Managing colour combination in the dyehouse

During the entire supply chain, luckily technology keeps on developing which helps to control colour - from the lab, to the shop-floor into the dye-house. This article provides several steps by which you can improve textile production more efficient, cost-effective in colour management throughout the process.

Dyers are still facing the challenges with noteworthy differentiation between colour philosophy and real world practices, bearing in mind over all the history of coloured textiles. Creating correctness and consistency in production is not easy due to the exclusive chemical procedure in the most modern dye-house for each and every dye, and hence designers and technicians are facing major challenges.

The expert-based colour technology today has adopted by the master dyer. On the practice of own each system's acquaintance based, many technologies like Datacolor's Smartmatch technology received theoretical colour guessing and regulating it on that base. It is a one type of colour matching system which provides distinctive way of gathering the significant information from relevant guide lines and it evaluate and displays colours in a user friendly manner according to the actual behavior of dyestuff process by its learning system of colour.

These software covers following aspects and benefits:

• Use of dyestuff combinations and separators: That permits applicators to prompt selection of the groups of dyestuffs with rapidly and effortlessly for applying it for colour combination through separate selection technique
• Formula modification: To fix off-shade dieing and equate colours on a selection of materials, formula modification procedure provides the architecture to modify the dye method while the process continues.
• Assessment: It provided with single touch button, which can asses with reflectance curves, on-screen colour displays, strength comparisons and lab colour plots with rapidly and it select from among numerous types of formulations.
• Alternative options: To meet the combination standard in an adaptable set-up like exposed by weight or volume and arrange by lowest formula cost or total colour dissimilarity, from single to multiple set-up displays, such as for worksheet, in an adaptable format and alternatives are provided that rapidly tests almost all possible formulations.
• Testing and manufacturing modification: To operate it by performing automatic additions, automatic reformulations, manual corrections, and even on-line evaluations of corrections, that decrease the number of lab test you require.
• New lot of production and blending improvement: It automatically determines and removes unwanted or unidentified materials from batches contained with in, which gives the standardized or corrected lot of production to the operator.

Colour monitoring process during manufacturing
Not only every part of the dyeing procedure requires to be automated for optimum effectiveness and control, some tasks, such as filling the dye-pots before to supply or move them to dye machines, may still be nearly too cost-effective when carried out manually. Regulating the effectiveness of the dye-house automation definitely requires advance colour combination efforts.
There are many types of software like ITMProcess (software integrated) are available to provide important implications to the colour combination and manufacturing management and this integration is also important in the manufacturing ending period or in quality control. Therefore you should have superior and fully incorporated colour quality control software for colour matching and combination system.

To determine differences in colour assessments between the supplier and the customer a sufficient colour quality control method required. Relating to quality aspects like its reports, statistics, and the appraisal and retrieving of data etc it must help in all the matters. The software should be fast, simple to control and must adjust itself to the individual requirement in the manufacturing procedure.

Colour quality control system must be planned according to:

• Easy operation: it should be design in such way that train operators in less than an hour can see the all activities with "single screen" operation.
• Easily conveyable: Speedily and at once anywhere in the world via an e-mail function colour data should communicated or transferred.
• Report or data acquisition: It must be designed in such way that it can generates printouts and pass/fail reports according to internal or customer's requirement
• Online Checking: Incoming raw materials undoubtedly recovered online for checking colour standards
• Customized configuration: The colour control screens must be designed according to customer specifications or as per requirement of internal operation

To replicate onto a definite fabric the colouration process begins with an objected colour that is clear and it is very vital. There seems to be an outstanding move forward in laboratory dyeing, finishing and wash-fastness testing today.

These types of system designed with three aims are as follows:

The relationship between the formula built-up in the lab and the formula applied in manufacturing is the vital factor for all three aims. System like Datacolor, built-up with the Spectra-dye Plus to confirm relation among the lab and production, it is an infrared exhaust laboratory-dyeing machine with an entire automated measurement system. Time-consuming labor-intensive dosing has turn out to be an event of the past in the textile industry with the supplement of the dosing carousal. For the period of the dying round supplementary would be automatically treated into the dyeing beaker with various dose capacities like linear, progressive through pump. The latest devise with improved connection between your lab and production formulas required. For each supplementary, the full range of shades, pale, medium and dark, units provides multiple alternatives.

Completely incorporated colour systems
To decrease dye as well as chemical and labor costs for the lab and during the entire manufacturing procedure, the textile industry requires to be guaranteed perfect operation with current just-in-time demands. It must cover important vital areas as mentioned and not require covering automating or general feature of dye production and the system, but must work all together. For example a high-quality colour combination system must functions according to the systems of laboratory administration to textile manufacturing management to colour quality control and colour database.

With correct and frequent colour volume and data evaluation of effective colour control and colour management operates with ease of function. In the market there are availability of a large quantity of computerized systems for enriching communication, quality, productivity and profitability. You can not be assured of a completely exact manufacturing method that manufactures less wasteful overall, if the system you preferred doesn't permit addition with the complete range of colour management conditions.

Eliminate errors in the lab
In the textile laboratory fast shifting vogue has changed the production and colour testing cycle too. In today's most successful lab environments the requirement is to make smaller lots in a wider range of colours and fabrics and it converts into a need for additional momentum and accuracy. Some of the most monotonous and prolonged schedules usually have been essential to attain desired results.

In order to carry textile dyeing and finishing function, today challenging lab surroundings needs for better and overall enhanced reproduced products. To control a broad range of laboratory testing, reporting, and dispensing the latest laboratory dispensing and solution maker products with flexibility and presentation required and it covers the whole thing from the estimate of accurate dye dilutions to complete reporting facilities.

In the textile laboratory solution building is a serious process. The concluding method will be wrong, if the preparatory dye-solutions are wrongly and variably arranged. However, you will have to be very precise, factual and promising methodology if the high-quality methods chosen for making the formulas.

• For example consider for a moment, the number of troubles and solutions linked with applying old cumbersome or labor-intensive methods for making solutions:
• Solutions for particular dyestuffs, deviation in the temperature of water applied can influence the firmness and exactness
• While counting physically, the amount of dyestuff auxiliary and water needed when producing solutions errors can be seen.
• Water in particular time is very timely and consuming and also physically dispensing auxiliaries are very overwhelming
• Constancy and dependability of solutions for particular dyestuffs can be influenced by factual error in the amount of auxiliary added
• The chance of mistakes is very excessive in an active manufacturing environment where evaluated physically and the precise amount of the needed dye bears time and expertise.

To enhance the momentum and correctness of solution preparation, system like AutoLab is manufactured in accordance for the same and it removes all of the above difficulties. There is a need of perfect dispensing for perfect stock solutions. Inaccuracy such as inappropriate dye-strength, erroneous additions of auxiliaries in the dye bath, and conflicting liquor ratios removed by the most automated AutoLab laboratory dispensers. For constant and precise formula dispensing, these dispensers keep better agitation and tube cleaning positioning. It also influenced by human error, though it is most up-to-date system and it requires experienced technicians to focus on other areas like cost-effectiveness.

• Wrongly addition of auxiliaries in the dye bath
• Inadequacy and negligence of recipes and their succeeding improvement
• Time-consuming and difficult work of lab workforce
• Huge amount of manual paperwork, encouraging errors
• Incorrect amount of dyestuff pipetting
• Infectivity from unclean pipettes
• Wrongly counting the amount of solution
• wrongly choosing appropriate solution strength
• Incorrect dyestuff pipetting
• Addition of the mistaken amounts of water which gives unreliable liquid ratios

Current laboratory dispensers are offered in a flexible product range, intended for quick job, improved throughput, and extreme accurateness. The system like AutoLab 100Plus has the ability of dispensing three formulas at the same time, it is the most recent development in the dispensing suite and it substantially increasing throughput. Up to hundred formulas can be repeatedly dispensed, one after the other, with the selective conveyor system also existed for the 100Plus system without the requirement of human involvement. There are other models with speedy operation with frequent accuracy available.

Easy efforts with fewer burdens
For constant development without any special attempt from the operators with the most difficult technology for colour matching, dyeing and dispensing to colour quality control an effortlessly incorporated normal textile production schedule should be available. Transported into their easy and click control over multiple colour management and control operations, the complete system should be configurable in to the diverse levels, for its user friendly, latest, adaptable graphically system requirement. It also gives the capacity to add the important formula for auxiliaries for dyeing, besides easy specific screens and printouts. From multi-tasking competency for formula, dispensing, and solution making - with no profound experience, various calculating and laboratory experience levels should be available to run the systems.

For all manufacturers colour has always been a challenging task and costly procedure. There are many systems like Datacolor's Colourite are available to provide a communication tool for colours for their specified colour target. Today the use the Internet to control colour with accuracy is also possible. It gives many advantages like lessen time to market, costs decrement that helps to the supply chain, and an overall improvement in colour quality and it applies latest web-based control system, colour management software and latest colour measuring equipment.

To make the use of system at maximum levels to an all colour combination and quality control tasks, the system must be made exclusive according to the need. For more easy communication and subjective terms like warmer, softer, lighter, the best potential targeted data about the colour in numerical elements should be brought by the latest software management and measuring instrument and it is a best combination of any colour management cycle. Well defined on-screen colour reproduction offered through the latest electronics medium, with a high grade of monitor calibration and the right colour control software for excellent colour communication which also covers the standard colourimetric parameters such as reflectance and the data, which immediately convert that data into visual colour on the screen for assessment.

A capability to generate and imagine colour electronically with digital sampling is possible with system like Colorite. It also prevents the laborious and expensive traditional method of sending coloured samples for sanction. Digital sampling technology is essential in dyehouse applications where perfect colour combination and reproduction is decisive while providing quality product. A little dyehouses can meet the expense to have perfect system in the changing textile market but the requirements are still high in these dyehoese laboratory.