Assignment On:

Textile Dyeing Machinery (Jigger & Winch)

Course Title: Machine Technology & Maintenance of Wet Processing Machinery

Course Code: WPT-403
Submitted To:

Tonmoy Saha
Lecturer,
Dept. of Textile Engineering
City University

Submitted By: Group- Rainbow

Name I.D Batch
Md. Azizul Haque (C) 141265542 26th
Md. Rakib Hasan 141265518 26th
Abdul Rabbi Ahmed 141265513 26th
Mohammadullah Riyadh 141265502 26th
Jubair Rahaman Jion 141265517 26th
Md. Selim Rana 141265549 26th

Date of Submission: Oct 31, 2017

Introduction:
Dyeing is a process of coloring textile materials for giving attractive look. In broadly we can
explain, dyeing is a process by which a yarn, fabric, garments and any other materials that come
to contact of dye by presence of auxiliaries that create the condition of dyeing environment. Dyeing
operation is done by different types of dyeing machine.

Dyeing Machine:
The machine which is used to dyeing or coloring of materials like yarn, fabric, garments or any
other materials is called dyeing machine. Dyeing machines come in all shapes and sizes to
accommodate the various forms and quantities of textile materials. Actually it is the device that is
used by different industries for imparting colors. Various types of dyeing machineries are used to
dye the textile materials.

Different Types of Dyeing Machine: We can classify dyeing machine in the

following way.

1. According to textile material:

A. Fiber dyeing machine
B. Yarn dyeing machine
C. Fabric dyeing machine

A. Fiber dyeing machine

1. Conical pan loose stock dyeing machine

2. Hussong loose cotton dyeing machine
3. Jagen barg dyeing machine
4. Simplex dyeing machine
5. Dreze dyeing machine

B. Yarn dyeing machine

a. Hank form:

1. Hussong hank dyeing machine

2. Pulsatur hank dyeing machine
3. Clauder Weldon hank dyeing machine

b. Package form:

1. Cop dyeing machine

2. Cheese dyeing machine
3. Warp dyeing machine
I. Cop dyeing machine

 Mather and platt cop dyeing machine

 Long close cop dyeing machine
 Beaumont cop dyeing machine

II. Cheese dyeing machine

 Ober maier cheese dyeing machine

 Franklin cheese dyeing machine
 Krantz cheese dyeing machine

III. Warp dyeing machine

 Zittau warp dyeing machine

 Ball warp dyeing machine
 Chain warp dyeing machine

C. Fabric dyeing machine

1. Jet dyeing machine

2. Jigger dyeing machine
3. Pad/padding mangle dyeing machine
4. Beam dyeing machine
5. Winch dyeing machine
6. High temperature winch dyeing machine
7. Solvent dyeing machine

2. According to dyeing process:

1. Open dyeing machine

2. Enclosed dyeing machine

3. According to material and liquor movement:

1. Material move but liquor does not circulate i.e; jigger, winch etc
2. Liquor circulate but materials does not move i.e; all package dyeing machine.
3. Both materials and liquor circulate i.e; jet dyeing machine

Jigger Dyeing Machine:

Jigg or jigger dyeing machine is one of the oldest dyeing machine used for cloth dyeing operations.
Jigger machine is suitable for dyeing of woven fabrics, up to boiling temperature without any
creasing. Jigs exert considerable lengthwise tension on the fabric and are more suitable for the
dyeing of woven than knitted fabrics. Since the fabric is handled in open-width, a jig is very
suitable for fabrics which crease when dyed in rope form.

Fig: Jigger Dyeing Machine

Features of Jigger Dyeing Machine:

 Discontinuous Dyeing.
 Most commonly used pieced dyeing m/c.
 Fabric is dyed in open width in uniform tension.
 Fabric moves but liquor does not circulate.
 M:L is 1:7 to 1:10
 In normal atmospheric pressure and under 1000C, fabric can be dyed.
 Time is required 4-10 hours for dyeing.
 500-1000 yards fabric can be dyed.
 It is used specially for woven fabrics.
 Rollers rotate clockwise and anticlockwise.

Technical Details:
 Fabric tension : 50 - 800 N
 Fabric speed : 10 to 150 m/min
 Fabric width : up to 5400 mm
 Roller width : up to 5600 mm
 Roller diameter* : 330 - 550 mm
 Batch diameter* : 1000/1230/1450 mm
Main parts of m/c:
1. Guide roller
2. Take up roller
3. Let off roller
4. Steam channel
5. Dye bath

Utilities required:
1. Water
2. Steam
3. Electricity

Dyeing Process of Jigger Dyeing Machine:

 The jigger consists of a trough fitted with rollers known as draw rollers arranged one along
either side and supported in metal bearings. Guide rollers and stream line are provided in
the trough.
 The fabric is wound, in open width, over rollers standing above a shallow trough
containing the dye liquor.
 The rollers by rotating in clockwise and anticlockwise directions alternately, pull the fabric
backward and forward through the dye liquor, completely immersion being ensured by
guide rollers at the bottom of the trough.
 The roller from which the fabric is taken out is called “let-off” roller while the other is
called “take-up” roller.
 When all the fabric passes through liquor from one roller to the other, the passage is called
an end or one turn. A no. of ends are given during which time the fabric passes to and fro
and passes through the dye solution a no. of times.
 The no. of ends given depends on several factors, including the size of roll or batch of
fabric.
 The time required for one end usually 10 to 15 min and on the depth of shade being dyed.

Fig: Jigger dyeing m/c (left) & Flow Diagram (right).

Advantages of Jigger Dyeing Machine:

 High speed dyeing machine.

 Better dye penetration.
 No crease mark in fabric.
 Economical dyeing process.
 Used for cotton fabrics specially woven fabric.
 The cloth is dyed in open width form in textile industry.
 The material to liquor ratio is 1:7 is used for dyed fabric in textile industry.
 Liquor ratio 1:7 saves huge amount of chemical cost and steam cost.
 Less chemical lose for woven fabric in textile industry.

Limitations of Jigger Dyeing:

 Uneven dyeing in fabric selvedge.
 Weak fabric may be damaged due to more tension.
 Dyeing room becomes dirty and hazard.
 Heat may be lost due to roller.
 Fabric is out of liquor is dyeing tank.
 Discontinuous Process.
 The low liquor ratio makes washing-off difficult.
 There is little mechanical action in a jig machine and it is less suitable where vigorous
scouring is required before dying.
 Moiré effects or water marks may arise on some acetate and nylon fabrics because of
pressure flattening the structure of the rolled fabric.

Woven fabrics which are conveniently dyed on Jigger: Given below-

 Taffettas
 Plain woven
 Satins
 Poplins
 Ducks
 Suiting and Shirting material.
 Sheeting’s etc.

Maintenance of the m/c:

 Motor rpm: motor rpm should check to maintain the proper revolution as we need.
Proper movement of roller: every free roller should move freely as required.
  Correct take up & let off: we have to look at the smooth take up of dyed fabric and
Proper let off of grey fabric without excessive tension in dyeing.

 Proper concentration of liquor: without even concentration of dyeing liquor even

Shade would not be achieved. Proper concentration of dye bath is necessary to
Ensure even and proper shade.

 Temperature of bath: proper temperature of the dye bath should maintain constantly
And should rise and lower evenly with the gradient as require.

Winch Dyeing Machines:

Winch dyeing machine is a rather old dyeing machine for fabrics in rope form with stationary liquor
and moving material. The machine operates at a maximum temperature of 95-98°C. The liquor ratio
is generally quite high (1:20-1:40). Winch dyeing machines are a low cost design that is simple to
operate and maintain, yet versatile in application proving invaluable for preparation, washing or
after treatments as well as the dyeing stage itself. In all winch dyeing machines a series of fabric
ropes of equal length are immersed in the dye bath but part of each rope is taken over two reels or
the winch itself. The rope of fabric is circulated through the dye bath being hauled up and over the
winch throughout the course of the dyeing operation. Dyestuff and auxiliaries may be dosed
manually or automatically in accordance with the recipe method.

. Fig: Winch dyeing machine.

Feature and parameter:
 The machine operates at a maximum temperature 95-98ºC.
 The liquor ratio is generally quite high (1:20-1:40).
 This is a dyeing machine for fabrics in rope form with stationary liquor and moving
material.
 As for all forms of rope dyeing, the fabric must be fairly resistant to length ways creasing.
 A perforated separating compartment, positioned at a distance of 15-30 cm from its vertical
side creates an inner space for heating and for adding reagents.
 Heating can be supplied by means of direct or indirect stem heating.
 The rope passes from the dye bath over two elevated reels. The first roller is free-running
(jockey or fly roller) and the second is winch reel.
 The winch reel not only controls the rate of movement of the fabric rope, but also the
configuration of the rope in the dye bath.
 The winch reel does not grip the fabric positively, but by the weight of the wet fabric and
the friction between the reel and fabric.
 Now-a-days stainless reels with corrugated and broken surface for increase frictional
forces are used.
 The maximum motion speed of the fabric must be approximately 40m/min.
 The winch dyeing method is suitable for all fabrics, expects those which tend to originate
permanent creases or which could easily distort under the winch stretching action.

Main parts of the m/c:

 Winch
 Water inlet pipe
 Steam pipe
 Dyeing tank
 Drain valve

Utilities required:

 Electricity
 Water
 Steam

Dyeing Method of Winch Dyeing Machine:

The basic principle of all winch dyeing machines is to have a number of loops or ropes of the
fabric in the dye bath, these ropes are of equal length which are mostly immersed in the liquor in
the bath.
1. The upper part of each rope runs over two reels which are mounted over dye bath. At the front
of the machine, above the top of the dye liquor is a smaller reel, which is called jockey or fly
roller.
2. The fly roller remain free wheeling along with fabric rope.
3. At the back of winch tank is the winch wheel, which pulls the fabric rope from the dye bath
over the jockey reel for dropping in the dye bath for immersion.
4. From the dropped location, the fabric rope travels back.to be lifted and fed to winch wheel.
5. The dyeing process on winch dyeing machines is based on higher M: L as compared with
other dyeing machines.
6. The process is conducted with very little tension.
7. The total dyeing time is lengthier as compared to other machine.

Fig: Winch dyeing m/c (inner-side)

Advantages of Winch Dyeing Machine:

1. Construction and operation of winch are very simple.

2. The winch dyeing machines are suitable for types of wet processing operations from desizing
to softening.
3. The winch dyeing machine is suitable for practically all types of fabrics.
4. The tension exerted on winch is less than other dyeing m/c.
5. The appearance of the dyed goods is clean and smooth on winch dyeing machines.
6. Dyed fabric is soft and durable.
7. Many batches can be dyed at a time.
Limitations of Winch Dyeing Machine:
1. Batch dyeing operations needs sewing, opening out the rope, loading and unloading for
individual lots separately.
2. Difficult to maintain uniform temperature at different parts.
3. Due to high liquor ratio product cost is higher.
4. Discontinuous process.
5. Heat consumption is high.
6. Permanent crease may occur due to not heat set of fabric.
7. Most of the machine work under atmospheric conditions.

Fabric which are dyed in Winch m/c:

 Woolen and silk fabric.

 Loosely woven cotton and synthetic fabric.
 Circular and warp knitted fabrics.
 Worsted fabric.

Maintenance of the m/c:

 Proper movement of winch: Winch should move freely. So we have to inspect it.
 Proper concentration: Without even concentration the dyeing will not give even
shade. So we have to look at proper concentration of the dye bath.
 Temperature maintain: We have to maintain proper temperature of dye bath by
steam or other utilities. So it should be maintained.
 Activate the valves: Different valves should be active properly. So we have to
inspect them to prevent failure.
 Proper guide & tension: The guide roller & tension roller are bound to give proper
guide & tension.

Conclusion:
Until 1960s the machines used for dyeing fabrics in batches were the winch, jigger and beam.
When polyester was first introduced as a textile material, conventional pressure free winch beck
equipped with a hood was mainly used for dyeing using carriers. Soon it become evident that
dyeing above 100ºC would be necessary to eliminate the use of carriers and accelerate the diffusion
of the dyes for cutting down dyeing time. This promoted machine manufacturers to construct high
temperature or high pressure modification of the existing winch dyeing machines.