| Procedure : |
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1 |
A padding length (-16” X 4”) is cut from fabric under test and weighed.
Call this weight “X”
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2 |
Pad the fabric through test liquor solution and “NIP’ through the rollers. |
3 |
Reweigh the fabric immediately after padding through rollers. Call this weigh “Y”.
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4 |
Repeat the procedure with the same fabric and reweigh immediately after padding through rollers.
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Call this weight “Z” |
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| 1 |
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Wet on Dry-Pick up |
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Wet on dry Pick up = Weight Y-Weight X X 100
Weight X |
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| 2 |
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Wet on Wet-Pick up |
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The following formula is used to calculate Pick-up |
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| (A) |
= |
Weight Y-Weight X X 100
Weight X |
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| (B) |
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Weight Z-Weight X X 100
Weight X |
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Wet on Wet Pick-up = (B – A) + AF
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Where F (interchange factor) = 0.7 |
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| Doses : |
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Target |
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| Fabric |
: |
Cotton |
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| Finocon 10X
(wetting agent & Detergent) |
: |
3 ml/kg |
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| Diquest SNA
(Sequesterant) |
: |
1 ml/kg |
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| Finostab CBR (Stabilizer) |
: |
5 ml/kg |
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| Caustic Soda(Lye 50%) |
: |
40 ml/kg |
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| Hydrogen Peroxide (50%) |
: |
28 ml/kg |
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| Pad Expression:: |
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Differential PU (DPU) = PU2 – PU1 |
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| PU1 PU2 |
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To Calculate feed rates and steady state fabric
add-on |
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For a 2 tank system, without automated feed
Control |
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| Flow rate per tank |
= |
Fab. Wt. (kg/m) X Speed (m/min.) X DPU
2 |
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| Initial Fill |
= |
Target ( g/kg) X DPU X Volume (I) |
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| Tank concentration |
= |
Target (g/kg) X Speed (mt/min) X Fab.wt(kg/m)
Flow rate (1/min) |
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| DOSES EXAMPLE : |
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For a 2 Tank system, without automated flow control.
Equal volume of tanks and good mixing. |
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| PU1 = 60% |
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PU2 = 110% |
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| Impregnator Volume |
= |
6001 ( actual filled volume) |
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| Fab.wt./Im |
= |
200 gms/linear meter (0.2 kg/m) |
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| Range Speed |
= |
60 Mts/min |
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| Target Add-on |
= |
3 g/kg |
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| DPU |
= |
PU2 - PU1
= 50% (0.5) |
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| Flow rate / tank (l/m) |
= |
0.2 X 60 X 0.5 3 l/m
2 |
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| Tank concentration |
= |
3 X 60 X 0.2 = 12 g/l
3 |
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| Initial fill (g) |
= |
3 X 600 = 3600 gl (6 g/l)
0.5 |
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FINEOTEX IN PARTNERSHIP WITH YOU |
TROUBLE SHOOTING CONTINUOUS PREPARATION |
PROBLEMS: ISSUES |
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| Residual Size : |
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Find out the size mixture |
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Increase the dose of Finozyme DX |
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Control the application temp. of desize steps |
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Ensure washers are working well and are hot |
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Increase the dwell / batch time |
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Add Finozyme DX to the tank after it is hot |
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Avoid steaming the enzyme for too long |
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| Pin holes : |
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Increase the dose of demineraliser in the size |
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Lower the demineralisation bath pH to 5.0 with acetic acid |
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Increase the dwell / batch time |
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Incorporate a separate demineralisation step |
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After desize, repeat acidic scour process with demineraliser |
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Use Diquest S in the bleach (1-2 gpl) |
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Use oxalic acid in the demineralisation step |
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| Cotton seed or Bits residue : |
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Check chemical application (Pick – up, dose)
Perhaps more bleach required |
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Increase dwell / batch time and temperature |
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Check for metal contamination |
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Add Diquest S to the bleach liquor |
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Ensure Peroxide bath is stabilized with Finostab SS |
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Poor Absorbency : |
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Check chemical application (Pick – up, dose, etc.)
Perhaps a stronger bleach is required |
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Increase caustic soda |
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Increase the dose of or Finocon LF in the bleach |
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Increase the dose of Finocon WK in Desize |
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Increase the dwell time |
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Increase Nip roller pressure for better washing |
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Adjust range temperatures for more cleaning energy |
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Adjust the water flow rates for maximum exchange |
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Yellow fabric or Damaged & Weak fabric : |
| This is probably due to over – oxidation of the fabric |
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Check Chemical application (PU, dose, etc.) |
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Perhaps less bleach required |
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Check that the dwell – box or steamer are closed (no oxygen ingress) |
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Reduce dwell time and temperature |
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Check for metal contamination |
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Add Diquest S to the bleach liquour |
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Increase the dose of Finostab SS in the liquor |
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Check the fabric before bleach for flaws |
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Carry out a prescour and then reduce the strength of bleach liquor |
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Do a cold pad – batch bleach in place of steaming |
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Avoid hot oxidative desizing |
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Tailing : Changing Whiteness or absorbency overtime : |
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Adjust recipe of feed tanks to initial fill
(Refer to dose – calculations) |
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Ensue feed tank solutions are stable and made fresh |
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Use stabiliser Finostab SS with the bleach liquour solution |
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Side to side variations : |
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This is probably due to either rollers or uneven drying
If after continuous Dyeing Process, it may be due to moisture migration in Dyeing Process |
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Check all application and expression rollers for even pick – up. (This means
Desize, scour and Bleach systems) |
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Check for uneveness of steam application (blocked steam line?) |
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Check for dripping from steamer, that may wash – off bleach liquour |
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Check for even drying during batching |
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Check for steam saturation in the steamer |
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Lines and patches : After Dyeing Process : |
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Check for complete desize before Dyeing Process
Lines may be warp size resist |
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Check for post – bleach contamination from machines or factory (oil spots) |
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Ensure temperature and chemical dose are correct for Desize |
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Ensure desize washing is with fresh water rather than bleach – backflow |
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| Detection of Sizes : Qualitative Analysis |
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Type of
Size |
Detection methods |
Colour
Reaction |
Observations |
| Starch |
2 drops Sol. # 1 |
Blue |
Misleading reaction with Alkaline
Cellulose
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| PVA |
2 drops sol. # 3 |
Brown |
If green, no PVA is present, |
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plus 4 drops Sol. # 4 |
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provided no starch is present |
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After 5 secs. reaction time |
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rub with glass rod. |
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| PVA |
2 drops Sol # 2 |
Purple |
Not together with starch |
| PVAC |
2 drops Sol # 1 |
Red brown |
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Polyacrylates Acrylic Acid
Esters |
Astrazon Red Test
or 5 drops of Sol # 6 |
Red
White Precipitate |
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| PES |
Astrazon Red Test |
Red |
See method below |
| CMC |
5 drops of Sol # 6 |
Green Colloidal Paste |
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Astrazon Red Test : |
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0.5% Astrazon Red F3BL |
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0.5% Acetic Acid (30%) |
Immerse the fabric cutting for 5 min at R.T. with freshly prepared dye
solution. Remove it and lay it on a glass plate for 30 sec. Rinse the
cutting with water for 1 min. A red colouration is formed if PES or
Acrylate size is present. |
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Rapid Test Solutions for size detection |
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1 |
2 |
3 |
4 |
5 |
6 |
| Iodine |
1.3 q |
0.13 q |
- |
- |
- |
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| Potassium Iodide |
2.4 q |
2.6 q |
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- |
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| Boric Acid |
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4 q |
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| Potassium Dichromate |
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11.58 q |
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| Conc. Sulphuric Acid |
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25 ml |
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| Sod. Hydroxide |
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30 q |
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| Copper Sulphate |
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10 q |
| Water |
1000 L |
100 ml |
50 ml |
70 ml |
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90 ml |
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Desize Conditions : |
| Starch |
: |
1. |
Desize with Finozyme DX and Demineralise with Diquest SNA & Scour. |
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Alkali Oxidative desize & bleach. |
| PVA |
: |
2. |
Alkali Hot – batch alongwith Finocon FBOL and wash hot – cold. |
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1. |
Alkali Hot – batch alongwith Finocon FBOL and wash hot – cold. |
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2. |
Alkali boil alongwith Finocon FBOL. Hot wash – cold wash. |
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| Acrylic |
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Alkali hot batch with Finocon FBOL 95 ° C X pH 10. Hot – cold wash. |
| Sizers Wax |
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Hot scour in jet or batching or Pad – Steam. 95 ° C X pH 10. |
| CMC |
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Hot scour alongwith Finocon FBOL – Wash. |
| PES |
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Hot scour alongwith Finocon FBOL. 95 ° C pH 10. |
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