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Project Guide:

MR. JYOTIRMOY ROY

Submitted To: Submitted By:


Mr. MAHESH GUPTA ABHISHEK JAGGA
NIT JALANDHAR
VICE PRESIDENT
AURO DYEING
Project Objective

TO CHECK THE LEVELNESS IN DYEING OF LYCRA


MADE FROM DIFFERENT WINDING MACHINES
WHY THIS PROJECT ?

 High demand of Lycra yarn ~5-6 tonnes per day.


 Capacity constraint of lycra pre winding machine.
There are only two XENO-Y pre winding machine.
 So, the other machines i.e PW2 and TW1-W are also
needed to meet the requirements of bulk production.
WHAT IS LEVELNESS?
 Variation in the shade of dyed fibre, yarn or
fabric ,dyed in same bath, is Levelness.
 For yarn specifically ,the variation in top, middle
and bottom of package determines its levelness.

Formation of
stripes

Last pick from top of pkg1

BOTTOM
MIDDLE
First pick from bottom ofTOP
pkg 2
HOW THE LEVELNESS IS TESTED?

 TMB Variation
By knitting or weaving a continuous fabric from
top, middle and bottom of a dyed package, the
variation is tested.
There are two methods of testing TMB fabric
 Visual

 E of Top-Middle and Top-Bottom

TOP
MIDDLE
BOTTOM
WHY THE PROBLEM OF POOR
LEVELNESS ARISES IN LYCRA?
 Lycra has a tendency to shrink in water, so when
Dyeing of lycra yarn is carried out the package
shrinks, so there’s a gradual increase in the
pressure from top to bottom resulting in less
penetration of dye and giving poor levelness.
PROCESS FLOW
• Grey material
1

• Pre winding
2

• Dyeing
3

• Quality check
4

• Post winding
5

6 • Dispatch
DIFFERENT PRE WINDING MACHINES
USED FOR LYCRA
SSM XENO-Y  SSM PW2  SSM TW1-W

No. of machines-2 No. of machines-1 No. of machines-3


METHOD USED IN TRIALS
 First the trial lots were planned
 Then the information of the lots was collected
 5 packages from different machines were wound with
different cheese colours
 Since SSM TW1-W has limitation for finer counts, so
finer counts were not wound over this machine
 The packages were sent for dyeing in same bath
 The packages were dried over dryers
 3 packages were sent to winding for TMB cones
 The fabric was knitted over the socks knitting
machine from the TMB cones
 Then the fabric was analysed visually and through
CCM
OBSERVATIONS
Package Dyeing SSM XENO-Y-- TMB SSM PW2-- TMB SSM TW1-W-- TMB
Sr No. Lot No. Shade Shade code Count Denier wt(gms) Machine Lot Size levelness levelness levelness
(ΔE) (ΔE) (ΔE) (ΔE) (ΔE)
Top to Top to Top to Top to Top to (ΔE)
middle bottom middle bottom middle Top to bottom
1 55578 Bleach WFL00003 14Lycra 40 900 YD-7 444 0.15 1.45 0.23 1.38 0.8 2.18

2 56347 DK Blue WTX41322 16Lycra 70 720 YD-9 561 0.33 0.42 0.2 0.67 0.42 0.59
0.32 0.39 0.19 0.29 0.4 0.48

3 56299 Black WTP71083 16Lycra 70 720 F 53 450 0.22 0.45 0.32 0.43 0.26 0.45
0.2 0.42 0.34 0.4 0.31 0.49

4 55955 Bleach WFL00003 14Lycra 40 900 F47 299 0.41 1.56 0.43 1.2 1.45 1.4

5 56049 Grey WTX70677 16Lycra 70 720 F1 207 0.54 0.67 0.55 0.7 0.62 0.77

6 56538 Cream WTM70785 16Lycra 70 720 F5 34 0.09 2.03 0.13 2.23 1.63 2.45

Empire
7 56484 Apple WTP33014 14Lycra 40 900 Thies9 45 0.09 0.55 0.16 0.38 0.14 0.73

8 56996 Grey WTX70677 16Lycra 70 720 Thies9 54 0.44 0.54 0.56 0.66 0.68 0.77

9 57252 Bleach WFL00003 16Lycra 40 900 F51 466 0.34 2 0.86 2.14 1.1 2.54

10 57017 Dk Blue WTX80908 12Lycra 70 720 Thies4 528 0.14 0.56 0.49 0.7 0.13 0.8

11 57109 LHS4007 WTX40915 16Lycra 70 900 F5 30 0.23 0.26 0.29 0.1 0.13 0.29

12 57203 Bleach WFL00003 10Lycra 70 900 F51 460 0.61 0.81 0.74 0.84 0.75 0.79

13 57503 Grey WTX70677 16Lycra 70 720 F36 84 0.15 0.55 0.24 0.55 0.42 0.59
Package Dyeing Lot SSM XENO-Y-- SSM PW2-- TMB
Sr No. Lot No. Shade Shade code Count Denier wt(gms) Machine Size TMB levelness levelness
(ΔE) (ΔE) (ΔE) (ΔE)
Top to Top to Top to Top to
middle bottom middle bottom
14 56841 Bleach WFL00003 50Lycra 40 500 Thies3 369 0.54 1.74 0.93 2.39

15 56485 Asphalt WTH71151 40Lycra 40 700 Thies9 42 0.64 0.37 0.42 0.45

16 56633 ECRU WTL51141 40Lycra 40 700 Thies9 51 0.35 0.42 0.3 0.46

17 56843 Bleach WFL00003 40Lycra 40 700 Thies6 197 0.49 1.88 0.95 1.6

Vapour
18 56849 Grey WTM70842 40Lycra 40 700 F37 75 0.51 0.76 0.78 0.66

19 56850 Black WTP94668 40Lycra 40 700 F38 140 0.46 0.94 0.43 0.27

20 56916 Bleach WFL00003 50Lycra 40 500 Thies3 284 0.67 1.58 0.68 2.22

Dark
21 56846 Cedar WTP51487 40Lycra 40 700 Thies11 18 0.44 0.65 0.12 0.93

22 56823 Olive WTS60722 40Lycra 40 700 F48 150 0.15 0.29 0.21 0.33

23 57024 Shadow WTH71212 40Lycra 40 700 Thies7 115 0.81 0.69 0.86 0.49
DEFORMATION OF PACKAGE

It was observed that


packages from TW1-W
Deformed during
dyeing .
OBSERVATIONS ON THE BASIS OF DEPTH
OF SHADE
BLEACH

Package Dyeing SSM XENO-Y-- SSM PW2-- TMB SSM TW1-W-- TMB
Lot No. Shade Shade code Count Denier wt(gms) Machine Lot Size TMB levelness levelness levelness

(ΔE) (ΔE) (ΔE) (ΔE) (ΔE) (ΔE)


Top to Top to Top to Top to Top to Top to
middle bottom middle bottom middle bottom

55578 Bleach WFL00003 14Lycra 40 900 YD-7 444 0.15 1.45 0.23 1.38 0.8 2.18

55955 Bleach WFL00003 14Lycra 40 900 F47 299 0.41 1.56 0.43 1.2 1.45 1.4

57252 Bleach WFL00003 16Lycra 40 900 F51 466 0.34 1.2 0.86 2.14 1.1 2.54

57203 Bleach WFL00003 10Lycra 70 900 F51 460 0.61 0.81 0.74 0.84 0.75 0.79

56841 Bleach WFL00003 50Lycra 40 500 Thies3 369 0.54 1.74 0.93 2.39

56843 Bleach WFL00003 40Lycra 40 700 Thies6 197 0.49 1.28 0.95 1.6

56916 Bleach WFL00003 50Lycra 40 500 Thies3 284 0.51 0.76 0.78 0.66
Light Shades

Package Dyeing SSM XENO-Y-- SSM PW2-- TMB SSM TW1-W-- TMB
Lot No. Shade Shade code Count Denier wt(gms) Machine Lot Size TMB levelness levelness levelness
(ΔE) (ΔE) (ΔE) (ΔE) (ΔE) (ΔE)
Top to Top to Top to Top to Top to Top to
middle bottom middle bottom middle bottom

56049 Grey WTX70677 16Lycra 70 720 F1 207 0.54 0.67 0.55 0.7 0.62 0.77

56538 Cream WTM70785 16Lycra 70 720 F5 34 0.09 2.03 0.13 2.23 1.63 2.45

56996 Grey WTX70677 16Lycra 70 720 Thies9 54 0.44 0.54 0.56 0.66 0.68 0.77

57503 Grey WTX70677 16Lycra 70 720 F36 84 0.15 0.55 0.24 0.55 0.45 0.59

56485 Asphalt WTH71151 40Lycra 40 700 Thies9 42 0.64 0.37 0.42 0.45

Vapour
56849 Grey WTM70842 40Lycra 40 700 F37 75 0.51 0.76 0.78 0.66
DARK SHADES
Lot Package Dyeing SSM XENO-Y-- TMB SSM PW2-- TMB SSM TW1-W-- TMB
No. Shade Shade code Count Denier wt(gms) Machine Lot Size levelness levelness levelness
(ΔE) (ΔE) (ΔE) (ΔE) (ΔE) (ΔE)
Top to Top to Top to Top to Top to Top to
middle bottom middle bottom middle bottom

56347 DK Blue WTX41322 16Lycra 70 720 YD-9 561 0.33 0.42 0.2 0.67 0.42 0.59
PEEL
OFF 0.32 0.39 0.19 0.29 0.4 0.48

56299 Black WTP71083 16Lycra 70 720 F 53 450 0.22 0.45 0.32 0.43 0.26 0.45
PEEL
OFF 0.2 0.42 0.34 0.4 0.31 0.49

Empire
56484 Apple WTP33014 14Lycra 40 900 Thies9 45 0.09 0.55 0.16 0.38 0.14 0.73

57017 Dk Blue WTX80908 12Lycra 70 720 Thies4 528 0.14 0.56 0.49 0.7 0.13 0.8

57109 LHS4007 WTX40915 16Lycra 70 900 F5 30 0.23 0.26 0.29 0.1 0.13 0.29

56633 ECRU WTL51141 40Lycra 40 700 Thies9 51 0.35 0.42 0.3 0.46

56850 Black WTP94668 40Lycra 40 700 F38 140 0.46 0.94 0.43 0.27

Dark
56846 Cedar WTP51487 40Lycra 40 700 Thies11 18 0.44 0.65 0.12 0.93

56823 Olive WTS60722 40Lycra 40 700 F48 150 0.15 0.29 0.21 0.33
ANALYSIS OF DATA
M/c-> XENO-Y PW2 TW1-W
Shade
Total No. No. of Total No. No. of Total No. No. of
of Lots OK Lots of Lots OK Lots of Lots OK Lots
Bleach 7 4 7 2 4 0
Light 6 3 6 3 4 1
Dark 11 10 11 9 5 5

•Bleach:- XENO-Y - Overall TMB levelness OK


PW2 - Overall TMB levelness OK
TW1-W - Overall TMB levelness NOT OK

•Light Shade:- XENO-Y - Overall TMB levelness OK


PW2 - Overall TMB levelness OK
TW1-W - Overall TMB levelness NOT OK

• Dark Shade:- XENO-Y - Overall TMB levelness OK


PW2 - Overall TMB levelness OK
TW1-W - Overall TMB levelness OK
CONCLUSION
 According to analysis of data, the compatibility of
machine according to shade is as follows
•Bleach:- XENO-Y - Compatible
PW2 - Compatible
TW1-W - Not Compatible

•Light Shade:- XENO-Y - Compatible


PW2 - Compatible
TW1-W - Not Compatible

• Dark Shade:- XENO-Y - Compatible


PW2 - Compatible
TW1-W - Marginally Compatible