Understanding About Batching for Dyeing and Finishing

Understanding About Batching for Dyeing & Finishing

Mustaque Ahammed Mamun
Department of Textile Engineering
Dhaka University of Engineering & Technology (DUET)
Cell: +8801723300703
Email: mamuntex09@gmail.com


Batching :
Batching is the process to get ready the fabrics which should be dyed and processed for a particular lot of a particular order.

Function or Purpose of Batch Section:
1. To receive the grey fabric roll from knitting section or other source.
2. Turn the grey fabric if require.
3. To prepare the batch of fabric for dyeing according to the following criteria –
  • Order sheet (Received from buyer)
  • Dyeing shade (color or white, light or dark)
  • M/C capacity
  • M/C available
  • Type of fabrics(100% cotton, PE, PC, CVC)
  • Emergency
4. To send the grey fabric to the dyeing floor with batch card.
5. To keep records for every previous dyeing.

Proper Batching Criteria:
  • To use maximum capacity of existing dyeing m/c.
  • To minimize the washing or dyeing time or preparation time & m/c stoppage time.
  • To keep the no. of batch as less as possible for same shade.
  • To use a particular m/c for dyeing same shade.
Batch Management:
Primarily batching is done by dyeing manager taking the above criteria under consideration. Batch section in charge receives this primary batch plan from dyeing manager. Some time planning is adjusted according to m/c condition or emergency.

GREY FABRIC INSPECTION:
The inspection and grading of fabric quality is one of the important functions of Quality Control in the grey or finished state, the grading of fabric is a difficult task, taking two primary considerations: as the frequency of effects and the seriousness of defects.
Grey fabric inspection

The grading has two primary functions: First, to classify the fabrics according to standard qualities based on the end-use and costumer demands and second, to supply information as to the qualities actually being produced.

The Knitted fabric can be classified into three levels of quality, each one have a number of points for defects as follows.
  • The First quality level .................40 points per 100 Linear Yards.
  • The Second quality level ............(40 – 80) points per 100 Linear Yards.
  • The Third quality level ............... 80 points or more per 100 Linear Yards.
General Instructions for the Final Inspection:
  1. All pieces will be graded on the base of 40 points per 100 Linear yards Mapping will be done on each piece to insure proper grading. Do not count more than 4 points per one yard.
  2. All defects must be recorded and marked in final inspection and an accurate account of points made to insure proper grading.
  3. All fabric must meet specifications.
  4. At the end of each piece of fabric, the inspector will add up total points and decide whether the piece can be shipped as first quality or not, reworked, placed in lower quality, or cut and upgraded for shipment. Fifteen yards or more can be shipped as first quality.
  5. The quality control supervisor must approve the grading of all quality levels and check the lower quality.
  6. Major or unsightly defects in the first and last yard of a roll or piece will be cut. All defects of one yard length or more will be cut out of the piece. Defects within the first 2 inches or the last 2 inches of a piece will not be cut out or counted in the grading.
  7. Open defects on the back of fabric such as drops, runs and hanging picks are to be included in the grading of fabric.
  8. Pieces can be connected together, once each piece must be the same shade.
  9. All defects such as runs that extend more than a yard in length will be cut out.
  10. Fabric up to 70 inches will be allowed a bow of not more than 1 inch and a Bias of not more than 2 inches.
  11. Defects within one inch of the fabric edge will not be counted except on tubular fabrics. All defects will be counted in tubular goods.
Grading Procedure:
  1. All open defects or major defects counted with 4 points per defect.
  2. Surface defects over 9 inch length counted with 4 points per defect.
  3. Surface defects 6 to 9 inches length counted with 3 points per defect.
  4. Surface defects 3 to 6 inches length counted with 2 points per defect.
  5. Surface defects up to 3 inches length counted with one point per defect.
  6. Running defects, such as tucks, needle lines, barre, crack marks, are judgment defects
Considerable parameters to add additional fabric for dyeing in Padma Polycotton Knit Fabrics ltd :

100% Cotton light to medium color:

Fabrics
Process
Open Finishing
Tube finishing
Single Jersy
Heavy enzyme

Enzyme

No Enzyme

Enzyme sueding
18%

17%

13%

20%
16%

14%

11%

11%
1X 1 rib
Do
Do
Do
Interlock
Do
Do
Do
pique
Do
Do
Do
Lycra S/j
Enzyme
17%
14%

CVC Light to medium color:

Single  jersy
Enzyme
15%
13%
100% cotton fabric  
brush
18%
16%
100% cotton fleece
brush+ sueding
20%
--
60% 40% fleece
Enzyme +brush
18%
18%
100% polyester

6%
6%

M/C s in batch section:

Machine Name
Air turning  machine
No. of M/c
02
Origin 
Local







Machine Name
Air turning  machine
No. of M/c
02
Origin 
Local




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