What is Beam Dyeing?
In beam dyeing method, the warp is dyed prior to weaving. Here, the yarn is wound on to a perforated warp beam and then immersed in a tank for dyeing it applying pressure. Beam dyeing is the much larger version of package dyeing. An entire warp beam is wound on to a perforated cylinder, which is then placed in the beam dyeing machine, where the flow of the dye bath alternate as in the package dyeing. Beam dyeing is similar to package dyeing but more economical than skein or package dyeing, but it is only used in the manufacture of woven fabrics where an entire warp beam is dyed. Knitted fabrics, which are mostly produced from the cones of the yarn, are not adaptable to beam dyeing. In beam dyeing, yarn or fabric is wrapped around a large perforated beam through which dye is pumped. Although high temperature–high-pressure beam dyeing machine can be used for open width dyeing of fabrics, they are preferably being used for dyeing weaving beams.
What is Beam Dyeing Machine?
A machine for dyeing yarns or fabrics that have been wound onto a special beam that has evenly perforated holes along its barrel. The dye is forced through the barrel into the yarn/fabric from inside to outside and vice versa. The beam dyeing machines may be capable of dyeing a single beam or to dye multiple beams. The fabric or yarn have better dyeing results because of there is no dimensional changes as well as there is no mechanical force applied to it. The high performance pumps circulate the dye liquor in efficient manner to achieve even dyeing results.

Before the advent of jet dyeing machines and HT jiggers, beam dyeing machines were universally used for dyeing polyester and polyester blended fabrics that required higher temperature and pressure. These horizontal fabric beam dyeing machines have proved suitable for dyeing warpknit fabrics, light-weight woven filament fabrics, polyester blended fabrics and so on. In these dyeing machines, the fabric batch remains stationary during dyeing while the dye liquor is circulated through the batch.
Features of Beam Dyeing Machine:
The features of two representative modern beam dyeing machines are given below.
New Generation beam dyeing machines/lines of Noseda, Italy
The main features of these machines are as follows:
- Full range of process systems available to suit any need.
- Hydraulic circuit for high flexibility for a wide range of applications with woven and knitted fabrics.
- Pumps of AISI 316 ss with high hydraulic and mechanical efficiency.
- New transistor control principle and proper distribution of pressure to reduce the risk of fabric lengthwise movements.
- New beam design with new full/empty ratios to improve flow distribution and to increase center to selvedge and end to end evenness.
- High Production Featured (HPF) models have increased lot size on single beam, improved quality and protection of material, reduced process time and cost with working temperatures of 143–160–170°C.
- Automatic adjustment of capacity/differential pressure, depending on the features of the material processed. Through control of hydraulic parameters, these can work with frequent changes in density during cycles, thereby giving increased process flexibility and reliability along with energy savings.
- Ability to monitor and constantly adjust the specific flow rate and the required number of bath cycles, leading to better quality, economy through optimum use of colors and chemicals and reduction in both process cycle time and production cost.
- Greater reliability and reproducibility of results through the required dosing, such as high and low temperature dosing/linear increased dosing/ positive and negative progressive dosing and in-line pH control.
- Volumetric liquor reduction devices that reduce the nominal capacity of single machine to optimize the liquor ratio.
- Axial reduction devices, which help to optimize liquor rates and allow considerable energy savings. Liquor ratio can be adapted to specific needs up to 1–4.
- Functional fittings including: automatic carrier transportation and beam loading, manual and pneumatic beam locking, manual or automatic closing of autoclave and beams adjustable in height without reduction clamps.
- Datawin System to select working parameters and monitor production processes. Its advantages include: guidance to operator in selecting the most suitable working parameters, in calculating ideal and the real capacity values to optimize time/temperature cycles and in calculating real liquor ratio to facilitate production cost control.
- Software package available in a Windows environment version.
High temperature beam dyeing machine type HST of Then, Germany
The features of the HST beam dyeing machine are as follows:
- Dyebath circulation by axial-reversible flow pump depending on the type of fabric with reversible liquor flow by heavy-duty centrifugal pump.
- Optimized bath distribution.
- Machines with semi-automatic control have automatic valves and THEN-Datocomp DCE00 time/temperature controller.
- Machines with fully automatic control are with THEN-Datocomp DCE10 automatic process controller. This can be connected to central host computer THEN-Datocomp DC.
- Equipment includes:
- Pressure and injection pump with pressure regulation valve and back-cooler.
- Preparation and expansion tanks.
- Flow rate controller.
- Overflow rinse device.
- Sampling device.
- Mobile dye beam carrier.
- Transport trucks for beam carrier with dye beam – possible to use one or more dye beams.
- Complete switch installation in watertight plastic switch cabinet.
Working Principle of Beam Dyeing Machine:
The working principle of beam dyeing machine is similar of HTHP yarn dyeing machines. The process of beam dyeing is as follows,
- The fabric or yarn in open width is rolled on to a perforated beam.
- The beam then subsequently inserted into a dyeing vessel.
- The machine is closed and pressurized.
- The dye liquor is circulated into out and out to in directions, under pressure and temperature is employed as per the process requirement.
- The chemicals and auxiliary are injected as per requirement of the process.
Nowadays, in order to increase the output capacity and further reduce the liquor ratio, manufacturers have begun to provide their beam dyeing systems with large-diameter perforated beams, equipped with internal plenum chambers to reduce idle spaces. Sleeves are used to equalize the liquor flow in the selvedge section.

The liquor, forced by a circulation pump, flows out through the holes and passes through the fabric forcing the dye into the fabric. The liquor path can be reversed. If the fabric is shorter than the beam, the holes not covered with fabric are closed by means of covers fixed under the fabric.
The fabrics must be wound with the correct tension; if the fabric is excessively stretched, the liquor cannot pass and the dye is not forced into the fabric. On the contrary, if the fabric winding tension is not uniform, a “moiré effect” will originate (the surface resembles water ripples). The control of pressure changes (internal/external), which must range between 0.1 and 0.5 kg/cm2, allows the control of winding accuracy; several photocells monitor possible fabric unwinding.
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This machine, which was very popular during the 1960s and the 1970s, is still widely used today, and is even experiencing a sort of revival. The liquor ratio varies between 1:10 and 1:15, but the use of internal plenum chambers allows the optimization of the required liquor volumes.
It can be used for both pretreatment and dyeing operations.
Advantages of Beam Dyeing Machine:
- The fabric is put under controlled tension, and is wound on to a perforated beam. This results in elimination of creases from the fabric. It also ensures total control of dimensions of the roll of the fabric.
- The fabric is not allowed to do any movement during the process of dyeing. This actually means that there is no application of mechanical action on to the fabric.
- This machine needs comparatively less amount of energy so lowers operational costs.
- It has versatile applications. Suitable for various types of fabric.
Disadvantages of Beam Dyeing Machine:
- Fabric of different width cannot be dyed together on a single beam.
- The dyed fabric may be display moiré effect if it is tightly due to shrinkage.
- Uneven dyeing may occur if the beam is fully loaded, as the dye liquor penetrates several layers of fabric.
- Limited production capacity so less efficient for high-volume production.
Conclusion:
Beam dyeing machine is used for dyeing yarns or fabrics that have been wound onto a special beam that has evenly perforated holes along its barrel. Beam dyeing is simply a much larger version of package dyeing. Beam dyeing machine is used for bleaching and dyeing all types of fabrics in open width on perforated beams. This machine operates with the same principle as that of package dyeing machine but is more economical. Yarn is wound on to a perforated warp beam or perforated cylinders, which is then placed in the beam dyeing machine where the flow of the dye bath alternates as in package dyeing.
References:
- Handbook of Textile and Industrial Dyeing, Volume 1: Principles, Processes and Types of Dyes Edited by M. Clark
- Textile Dyeing By Dr. N. N. Mahapatra
- Reference Book of Finishing By Pietro Bellini, Ferruccio Bonetti, Ester Franzetti, giuseppe Rosace, Sergio Vago
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Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. Mr. Kiron is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.