The working of a continuous dyeing process is described here.

The textile substrates are feeded

continuously into a dye range. The speeds can vary between 50 to 250 meters per minute. According to
Industry estimates Continuous dyeing is a popular dyeing method and accounts for around 60% of total
yardage of the products that are dyed.

A Continuous dyeing process typically consists the following. Dye application, dye fixation with heat or
chemicals and finally washing. Continuous dyeing has been found to be most suitable for woven fabrics.
Mostly continuous dye ranges are designed for dyeing blends of polyester and cotton. The step of
padding plays a key role in the operation of continuous dyeing. Sometimes Nylon carpets are also dyed in
continuous processes, but the design ranges for them is unlike that for flat fabrics. Warps are also dyed in
continuous process. Very good examples of such warp dyeing are long chain warp dyeing and slasher
dyeing using indigo.

A continuous dye range has been found useful and economically sustainable for dyeing long runs of a
given shade. One important factor that separates continuous dyeing from batch dyeing is the tolerance
factor for color variation. That is more for continuous dyeing as compared to batch dyeing. This is so
because of two reasons a) the speed of the process. b) presence of a large number of process variables
which affects dye application. The process that is illustrated below is designed for dyeing of blended
fabric of polyester and cotton.

http://www.scribd.com/doc/21333479/continous-dyeing-project

History of Continous Dyeing

This invention relates to the dyeing of textile fabrics, and in particular to a continuous
process for dyeing textile fabrics formed at least partially of polyester fibers.
It is known from the technical literature (for example, W. Bernard Praxis des Bleichens und
Faerbens von Textilien [Bleaching and Dyeing Practice of Textiles], Springer Verlag, 1966) and
from pertinent publications that textile fabrics of polyester fibers and/or their blends with
cellulosic fibers can be continuously dyed by the so-called "Thermosol Process." In applying this
method, the fabric is impregnated with a cold to warm, aqueous dispersion of suitable dyestuffs
and auxiliary agents to a defined weight increase, dried, subsequently "thermally fixed" at
temperatures of 180.degree. to 220.degree. C., and again liberated from excessive dyestuff by
washing. During the thermal fixation, the dyestuffs diffuse into the polyester fiber in a finely
dispersed or monomolecular form, and are dissolved in the fiber. The advantage of this method is
the possibility of simultaneously fixing the polyester fibers and obtaining very fast colors within
a short period of time ranging from 40 to 120 seconds at 180.degree.
to
220.degree.
C.
A prerequisite for the success of the process is that the dyestuffs are already uniformly
distributed in the textile product after the impregnation and intermediate drying. If not,
nonuniform coloration will result. Another prerequisite is that the product is dried before the
thermal fixation, since otherwise the temperatures for the Thermosol Process will not be reached
because
of
evaporation
of
the
dyebaths.
However, the Thermosol method has been found disadvantageous in practice, in that not all
textile fabrics of polyester fibers can be dyed by this process, and that it is absolutely necessary
to dry the product following the padding. In particular, it is not possible to dye pile fabrics by
this method, since the dyebath migrates to the pile tips and bases during the intermediate drying,
and thus, the product is dyed unevenly. Furthermore, the process is uneconomical, since the
fabric needs to be dried twice during the dyeing process. Even though attempts have been made
to overcome these disadvantages by the use of so-called migration inhibitors and special padding
assistants, they have been unsuccessful in the case of the pile fabrics, such as, plushes, velvets
and velours. A further problem with the pile fabrics, due to their high bulk and insulating
characteristics, is that it is not possible to achieve Thermosol temperatures throughout the fabric
in a reasonably short duration without overheating and fusing the tips of the pile yarns or leaving
inner portions of the fabric insufficiently
heated.
It is, therefore, an object of the present invention to develop a method for continuously dyeing
polyester fibers and filaments and/or their blends with cellulosic fibers, which overcomes the
aforementioned disadvantages and by which also pile fabrics can be satisfactorily dyed

Pad thermosol
it is a machine which is used to pad, dry and cure to all kinds of fabrics. This machine is
categorized under continuous process of dyeing

Machine details of pad-thermosol:

Pad-thermosol consists of following parts that dye and guide the fabric during
dyeing

Batcher
Guide rollers
Screy
Trough
Squeezing rollers
Padder
VTG rollers
IR-dryers
Drying chambers
 Curing chamber
Piller
Now we will see these parts individually by using figures

Batcher:
When the fabric is taken to dye , it is in the form of batcher that is taken after
mercerizing as shown in the following fig
The fabric width depends on the size of the batcher and the fabric of different length is
winded on it . This length may vary from 100 to 70,000 meters

Guide rollers:

These are the rollers which are used to guide the fabric from different paths. Their function is only to
direct the fabric toward it’s outlet. Guide rollers are shown in the following fig.

Trough:
It is the first main part of this machine. This part is filled with liquor which is filled with dyes and chemicals
it’s capacity is nearly 1400lilres. It is dozed manually as well as automatically. The dozing structure is
shown in the following fig.

The temperature of this bath is room temp. the fabric capacity is 1-1.5m within this dye bath

or trough.following recipe is used in this trough.

• Dyes
• Urea (moisturizing agent)
• Soda ash( for reactive dyes)
• Sodium bicarbonate(for pigments)
• Primazol FFAM (anti-migrating agent)
• NF

Padder
This is the main part of the machine. All the pick-up of dye depends upon the padder. It is a pair of two
rollers. Two rollers move in opposite direction to each other. These rollers are also rubber coated but have
special type. L-C-R (left-center-right). This is the most sensitive factor that require more concentration
than any other part. Basically L-C-R fault means that the fabric dye is varying from left,right and center.
The structure of padder is shown in the following fig
VTG Roller:
These are called vertical tentioner guide rollers . These are the rollers that give tension
and rest to the dyed fabric and fabric contact with air. There are 9 rollers that are used
for this purpose,5 above(driver) and 4 down (driven). The structural diagram is shown in
the following fig.
IR dryers :

These are called infra red dryers. IR-dryers are also called pre-dryers. 30% of fabric
is dry in this section. The temperature of these dryers vary from 1000-1300C. these
dryers have very important role in dyeing the fabric uniformly. The fig. of IR is
shown as follows
When the fabric is passed from the padder then there is an uneven dyeing that
cause the face- back problem on the fabric. The structural diagrame of the dye
particles shown in the figure after padding as Two IR are used for heavy quality and
one is used for light quality.And when the fabric is passed through the IR dryers the
dye par2ticles migrate from surface to the core of the fabric with help of infra red
rays. After passing through IR the the dye particles are shown bellow on the fabric
surface

Drying chambers:

There are two drying chambers used for thermosoling .These are the

chambers where thermosoling is done. The fabric passes through the rollers in the
chamber

and thermoil react with fabric in these chambers. The diagram is shown in the
following fig

The thermoil is given to the chambers in pipes attatched to the radiator and it
circulates within the chamber with the help of circulating fans.
The temperature of these dryers vary with quality of the fabric and dye stuff used
because different dye stuff have different range of temperature for it’s fixation ,
20% fabric is dry in these chambers.

Curing chambers:

There are two chambers that are responsible for the curing process. Curing
chambers are used for the fixation of the dye into the fibre.These are the chambers
where remaining fabric is dry i.e 50%. As there is more temperature within these
chambers so we need moisturizing agent that produce the humidity within the
chambers and the fixation process is carried out. For producing the moisture we use
urea as a moisturizing agent. This chemical is mixed with the dye recipe in the
trough. The curing chambers are shown as follows