Steps for wool dyeing in sweater knitting factories
In the industrial production of sweater factories, the steps for wool dyeing are usually as follows:
Pretreatment: Put the wool into an industrial washing machine, add 30-40℃ water, wash for 5-10 minutes, and remove dust and impurities.
Dyeing: Add 40℃ water to the dyeing vat, add dyes, auxiliaries, etc., put the wool into the dyeing vat, control the temperature and time, and dye.
Fixing: After dyeing, add a fixing agent for fixing.
Cleaning: Put the fixed wool into an industrial washing machine, add clean water, wash, and remove excess dyes and auxiliaries.
Drying: Put the washed wool into a dryer and dry it to reach the specified moisture content.
Post-treatment: According to needs, the dried wool is softened, anti-static and other post-treatments are performed.
It should be noted that different wool materials and colors may require different dyeing processes and parameters, so in actual production, it is necessary to adjust and optimize according to specific circumstances. At the same time, in order to ensure the dyeing quality and production efficiency, the dyeing equipment needs to be regularly maintained and maintained.
In industrial production, to ensure the stable quality of wool dyeing, we can start from the following aspects:
Selection and inspection of raw materials
Select high-quality wool: According to product requirements, select wool with good quality, high fiber strength, uniform length and few impurities to provide a good foundation for dyeing. Wool of different materials has different affinity and coloring effects for dyes. For example, wool yarn, acrylic yarn, etc. need to choose suitable dyes.
Strictly inspect dyes: Select dyes with high color fastness, strong stability and good compatibility, test their purity, solubility and other indicators, and conduct small-scale dyeing to observe the dyeing effect and fastness performance to ensure that they meet production requirements. For example, reactive dyes have relatively good washing fastness, which is suitable for products with high requirements for washing fastness; while acid mordant dyes can provide good soaping and light fastness.
Control the quality of auxiliaries: Reasonably use auxiliaries such as leveling agents, dyeing accelerators, fixing agents, chelating agents, etc. to ensure their stable quality and excellent performance. For example, leveling agents can make dyes slowly, evenly, and fully dye fibers, reducing the phenomenon of color flowers; fixing agents can improve dyeing fastness.
Maintenance and management of equipment
Regular maintenance of equipment: formulate equipment maintenance plans, regularly check dyeing equipment such as dyeing tanks, circulation pumps, heating devices, temperature control systems, etc., to ensure their normal operation, and avoid dyeing quality problems caused by equipment failures, such as poor sealing of dyeing tanks and insufficient flow of circulation pumps, which will cause uneven dyeing.
Calibrate measuring instruments: Regularly calibrate measuring instruments used in the dyeing process, such as thermometers, flow meters, pH meters, etc., to ensure the accuracy of measurement data, so as to accurately control dyeing process parameters.
Update equipment technology: Pay attention to the technological development of dyeing equipment, introduce advanced equipment and automatic control systems in a timely manner, improve the uniformity and stability of dyeing, and reduce the influence of human factors. For example, the microcomputer second-order control system can effectively ensure the stability of dyeing quality.
Production process formulation and implementation
Optimize process parameters: According to factors such as wool material and dye characteristics, determine the best dyeing process parameters through experiments and practice, including dyeing temperature, time, pH value, bath ratio, etc., and operate strictly in accordance with process requirements.
Strengthen process monitoring: During the dyeing process, monitor the changes in process parameters in real time to ensure that they fluctuate within the specified range, such as using online monitoring equipment to monitor dyeing temperature and pH. Real-time detection and automatic adjustment of values, etc.
Standardized operation procedures: formulate detailed and standardized dyeing operation procedures and work instructions, strengthen employee training, improve employee operation skills and quality awareness, ensure that every employee can proficiently and accurately produce according to standard operation procedures, and reduce quality problems caused by improper operation.
Quality inspection and control
Improve the inspection system: establish a complete quality inspection system, equipped with professional inspection equipment and personnel, and conduct comprehensive inspection of dyed wool, including color accuracy, color fastness, color difference and other indicators.
Strengthen process inspection: set up multiple inspection links in the dyeing process, such as grey cloth inspection, dyeing liquid inspection, semi-finished product inspection, etc., to timely discover and solve problems and avoid unqualified products from flowing into the next process.
Strict finished product inspection: Strict final inspection of dyed finished wool yarn to ensure that product quality meets standards and customer requirements. Unqualified products should be isolated, labeled and processed to prevent them from being mixed with qualified products before leaving the factory.
Control of environmental factors
Control of water quality: Ensure the quality of dyeing water, soften and desalinate the water, reduce the content of impurities and metal ions in the water, prevent them from reacting with dyes and affecting dyeing effects and color fastness.
Stable production environment: Keep the temperature and humidity of the production workshop relatively stable to avoid adverse effects of environmental factors on dyeing quality. For example, too high or too low temperature may cause changes in dye uptake rate, and high humidity may affect drying effect and color fastness.
