YARN DYEING INDUSTRY
OPTIMAL DYEING CARRIER DESIGN “KnowHow” Wish You Knew When You Were 20 BOUGHT BY
CURRENTLY THERE ARE MANY SIZES OF DYE SPINDLE
Traditionally and Wrongly the Size Of The Spindle Was Always Defined By The Size Of the Dye tube Used By The Dyer It Has Never Been Part Of The Dyeing Machine Design To Maximise The Thru Put With Optimum Dyeing Parameters
Last Paper, We Concluded Triangular Spindles Are Better Then Cylindrical Spindles
Currently Spindle Dia is a Function of Dye tube ID And Spindle Length is a Function of Machine Height BOTH ARE WRONG WAY FOR OPTIMISING THE CARRIER THRU PUT
This Paper, We Will Examine
OPTIMAL DYEING CARRIER DESIGN CARRIER HAS 3 VARIABLES SPINDLE POLE DIAMETER SPINDLE POLE LENGTH NOS. OF POLES OPTIMAL DYE CARRIER WILL HAVE MAXIMUM NUMBER OF POLES LONG ENOUGH TO CARRY THE DESIRED PRESSED PACKAGES WITH SUITABLE PUMP HEAD AND NOT DEFINED BY THE MACHINE HEIGHT. CONTRARILY, THE MACHINE HEIGHT DEFINED BY THE POLE LENGTH DIAMETER TO SUIT THE FLUID FLOW MECHANICS AND DYEING KINETICS AND NOT THE SUITABILITY AS PER THE ID OF THE WINDING PACKAGE Let Us First Study The Easy One
Spindle Pole Length The Pole Length Has to be Calculated From Nos. Of Packages x 155 mm ( Traverse ) X Compression Percentage Say Standard is 1100mm spindle Length Recommended For Most Machines To Take Care of Pump Pressure losses in Longer Pole Nos. Of Packages On 1100mm with 155 mm Traverse = 7.09 Nos.. Assuming 10 to 15% Pressing in Precision Winding After Compression 1100 x 0.85 = 935 mm of Spindle length is Used and 1100 - 935 = 165 mm gets Avl for Additional Package To be Taken.
8 pkgs x 155mm x 0.85 = 1054mm The Balance 56 mm provides lee way for compression percentage from 10 to 15%. Also, traverse of pkgs vary from 155 to 165mm 1100 mm is the Clear Length Of Spindle from Bottom To Top . Addl length for Follow Down Cap has to be calculated Pressing Has Two Advantages 1 . It Increases the Loading of the carrier 2. It corrects the Density Variation from Winding and Provides adequate room for the additional package Eg : A 200 kgs machine, which has 7 pkgs per spindle design now on account of 8 pkgs per spindle design already gives 15% higher productivity and capacity expands to 230 kgs We will study the influence of Material Liquor Ratio and Pump Pressure for this expanded capacity after the capacity is further optimised with the spindle pole diameter In Short, it is recommended that 1100 mm Should Be The Pole Length for Optimum Compression and Optimum Loading Some Dyers Have As High As 18 Packages In One Pole The Risk Is Higher Pressure Losses along Spindle Axis as Liquor Moves Against Gravity To Higher Position Shearing Losses, hence poor dye diffusion coefficient Temperature Losses Turbulent Flow with Higher Pressure Head For Smaller Capacity Machines ( Less Then 100 kgs) Length Calculations Still Follow The Same Formula, however number of packages may be lower
CONCLUSION OPTIMUM SPINDLE LENGTH NOS. OF PACKAGES X TRAVERSE X COMPRESSION PERCENT RECOMMENDED SPINDLE LENGTH : 1100MM = 8 pkgs
SHORTER POLE LENGTH IS CRIMINAL LOSS OF CAPACITY What Happens, If Machine Capacity is 1000 kgs. Well In Such Case, One Uses Double Decker Carriers and Not Longer Poles
DYEING CARRIER WITH OPTIMAL LENGTH BUT SUB OPTIMAL LOADING
SPINDLE POLE DIAMETER Spindle Pole Diameter Currently Vary With Size Of Winding Tube Following Sizes of Dye tubes are Currently seen Type Cone Small Medium Medium II Medium III Large Large II Large III Large IV
ID of Dye Spring (mm)
OD of Spindle ( mm) 33 42 54 56 57 625 69 71 75
30 40 51 53 53 60 66 68 72
Technically There is a 3 mm Maximum Gap Between OD Of Spindle and ID of Dyespring Now, If you were to make a choice between the size of Dyespring Best Suitable For Your Investment Ideally, you will like to take the lowest size of Spindle, so that the yarn carrier will take maxim number of poles and hence the best output of a dyeing machine. Let Us Design Ideal Diameter Of Dyeing Spindle Spindle Pole Size will have following variables Flow Rate Flow Velocity Flow Pressure The Three Variables Should Be Able To comply with the Kinetics of Dye Absorption
What Does Yarn Dyeing Technology Say On Fluid Flow And Adsorption of Dyes
The rate of absorption or desorption of dye by textile fibers is controlled by several fundamental physico-chemical parameters. At a given dyeing temper- ature, these parameters include the: 1. Denier/ Count which is proportional to radius of the cylindrical fiber or the apparent radius of the non-cylindrical fiber; 2. Liquor ratio, i. e., the ratio of the volume of the dye bath to the volume of the fiber mass; 3. Distribution coefficient or ratio of the equilibrium concentration of dye in both the application medium and the fiber; 4. Diffusion coefficient of the dye in both the application medium and the fiber; 5. Thickness
of the
diffusion boundary layer at the fiber surface. In Short
Dye Absorption In The Dye Package is not influenced by Flow velocity changes, but flow velocity influences levelness, as we studied earlier. Flow Rate therefore only influences the Flow Velocity and lower Flow Rate give the optimum dyeing.
Speed at which a Dye Molecule Penetrates The Fibre Is Based On Diffusion Co-efficent And Not The Flow Rate. Higher The Diffusion Coefficent , Speed of Molecure Through The Medium Increases Normally Flow Rates of 30 Litres Per Kg Per Min Is Considered Optimum For Cotton Dyeing and Usually one full cycle of dye bath through a Package Takes around 30 seconds
Armed with this Basic Technology. now the challenge is to do Detailed Engineering For Designing An Optimum Spindle Design We have already established that Triangular Shape Provides The Best Mass Flow Rate of Dye Liquor We have also established that Length Of Dye Spring should be 1100mm The Last Variable is Diameter Of The Spindle Let us Study The Effect Of Change In Flow Velocity With Change In Spindle Diameter, considering the same Kinematics Viscosity Of the Dye Liquor And The Same Pressure For Given Flow Rate Of 30 Litres Per kg Per Minute Spindle Dia
Flow Velocity ( metres per Sec) 30 40 51 53 60 66
0,71 0,4 0,25 0,22 0,17 0,14
Flow Velocity = Q ( Flow Rate ) x 21.22 / Dia of Spindle Square. As we can see there is insignificant difference between flow velocity changes on account of Spindle Diameter. The Flow velocity is in first decimal place. That is the reason that even for lowest Spindle Diameter Of 30 mm, also the dyeing is uniform as long as other conditions are met. Therefore technically one can use 30 mm Spindles and yet get the optimum dyeing results. The biggest Advantage though will be Improved Productivity Of The Dyeing Machine to the extent of 50% higher Productivity Over The standard Size spindle pole of 53 mm largely used in the Industry. Say a 200 kgs machine, which has 7 packages per Spindle with Spindle Pole Diameter of 53 mm with spindle Pole Diameter changed to 30 mm now gives 15% Additional Capacity Vertically on account of pressing But Gives 40% Higher Productivity on Account Of Lower OD of spindle Say A Carrier Of 1450 mm Diameter for 200 kgs machine is loaded with 53 mm OD spindles and 190 mm space between spindles is now changed to 30 mm OD spindle. For 190 mm Space Gap Between Spindles for 53 mm OD spindle makes it 3.14 x 1450/190 24 Spindles Capacity : 24 x 1.2 kgs x 7 pkgs = 201 kgs Machine
When Spindle Size is Changed From 53 to 30 mm. Extra 23 mm Diameter is realised between Spindles Which is ( 3.14 x 53) - ( 3.14 x 30) = 72 mm Of Extra Dia Space Avl Between Each Spindle 24 spindles x 72 mm = 1728 mm Free Dia Space Avl 1728 mm /190 mm = 9 Extra Spindles 9 x7 x 1.2 kgs = 75 kgs Extra Production Extra Production On 200 kgs Machine By Optimising Length : ( 24 + 9 Extra Spls) x 1 Extra Pkg x 1. 2 kgs = 39.6kgs By Optimising Spindle Dia : (24 + 9 Extra Spls ) x 1.2 kgs x 7 = 277.2 kgs Total Expanded Capacity : Say 40 kgs + 277 kgs = 317 kgs Or 159 % of Original Capacity By Only Changing The Carrier, the Machine of 200 kgs now is capable of dyeing 317 kgs Material to Liquor Ratio which was earlier 1: 5 as per machine design now changes to 200 kgs = 1000 litres of water After Optimising Carrier 317 kgs = 1000 litres of water M: L ratio of 1: 3.17 However, while The Dye Spindle Gets Optimised In This System, The Precision Winding Machines normally cannot Process a dye centre with ID less then 42 mm. Though with random winder, one can still use 33 mm ID dye centres. However, with random winders, the package size is 1 kgs and not 1.2 kgs . (At Mantex Technologies, we have seen hundreds of Dyers Across The World Using 30 mm Spindle Diameter And Successful) In Order to Optimise Between Winding And Dyeing. We will Select 42 mm ID Dye centres compatible with Pole Diameter of 40 mm In Such case on a 200 kgs dyeing machine with 53 mm OD spindle 53 mm - 40 mm = 13 mm per spl space saving Free Diameter Space : 3.14 x ( 53-40 ) = 40.82 mm between each spindle
40.82 mm x 24 spindles = Around 980 mm Nos.. of Extra Spindles Possible = 980mm /190 mm = 5.15 spls ,( Say 5) Extra Production on 200 kgs Machine By Optimising Length : ( 24 + 5 Extra Spls) x 1 Extra Pkg x 1. 2 kgs = 34.8 kgs By Optimising Spindle Dia : (24 + 5Extra Spls ) x 1.2 kgs x 7 = 243.6 kgs Total Expanded Capacity : Say 34.8 kgs + 243.6 kgs = 278 kgs Or 140% of Original Capacity Further with 42 mm ID Dyespring and 180 mm OD at Density of 360 gms per litre Package Weight on Precision Winding is as Below
PARTICULARS CONICITY
TO FIND DENSITY, FOR A PARTICULAR WEIGHT 0 DEG 0 MIN
EMPTY CHEESE OD IN MM
42
FULL CHEESE OD IN MM
180
TRAVERSE LENGTH IN MM
155
VOLUME IN CC NET WEIGHT IN GRAMS.
3.731,03 1350
DENSITY IN GMS/C.C.
0,362
The Other Invisible Benefit is Package Weight Going up from 1.2 kgs to 1.35 kgs , though keeping the same density of only 362 gms per litre. Additional 12.5% Capacity Possible Precision Winder Makers Should Learn From This That It Is Not The Density Increase Which Can Give Productivity Increase In Dyeing, But Optimising The Dye Package Inner Diameter, Which Gives Desirable Density And Yet Higher Package Weight And Precision Winders Are Effective Contributors To It So Should Yarn Dyeing Machine Makers Review The Offerings Of Spindle Size of 53 mm As Standard Size
Spot The Smartest Guy Below
Nice And Clean Winding On Dyespring of 42 x 175mm with 180 mm OD
The Argument Forwarded For Larger Pole Diameter Are Larger Surface Area Available For Liquor To Penetrate The Package. Fact Penetration Of Dye liquor depends upon density of package and not surface area Dye Diffusion Does Depend Upon Material to Liquor Ratio. However M:L Ratio rationalisation does not need sub optimisation of spindle , but optimal designing of pressurised vessel. Though the smartest dyers are those, who can dye with lowest M: L Ratio of say 1: 3.5. We will study in one of the upcoming papers, the Optimal M: L Ratio for Dyeing of various substrates
Flow Rate Within A Package Can be Calculated AS Below F = (KPNpD)/(VT) Where, F = rate of flow of liquor per unit area K = Constant P = Pressure difference between inside & outside of the package N = No. of Channels per unit crosssection D = Diameter of Channels per unit crosssection V = Viscosity of liquor T = Wall thickness of the package
For Knowing The Exact Calculations, Please Send a Request
This Forms The Basis Of Pump Capacity Calculations For Given Loading on Carrier
CONCLUSION
The Optimum Size Of Spindle Spindle Shape : Triangular Spindle Length : 1100mm Spindle Pole Diameter : 40 mm Nos. Of Spindles On Carrier will depend upon the Diameter Of the Carrier Flow Rate , does not alter with spindle diameter Flow Pressure is Better with smaller Size Spindle and lower pressure losses Flow Velocity has Insignificant effect on dyeing with change in pole diameter ( For Texturizing, the direct pkg out of Machine saves cost of winding, so 53mm is ok)
RECAP Optimal Dye Package Weight : 1.2kgs ( Cotton) Optimal Dyeing Spindle : Triangular Optimal Spindle Spec : 40mm OD X 1100mm L OPTIMUM DYE PACKAGE CENTRE : MANTEX ECO CENTRE ULTIMATE YARN DYEING MACHINE : Thies ULTIMATE SOFT WINDING MACHINE : SSM IN CHINA THE SPINDLE SIZE IS 48 MM AND DYE TUBE SIZE IS 50 MM THE CHINESE ARE ALREADY SMART ENOUGH TO REDUCE THE SPINDLE DIAMETER FROM 53 MM BY 10% TO 48 MM. THIS IS WHY THE CHINESE COST OF DYEING BECOMES MORE COMPETITIVE THEN OTHER COUNTRIES CURRENT INDUSTRY STANDARD IS 53 MM AND EVEN BEFORE IT TAKES A GIANT LEAP TOWARDS 40 MM OD SPINDLE, ATLEAST IT CAN TAKE A LEAF OUT OF CHINESE YARN DYEING INDUSTRY TO REDUCE THE POLE DIAMETER TO 48 MM AND GET THE ADVANTAGE OF HIGHER PRODUCTIVITY AND BETTER M: L GAIN
SMART CHINESE YARN CARRIER WITH TRIANGULAR SPINDLE AND POLE DIAMETER OF 48 MM TAKING 50 MM ID DYE TUBE FIGHTING COMPETITION AGAINST YOUR 53 MM SPINDLE AND 56 MM DYE TUBE. ONLY THAT IT HAS A SUB OPTIMAL DYE TUBE AND NOT SPRING
YOUR TECHNOLOGY PARTNER FOR YARN DYEING
MANTEX ECO CENTRES DYEING WITH DIGNITY
31/9, NCP Towers,1ST MAIN, 2ND Floor, Mount joy extension, Bangalore-560019 INDIA Phone: 080-22427863, mobile: 9743877863
E-mail: info@dyespring.net; mantexindia2012@gmail.com
CHANNEL PARTNERS
COIMBATORE
Mr S Sriram Visveswar
94875 - 45184
DELHI
Mr Amitabh Ghosh : 9810150391
LUDHIANA
Mr A P Singh
:9356931429
CHANDIGARH
Mr Vijay Mishra
: 9311495506
SURAT
Mr Vijay Pathak
MUMABI
Mr MM Chaudhary : 9324615110
AHMEDABAD
Mr Dinesh Dhagat
: 93270-14844
CALCUTTA
Mr Anil Saria
: 9831047494
BANGLADESH
Mr Shohidul Islam
: 93276-10930
: 8801714077055