Process Sequence of Batch Preparation for Dyeing

Last Updated on 25/02/2023

What is Batch Preparation for Dyeing?
Batch preparation is a crucial step in the dyeing process that involves preparing the fabric or textile material to be dyed prior to the actual dyeing process. This step typically involves several different procedures, such as scouring, bleaching, desizing, mercerizing and heat setting.

Batch Preparation for dyeing
Fig: Batch preparation for dyeing

Production planning for dyeing is called “Batch Plan or Batch preparation”. According to the batch no, colour, width, style and construction the batch plan is made.

Process Sequence of Batch Preparation for Dyeing:

Receive batch card from grey in-charge

Make the priority as per dyeing plan

Take one specific batch card

Read the batch card for own understanding

Check the availability of fabric

Take required quantity of body fabric from ware-house

Make required no. of rope maintaining equal length

Take collar / cuff as per size, keep the total weight

Distribute the collar / cuff or rib in each rope equally ensure equal length

Stitch the fabric

Write down the weight against roll no. in the back side of the batch card

Write the total weight in batch card

Put signature and date

Fill up the production report form

Steps Involved in Batch Preparation in Dyeing:
The batch preparation process in dyeing floor typically involves several steps, including:

1. Desizing: Many fabrics are treated with sizing agents during the weaving process to improve their strength and stability. However, these sizing agents can interfere with the dyeing process, so they need to be removed before dyeing. Desizing agents, such as enzymes or acids, are used to remove the sizing agents from the fabric.

2. Scouring: Scouring is the process of washing the fabric with a detergent or alkali solution to remove any natural impurities such as waxes, oils, dirt, and other contaminants. Scouring is a critical step, as the presence of impurities can interfere with dye absorption and cause uneven colouration. Scouring can be done by a variety of methods, such as hot water washing, solvent extraction, or enzymatic treatment.

3. Bleaching: If the fabric has any residual color or if it has been previously dyed, bleaching is necessary to remove the color and ensure that the final color is uniform. Bleaching agents, such as hydrogen peroxide or sodium hypochlorite, are used to remove the color from the fabric. The fabric is typically soaked in the bleach solution for a set period, then rinsed thoroughly to remove any residual bleach.

4. Mercerizing: Mercerization is a process that involves treating the fabric with a concentrated caustic soda solution to increase its affinity to dyes. This treatment causes the fabric to swell and become more porous, making them more receptive to dye molecules.

5. Heat setting: Heat setting is also an important step in the batch preparation of Lycra fabric for dyeing. Lycra is a synthetic elastane fibre that is widely used in the apparel industry for its stretch and recovery properties. The heat setting process helps to improve the fabric’s ability to absorb dye evenly, resulting in consistent and vibrant colouration. Typically, the fabric is stretched to a specific length, then held in place while it is exposed to high temperatures, typically around 160-180°C, for a set period, typically 30-60 seconds.

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