Zeres Tekstil Yarn Dyeing
SYNTHETIC FIBERS
Polyester
Polyester Nylon
Polyester Micro
Polyester Micro Elastane
Polyester Elastane
Polyester Beard
Corespun
Nylon
Nylon Elastane
Nylon Beard
Pbt
Cross Section Fiber
Metrix
Antiway (ITY)
NATURAL FIBERS
Cotton
Viscose
linen
Viscose Linen
Cotton Linen
Wool
Wool Silk
Flush
Bamboo Cotton
Tencel
NEW PRODUCT RANGE
SULFUR PAINT
ANTIQUE PAINT
INDIGO PAINT
BOILER AND COIL CAPACITIES
Capacities
SPECIAL PROCEDURES
Washing / Softening Process
Cotton and Viscose Fluorocarbon Process
Fluoric Optical Process of Nylon And Polyester
Hydrofile Treatment for Natural Fibers
Flame Retardant to Thread
It is called yarn dyeing when the fibers are spun as yarn and before being woven or knitted fabric. Fabrics made of dyed yarn are called "yarn dyed".
There are several advantages and disadvantages to fabrics being yarn-dyed. Dyeing yarn is less costly than fiber or top dyeing. Colors appear more clearly in yarn dyeing. Unevenness is less noticeable compared to fabric dyeing. Dyestuffs used in yarn dyeing must have high fastness due to the processes they will see later, which makes their usage fastness very good. Yarn dyeing can be done in two different forms of yarn. First, the threads are formed into bobbins and dyed in this form. Second, the threads are dyed by making them in hank.
BOBBIN DYEING
It is an application in which bobbed yarns are dyed in special apparatus.
It is often preferred to dye the yarn on the bobbin. Because in this way, some disadvantages of other painting forms are eliminated. In this application, the threads are wrapped in metal or plastic pressurized cones or sleeves. Barrels (Coils) are generally cylindrical.
Since cylindrical bobbins are uniform in diameter, they give more uniform dyeing. Before the yarn is wrapped, knitted fabric or permeable paper is covered on the outside of the shells (Bobbins). This provides a more uniform distribution of pressure. Each bobbin contains between 500-1000 g of yarn. The thread wound on the bobbins should be wound softly. Especially, it is difficult for the liquor to reach the corners of the bobbins. To prevent this, these regions of the coils are wound more gently.
BOBBIN DYEING MACHINES
Bobbin dyeing machines are machines with a cylindrical body that can be pressurized and can reach high temperatures. It has three types, vertical and horizontal body and horizontal spindle. The basic parts of a bobbin yarn dyeing machine are as follows:
1-Painting boiler
2-carrier unit
3-Circulation pump
4-Unit that controls bath flow rate
5-Heat exchanger (Heat exchanger)
The body of the pressurized paint boiler is generally cylindrical. It has a domed cover on its upper part and this cover is fastened to the boiler with a series of bolts or threaded rods. There is a circulation pump just below the vertical body boilers. Due to the height of the machine and the loading of the machine from above with the help of a crane, either a high ceiling place is needed within the enterprise or the machine should be buried in the floor of the enterprise. The machines are aligned in a row and a single crane allows the machines to be loaded and unloaded. There is no such problem in the horizontal body bobbin dyeing machine.
The coils are still in an upright position, but since the body is positioned horizontally, in this case, the coils can be placed in the boiler with a railed slide system. However, these types of machines occupy a larger place in the machine field in the factory compared to the vertical ones. Horizontal spindle machines take up much less space and their bodies are prism-shaped rather than cylindrical.
Coils are placed in the boiler with specially developed apparatus. These apparatuses are placed on the hollow spindles with holes and vertical position in a way to allow the flow of the dye bath. These spindles are neatly lined up on a circular plate called a frame.
The frame sits on the bottom of the paint boiler, directly above the pipe coming from the circulation pump. In machines with horizontal spindles, the bobbins placed on the spindles are placed into the slots in the machine one by one manually. The circulation pump is located at the bottom of the vertical boilers, and at the rear of the horizontal boilers.
Heating of the dye bath is carried out by feeding the high pressure water vapor into the helical and horizontal heating element located at the lower end of the paint boiler just below the frame carrying the coils. The cooling process is done by passing cold water through the same pipes. Due to the fact that the heating and cooling elements are in the dye bath, it is difficult to detect cracks or contaminations that may occur in these elements due to sudden and high temperature changes. Especially cracks and oligomer formation can be a problem. There is another small boiler on the side of the machine. This boiler is known as additive tank. The chemicals required for the flotte are prepared in this tank and transferred into the boiler from here.
ARD OPERATIONS
After the coils are dyed, they are dried in hot air blowing machines or infrared heaters. Coils are fed into the machine manually one by one.
WHERE COIL DYEING IS USED
It is used in the production of all kinds of fabrics, including fancy yarn. It is preferred especially for dyestuffs used for yarn dyed products because of their high fastness. It is preferred as dyed in yarns to be used in carpet production.
HANK PAINTING
Yarns can be dyed in bobbins or in hanks. Hank dyeing is the dyeing of yarns in a wide loosely wound state. Since it is difficult to dye very tightly twisted, high-bulk (acrylic yarn formed by twisting yarns with different tension) yarns in bobbins, hank dyeing is performed. In hank dyeing, it is used in a longer float than bobbin dyeing. There are three types of machines used in hank dyeing. The first type is in the form of a cabinet, the second type is the universal dyeing boiler in which skeins are made by attaching to the hangers, and the third type is sprayed hank dyeing machines.
HANK DYEING MACHINES
In the universal painting boilers, the hanks are suspended on the bars in a frame and then dipped into a rectangular shaped cauldron with paint solution by means of a crane. There is a perforated plate at the bottom of the boiler. Under this plate, there is a heat exchanger exchanger, as in coil and fiber dyeing machines. Flotte circulation is provided by a pump. This machine is similar to fiber and bobbin dyeing machines. In the cabinet dyeing machine, the setup is similar, but the machine is similar to a cabinet. Its covers are opened from the front and placed into the cabinet with the material attached to the bars placed in parallel on a rectangular hanger. Again, these types of boilers have perforated grids on the floor and ceiling. Flotte circulation is bidirectional, from bottom to top or top to bottom.
In spraying machines, skeins are hung on special rods with holes and dyeing float is sprayed to the yarns through these holes. During this process, the rods on which the hanks hang turn and move up and down, trying to ensure dye intake all over the threads.
HANG DYEING PROCESS
It is one of the oldest methods used in yarn dyeing. Skeins are loosely wound in a certain length loop. Care should be taken that it is not too thick or too thin. The quantity depends on the thickness of the thread. It is more costly than coil dyeing. Skeins should be placed on the parallel bars to the frames at a certain tension. Some advance feed is made for elastic fibers or fibers that shrink as they get wet. In hank dyeing, the penetration of the dye into the fiber is very high. As the machine capacity decreases in hank dyeing, the production speed is slow. The consumption of dyestuff and chemicals is also high, as it works with longer liquor ratios than bobbin dyeing.
ARD OPERATIONS
The yarns dyed in hank are dried in the drying machines specially designed for the yarns in the form of skein after removing the excess water in the centrifuge machine. These machines have metal rods on which the hanks can be hung, these rods are circulated in the hot air blow machine by special carriers and dried.
WHERE HANK PAINTING IS USED
Hank dyeing is used for dyeing high-bulk yarns (acrylic yarn formed by twisting yarns of different tension), flexible or sensitive yarns that are suitable for stretching. It is also used for dyeing hand knitting yarns.