Dye House

Dye House is a building in which dyeing is carried on.
For improving quality and fast turn arounds, there is a need of fully integrated dye house network that comprises of a vast range of automated system components properly synchronized to each other. With the proper integration of dyeing equipment into a sound organized network, it is quite obvious that the dyehouses can give away its valuable resources very cheaply.

A typical Dye house network should be equipped with the machines that are capable of performing a number of operations like dyeing, heat setting, compacting, stentering, hydro-extraction, brushing and washing etc. Another vital task is the control of the system. Although every single device from the color kitchen to dyeing machines these days are PC-controlled, however modern dye houses prefer to employ a Dye house automation system.

Dye house automation system ensures that the machines are able to synchronize with each other and can optimise their capacities. Apart from this the automation system facilitates linking of the order management with the necessary machine control units. This helps to complete a fully integrated dye house network. The diagram that follows next gives a perfect example of Dye house that is complete in every respect. Most modern dye houses are today following the concept of totally networked Dye House.

A perfect dye house should meet the following criteria, that are given below:
A perfect dye house should meet the following criteria, that are given below: Computer aided Dyeing system- By implementing a Computer aided Dyeing system it has been possible to cut down on both costs and time. For example it has been found that by using the system there has been reduction in the acrylic dyeing batch time by at least 30 percent.

Modern laboratories- New formulas are first tried in the lab before implementing in production. If there is closer liquor ratio agreement between the production and laboratory, better would be the final result.

Package preparation- Latest stainless steel spacer should be used for holding the shape of package ends. This allows for smooth unwinding. Though backwinding to paper cones along with intermediate lubrication is more in vogue, but that costs money and time. Dyers must master new ways to bypass the idea of backwinding.

Package handling- Increasingly the dye houses are insisting on the technology of robotic package handling. Use of Robotics demands uniformity. Robots need the packages to be placed in a specific location.

Quality- In today's fiercely competitive market, if a manufacturer doesn't have a consistent quality, probably they just can't stay put in business. Therefore a manufacturer must insist on receiving only quality and genuine products from suppliers. In fact adhering to different International quality standards that has written down procedures and manuals is now more than just a norm. There are now various information technology companies that are into the field of operations management. If they are called for and allowed to work on a program at a dye house and follows up it through the completion, then a dye house will be equipped with a totally integrated data base system. This will offer solutions in every sphere of operations like manufacturing, production, financial, forecasting, planning, scheduling and delivery.

Challenges of globalisation- Over the years the supply of material has changed. Today suppliers are challenged from across globe with products of superior quality, and low cost. For example yarn suppliers continues to search for non-branded suppliers of polyester and acrylic for replacing more costlier brand names. Today's mantra is innovate or perish.

Savings in energy- Saving in energy, chemicals and water is now vital for survival of any dye house. Machine vendors are now constantly redesigning dye machines that has the lowest liquid to goods ratio. For example a high pressure dyeing machine consumes much less water for processing. The liquid to goods ratio being 1:5 (i.e. to process 1 kilogram of fabric, five litres of water are used) now compare this to traditional units that are fitted with conventional winches whose water to liquid ratio is in the range of 1:15 or even sometimes 1:20. Survival for such dye houses is impossible.

Maintenance- It is a general tendency to view maintenance time as an opportunity lost to manufacture dyed sales yarn. Preventive maintenance is clearly less expensive than unscheduled halt and a spoiled dyeing.