43
50
57
64
71
78
85
92
99
1
8
-10.00
-20.00
Peroksit THE NUMBER OF MEASUREMENT
Kostik
Stabilizator ve Iyon Tutucu
Islatici
Wetting
Peroxide NaOH Stabilizator
Agent
The
Average Of 0.85 1.82 3.07 4.70
% Excess
Graph 8: The Values Of Control Of Bleaching Chemical Pumps.
The Control Of The Bleaching Washing Water

Washing baths in the end of exit of bleaching must be some times controlled. PH
of last neutralization bath must be especially measured. There are automatic
apparatus of measurement of PH in last neutralization tank in many bleaching
machines. However, this apparatus must be updated and confirmed periodically.

The Control Of Squeezing Padders At The Entrance Of Dipsat
In the bleaching operation, before the steaming unit, chemical bath that is the
squeezing padders at the entrance of dipsat must be regularly controlled. Since it
is done from wet to wet, it is vital.
Since side-middle-side difference likely to be originated from squeezing cannot
happen, squeezing in equal power is required. That’s over trough the surface of
fabric; the pressure must be same level. As seen in figure 23, the pressure
regularity and level of padders must be equal on whole surface.
Figure 23: The Samples Of Pressure Padders (Search: Kuesters)
There are various methods to control of regularity of pressure. Such as

carbon test, powder test, pick-up test.
Carbon Test:
Setting a carbon paper in between paper in which length is up to padder
does carbon test. The paper prepared by setting carbon between paper is set
regularly among the padders and pressure applied in machine gives pressure to
padder, paper afterwards waited 1-2 minutes are taken and then the regularity of

trace of carbon on the surface of paper is checked. The equal level of pressure on
the surface is supplied.
If there is an irregularity of pressure of padder, it is understood from the
trace originated carbon and the caution is taken immediately. By altering the
adjustment of pressure or worn out padder, the padder pressure regularity is
supplied.
Powder Test
It looks like carbon test but powder is spilled among the padders and the
pressure-applied padders are given, the pressure trace powder made on padders
is measured. According to the values, pressure is adjusted or padders are
changed.
Pick-Up Test:
Fabric passing through padders realizes pick-Up test. 3-5 meters fabric likely to
be tested is wetted by passing from wet trough with desired pressure values and
passing padders in deired pressure stops machine. The fabric samples taken from
right-middle-left parts of fabric are balanced immediately by putting nylon bag
balanced before. Afterwards, the samples of fabric are dried till provide. Fixed
balance and the wetting on the surface of fabric is determined via wet-dry rates.
By evaluating the rates obtained the regularity of padders pressure is determined.
THE PRESSURE VALUES OF PRESSURE PADDERS
20
PRESSURE mm
15
10
0
1 2 3 4 5 6 7 8 9 10 11 12 13
THE NUMBER OF MEASUREMENT

Graph 9: The pressure Values Of Pressure Padders
THE PRESSURE VALUES OF PRESSURE PADDERS

MERSERISE FIRST ENTRANCE
25
PRESSUREmm
20
15
10
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
THE NUMBER OF MEASUREMENT
Graph 10: The Pressure Values Of Pressure Padders Mercerize First Entrance
THE PRESSURE VALUES OF BLEACHING DIPSAT

ENTRANCE PADDERS
30
25
Pressure mm
20
15
10
5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
The Number Of Measurement
Graph 11: The Pressure Values Of Pressure Padders Bleaching (Dipsat) First
Entrance

2.4.2.1 The Controls Of The Surface Of Bleaching Fabric
Absorbing Test (Capillarity Test)
Absorption test is the control of absorption power of bleached fabric. It is
done to control the speed of absorption of dye through fabric. The coming to
period to dye desired level is accounted by dispensing in drops on the end of
bleaching dried fabric part port of small fabric parts in particular standards is
dived in dye solution. (See fig.24). This period changes depending on the kind of
fabric but 0-6 seconds are ideal period.
PH : 4.5-5
Figure 24: The Control Of Fabric Surface

The PH Control On Fabric
The fabric whose bleaching operation is completed must have appropriate
PH level. Therefore, PH level on fabric is accounted by the special PH
measurement solution to be dispensed in drops on fabric PH level on fabric is
approximate 5,5-6 ideal. The control must be continuously done and it requires
records.

The Control Of The Existence Of Enzyme
The enzyme of fabric coming to the phase of bleaching operation must be
removed. Bleaching operation is done after enzyme removing and essentially
enzyme removing is realized particularly. The fabric in whom bleaching
operation is done must have no remains of enzyme. The solution used for special
determining enzyme is dispensed in drops on fabric and the color changes are
followed from the statistic. Namely, in starch enzyme control after solution is
dropped on fabric, if the colour is yellow, it is understood that singeing (enzyme)
is removed, if the colour is blue or purple it is the indicator that there is starch
enzyme remain.
Peroxide Control
After the fabric whose bleaching operation is completed is dried, the control
whether there is peroxide. The peroxide scale controls special peroxide control
solution dropped on fabric such as enzyme and PH control.
The Existence Of Iron Control
The existence of control iron on the bleached fabric must be controlled. Iron ion
generated bath machine and fabric. If the iron is seen on fabric, the caution must
be taken immediately. The control of iron existence is done by the solution
dropping on fabric. Dark pink or red colour indicates the iron existence.
The Control Of Whiteness
On of the most important criteria of bleaching operations is the degree or
level of whiteness. Because of bath the changes of waiting period and chemical
pumping amount during bleaching operation the difference of fabric whiteness
occurs. Therefore, the whiteness of fabric after bleaching operation is beneficial
to be measured. Since the whiteness alters according to the kind of fabric,
considering this fact must do the evaluation.

The Control Of Trace Of Pilling Up Of Fabric
One of the vital issues during bleaching operation is trace originated from
waiting. There is high temperature in cabins where steaming is realized and the
fabric piled up by pleating, waiting pilling up trace is encountered. Because of
the chemicals used for steaming, foam occurs. Therefore, the sufficiency of rate
of wetting agent and stabilization must be controlled.
The Irregularly Of Sewing
The irregularly of sewing begins the opening good and goes on till end
off process. Due to irregularity of sewing, many meters of fabric are wasted.
Irregularity of sewing arises the impropriety of the sewing cotton and it causes
trace in each windings. As a result of this, many meters of fabric are wasted. To
prevent this problem the control must be entirely done.
Fractured Fabric Problem
The Fractured fabric problem taken great problem for textile
managements and requires good control. The regular action of fabric without
pleating is provided from pre-operation to final operation. Adjusting machines
and controlling of squeezing tension, using clothespins, solve this problem. The
machine operator must look through fabric during operation.
The Clothespin Problem
The clothespin used for bleaching operation and aimed to prevent
fractured time causes trace. If clothespin used is metal, it is coated and causes
trace on fabric. Therefore, clothespin must be less used and chosen to be good
quality.

Cold Bleaching:
The bleaching operation of Lycra or some special fabrics being sensitive
to the temperature is not done. Since these kinds of fabrics are sensitive to the
temperature and the temperature is harmful to the fabric, low temperature
bleaching operation is applied. Cold Bleaching is done in different ways
depending on the type of fabric.
2.4.3 Operation Of Mercerize
In pre-treatment operations, mercerizing operations is extra operation. It

is realized depending on whether the customer wants. Mercerized operation is
realized to give a bright and regular appearance and increase the durability.
Mercerized operation is based on the operation between low 28 °Be caustic and
fabric. It is done by opening fibers of fabric and distending fibers. The opening
and distending of fibers increase the durability. (In figure 25 below, the samples
of fabric mercerized and unmercerized.
Unmercerized Mercerized
Cotton Cotton
Figure 25: The Sample Of Merserized and Unmerserized Cotton

(Search: Odevim.com)

Basics Of Mercerization
Significantly increases the colour depth

Increase of dimension stability
Increase of tensile strength
Enhances the lustre
Reduction of abrasion tendency
Minimise effects of dead/immature cotton
Reduction of wettability
Common faults in Pre-treatment
Insufficient removal of lubricants, softeners and sizes

Defects during singeing due to non-centred guide rollers;
irregular flame, differences in moisture/humidity
Differences in tension and faulty squeezing device
Change in caustic soda concentration during mercerisation
Inadequate neutralisation after mercerisation
Overdrying of the goods
Poor wetting properties and residues

2.5 Finishing Operations
The fabrics of whom dye operations are completed are subject to different
finishing operations according to the customer demands. Final operations such
as washing, drying, sanforization, are important and an operation wrongly or
improperly applied cause fabric manufacturing in undesired and unacceptable
appearance and quality. So finishing operations must be done carefully in right
processes since washing and drying operations particularly affect the fabric dye
or colour, these operations must be considered.
2.5.1 The Washing Operations Of Dyed Fabrics
The washing operation of dyed fabric is vital. The washing machines
features are same. First are and second bath entirely with opened valve. Bath is
continuously fresher. Main continues washing machines have 6-7 or 8 cabins.
Temperatures are generally the same in reactive washings. When we give on
example of reactive washing
PH= 5-5.5 With

A. Acid
Opened Valve Closed Valve

Channel
EJANJOR (Reearn of temperature)
Figure 26: Washing off Samples

1. 2. 3. 4. 5. 6.
BATH BATH BATH BATH BATH BATH
Figure 27: Washing Liquid Samples

The colour of bath water is washing bath is important. Good washing and
the removing the hydrolyzed are necessary while dark colours are dyed, last
bath colour in washing machines must be controlled. Figure above a sample of
center colour washing solution is seen.
As seen, from the fourth bath, the solution is likely to be rinsed. In last
two bath, hybridization must be removed. In figure 27, the samples of solutions
taken from washing baths are indicated.
Additionally, PH of last bath must be adjusted as 5,5-6. Although there is
PH meter in same washing machines, the truth of PH meters must be controlled.

2.5.2 Drying Operations
The drying operation of bath dyed fabric takes great importance. There
are various drying operations. Drying operations are carried out in hot air,
padders with hot steam or various ways. Generally in continuo process open and
hot air blow-drying machines.
Figure 28: The Sample of Open-end Stander Machine (Search: Monforts)
While realizing drying operations, machine stops are done. Machines are
time to time stopped to wind fabric. Rules in entrance and exit of machine or
attach the guide at the end of drying. Dyed fabric is much dried and subject to
temperature during stops. The colours affected temperature such as red has
risks. So as soon as possible, machines must not stopped. On of the important
point in drying machines is the exit of drying. The temperature of the cotton in
the exit of drying is up to 50-60 °C. The fabric at this temperature is winded
without cooling and sometimes fabric is dyed without waiting. This issue is
dangerous for dyeing operation.
Though the cooling padders in dyeing machines decline the temperature
of fabric, the conditions of fabric good conditioned before dyeing are better
suitable. So the existence of cooling padders in exit of drying is advantages.

Chapter 3.0 THE EVALUATIONS OF COLOUR
MEASUREMENT TAILING
The example of colour evaluation belonging to the dyed parties with pad-
batch dyeing operation in Gerede Textile Company is below:
As seen in the graphs, after a period of beginning the dyeing
(approximately 100-150 meters) both the value of ∆L* (Lightness) and ∆E*
change. The colour as shade in first 100-150 meters is lighter. Afterwards it is
stable and goes on in that way till the end of dyeing. Last 50 and 100 meters are
darker.
The result of this is: The colour difference occurred in first meters at the
beginning of dyeing are sourced from the factors and criteria’s in Cold Pad
Batch dyeing mentioned. As stated in chapter 2.1.5.1, these variations in Pad
Batch Dyeing process cause the colour difference and this issue lets much harm.
So as seen in the results obtained, the whole factors to be cared must be
under control thus the errors will be declined.

∆L* Values During Dyeing Process
2
1.5
1
0.5
0
11
13
15
17
19
21
23
25
27
29
1
9
-0.5
-1
-1.5
∆L* Measurements Ligtness (Renk Tonu)
Graph 12: ∆L* Values During Dyeing Process
∆ E Values During Dyeing Process

2
1.5
0.5
0
1
11
13
15
17
19
21
23
25
27
29
∆ E Measurements E* Degerleri
Graph 13: ∆E* Values During Dyeing Process

Chapter 4.0 SUGGESTIONS
Pre-treatment operations are so important in all continuo dyeing. The

better pre-treatment of fabric to be dyed is done, the better quality of dyeing you
get. The quality of fabric must be considered in bath pad-batch process and
other continuo dye process.
Before dyeing the all pre-operations first such as bleaching, mercerized,
singeing must be checked and done well in order to realize good pad-batch,
firstly dye manufacturing. It must not be in climate affecting temperature. As
soon as possible, the conditions supplying temperature and humidity of dyeing
being fixed must be considered. The fabric conditioned at fixed temperature
will provide the repeatability of fabric dyeing one of the important points is the
regularity of fabric temperature. The temperature of fabric before dyeing must
not be over 25 °C and as soon as possible the temperature and fabric humidity
must be fixed.
The changes of temperature in fabric will affect cooling systems arte
beneficial to be used. Cooling padders, cooling ventilators, conditions apparatus
etc.)
Since one of the most important factors to be considered in pad batch
dyeing is temperature, the temperature in this process must be fixed. The
temperature in this process must be fixed. The temperature of dye solution,
manufacturing water, fabric, fabric winding and after winding is important and
ideal temperature must be 20-25 °C.

The dye and chemicals used must be cared and suitable dye and
chemicals have to be used. Dye combination must be appropriate with the
combinations. Suggested by dye companies and good dye must be chosen.
Preparing and solving dye must be done carefully. Laboratory studies
must be sensitive, reliable and repeatable. The minor error in laboratory causes
big problems and wrong producing in manufacturing.
The final operations after dyeing are so important. It must not be
forgotten that any chemicals and softer used will affect the colours.
The quality control operations are essentially such minor of
manufacturing. Faults must be determined and statistical data must be obtained.
As a result of statistical data, corrective and preventive actions are realized
according to the rates of fault.
Whole factors in Pad-Batch dyeing are tried to explain in project. Since
every manufacturing especially textile manufacturing encounter various
problems every day. Due to it, the whole factors causing problem must be under
control.

7.0 REFERANCES
1. Ciba Special Chemicals, internal intranet.

2. Mark J. Kiemele, Stephen R. Schmidt and Ronald J. Berdine, Basic
Statistics: Tools for Continuous Improvement, (Colorado Springs, CO:
Air Academy Press, 4th Ed., 1997)
3. Wild, R. (1995), Production and Operations Management, 5th Edition,
cassell, New York
4. Ciba-Geigy, Cibacron C Documentation, Edition 1987
5. Wersch, K.V. (1993), “On-line control in continuous dyeing”, Volume:
74, pp.49
6. Wersch, K.V. (1998), “Economic dyeing of small batches on a
continuous dyeing range”, Volume: 69, pp.431-435
7. Wersch, K.V. (1997), “Processes for dyeing cellulosic fibres with
reactive dyes”, Volume: 1, pp. 1-4
8. CIBA Textile Ltd., (200), “Cibacron Dyes”, Technical Information
Journal, pp. 216-217
9. Wersch, K.V.(2000), “The Continuous Dyeing of Cellulose Fibres using
Reactive Dyestuffs-Aspects of Economy and Ecology”, pp.1-6
10.Wersch, K.V. (1989), “Automation in continuous dyeing by means of
intelligent system”, “International Textile Reports”, Volume: E288-E290,
pp. 677

6.0 BIBLIYOGRAPHY
1. Peter, M., Rouette, H.K., “Grundlagen der Textilveredlung”, 13th Edition,

p.510
2. Smith, D. (2000), The Measurement Nightmare: How the Theory of
Constrains Can Resolve Conflicting Strategies, Policies, and Measures,
St. Lucie Press, US.
3. Buffa, E. S. and Sarin, R. K. (1987), Modern Production/ Operations
Management, 8th ed., John Wiley&Sons Inc.
4. Schön, Donald. The design process. In V Howard (ed). Varieties of
Thinking. New York: Routledge, 1990.
5. Wersch, K.V. (1998), “TAD Textile Journal”, Volume: 2, pp.108-110

6. Wersch, K.V. (1992), “High moisture measuring or colorimetric on-line
metering for the automatic control of padders”, Volume: 1, pp. 1-5
7. www.dystar.com
8. www.monforts.de
9. www.kuesters.com
10.www.goller.de

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CONTINUOUS PROCESSES,

COLD PAD-BATCH DYEING

HUNTSMAN TEXTILE EFFECTS

Mobile: +90 533 391 77 79

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 1

Dyeing cellulose takes great place in textile sector today. Dyeing

Exhaust: %53, %13 Hot Dyeing 80 °C

The most important dyeing process of Europe textile sector about

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 2

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 3

There is no way to fully acknowledge my depth to the many people

I am grateful to Ciba Special Chemicals Co. I am working for to enable

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 4

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 5

Chapter 2: Literature Review........................................................................16

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 6

Chapter 3: The Evaluation of Colour Measurement of Tailing………….55

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 7

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 8

Graph 2 The Temperature Of Fabric Before Cooling Padders 26

Graph 3 The Temperature Of Fabric Before Trough Entrance 27

Graph 4 The Temperature Of Fabric Trough Exist 28

Graph 5 The Temperature Of Fabric Afterward Waiting,

Graph 6 The Temperature Of Dye Trough 31

Graph 7 The Measurement Of Dye Trough 32

Graph 8 The Values Of Control Of Bleaching Chemical Pumps 43

Graph 9 The Pressure Values Of Padders 45

Graph 10 The Pressure Values Of Padders Mercerize First 46

Graph 11 The Pressure Values Of Padders Bleaching First 46

Graph 12 ∆L* Values During Dyeing Process 56

Graph 13 ∆E* Values During Dyeing Process 56

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 9

Dipsat It is chemical troughs used before steaming unit in

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 10

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 11

The points To Be Cared In Cold Pad Batch Dyeing Process:

Appropriate Fabric Humidity

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 12

1.2 Utility Of This Project:

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 13

In order to increase manufacturing quality, we must consider our losses

1.3 The Methodology Of Solving Of Problem

By considering all possibilities causing problem, we must evaluate the

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 14

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 15

2.1.1 Pad-Dry-Pad-Steam Process

Figure 2: Pad-Dry-Pad-Steam Process (Search: Kuesters)

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 16

Cotton weaved fabric is generally dyed by continue process. The criteria

Figure 3: Pad -(Pad)- Steam Process (Search: Kuesters)

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 17

Firstly, right prep operations must be done to realize good dyeing.

Figure 4: Pad-Dry Steam Process (Search: Kuesters)

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 18

Figure 5: E-Control Process (Search: Kuesters)

E-Control process is improved by the cooperation of Monforts Company.

TECHNICAL INFO FOR PAD DYEING Murat ŞAHİNLİ SAYFA 19

Dry 308 ton