Dyehouse Management Software: Function, Process and Treatment
Engr. Kh. Mashiur Rahman
Garment Auto Machine Technologist,
The successful dyehouse management in textile industry depends on management techniques and on the system. Dyeing and finishing is a high-tech industry; laboratory and production equipment has been developed to achieve the latest requirements from modern dyeing and finishing plants. The dyeing and finishing sector is very critical for growth and sustainability of the sector. Being the major user of key resources like gas, electricity, water, and chemicals the dyehouses are having great impact on environment. Dyehouse management software do the following task: Optimized recipes management based on predefined rules, Dye procedure management based on rules enabling to run the same procedure on dyeing machines with different configurations, Creation of combined recipe/dye process, Management of optimized dissolving parameters and online scheduling for dissolving, Chemicals and dyestuffs stocks and orders management etc. Sedo Treepoint’s SedoMaster is such dyehouse management system. Built up around a graphical plan board, an editor and reporting, it offers all possibilities a modern dyeing/ finishing plant requires.
SedoMaster dyehouse management software:
SedoMaster is a dyehouse management software. It is a Windows based solution, designed to manage the dye house or an entire textile finishing plant. SedoMaster provides everyone, from the operator to the chief executive with an integrated solution, allowing them to manage production scheduling, recipes, processes, and reports. SedoMaster supports all required interfaces to other systems such as chemical dispensing, recipe management and ERP. The result is optimization of all machinery (dyeing, washing, bleaching, stenter, dryer, calendar, etc.), minimizing the cost. This software integrates all dyeing and finishing machines and controllers into a central computer. As a result, the dyeing professional can monitor the dyeing recipe & dyeing batch system centrally. This software has a modular structure with modules for planning, modules for reporting and an editor that focusses on process, treatment, function & machine group.
In this article I will discuss about the SedoMasterEditor, where dye process and recipe come together.
With the SedoMaster editor, the user can create the dye processes in a comfortable way on the SedoMaster computer, far away from the dyeing machines. As all information is stored in a Database, traceability is guaranteed. Sedo Treepoint is using a structure that is optimally suited for communicating with recipe systems and automatic dispenser installations.
In the SedoMaster software, a dye process has a structure based on Process, Treatment and Functions.
A process, for example dyeing program, consists out of individual treatments. Processes are sent to the dye house controllers & are used in the controller as dyeing program. Processes are organized in process types for a better overview.
A treatment is part of a process & is used for a specific task, for example pre-washing, bleaching, dyeing, soaping, boiling, etc. You notice, this is general terminology. A dyer doesn’t need to know all technical details of a machine for being able to compose a process based on treatments. Pre-washing, or soaping, or dyeing are functionalities that are valid for all types of machines, be it a jet dye machine, an autoclave or even a jigger. Treatments consist of functions, for example filling, draining, heating, temperature control, etc. These functions have parameters like for example temperature, gradient, differential pressure, speed, etc.
These functions are very specific per machine. Filling a jet dye machine will probably use other valves than a jigger. The pump on a jet dye machine is controlled in a different way compared to an autoclave. For that reason, treatments are created to be used with a specific machine group. To improve the overview, treatments are grouped into treatment classes. A treatment can be used in different processes & is only valid for the machine group which was assigned to the treatment. Typically for Sedo Treepoint, a treatment has several windows paths.The first window or main window controls the main part of the machine.
The structure based on treatments is a perfect way to integrate SedoMaster with recipe systems that tend to use a similar architecture, for example the modules in Sedo Treepoint’sColorMaster recipe system
Functions are assigned to treatments. Examples for functions are loading, filling, heating and user call etc. Functions can have parameters likedyeing temperature, gradient, hold time, fill level, etc. It is obvious that the functions will be different for different types of machines. Functions are grouped in functiongroups in the SedoMaster editor.
A machine group is a group of machines with the same functionality as functions and parameter etc. & the same type of controller. That means all controllers must have the same configuration for belonging to a same machine group.
When a process is made, it is not necessary, to define the machine group module for which the process should be valid. A treatment module however can run only on the machine or in machine group module if all treatments within the process are valid for this machine group.
These definitions for process, treatment and functions are the heart of the dye process. It will determine how efficient your production will run, maximizing the capabilities of the connected dyeing machines.
SedoMaster dye house management:
Overall performance of the production will be increased if also the graphical plan board is used for efficient scheduling of the production and with the reporting modules allowing to analyze the performance of machines and processes. With the links to external systems like ColorMaster recipe management, dispensers, weighing stations, ERP-systems, etc., a fully integrated dye house solution is in reach for every textile dyeing and finishing company.
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Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. He is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.