Jigger dyeing machine

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 fo

Jigger Dyeing Machine

Prepared By : Mazadul Hasan sheshir

Piece Jig Dyeing

1. Fabric is treated in open width and is passed through the dye bath rather than immersed in to a dye bath and this is repeated

2. There is a degree of tension on the fabric and is therefore used on woven fabrics and not knits

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.

Jigg or jigger dyeing machine

1 Jigs exert considerable lengthwise tension on the fabric and are more suitable for the

dyeing of woven than knitted fabrics

2 There are mainly two types of jigger dyeing machine One is open jigger dyeing machine

and other is closed jigger dyeing machine.

3 The number of ends or turns depends upon the type of the fabric and also the

percentage of the shade.

4 It exerts lot of tension in the warp direction and because of this normally knitted fabrics

is not dyed in jigger dyeing machine.

Study of Jigger Dyeing Machine.

Main parts:

A B

D D

E F

A=Let off roller

Flow Diagram

Fabric tension: 5 to 70 kg/cm²

Speed: 10 to 150 m/min

Fabric width, max 3800 mm

Roller width, max 4000 mm

Roller diameter: 270 mm

Roller batch dia : 1000 or 1230 mm (dependent on the type of m/c)

Fabric height: 365 or 475 mm (dependent on the type of m/c)

Fig: Schematic diagram of Jigger dyeing machine

Technical Advantages:

• Fabric Rope Controller

1. automatically calculates the r.p.m ensuring exact fabric

2. speed and tension providing excellent dye penetration

3. Automatic sampling point selection

•. Direct drive of the main rollers

by frequency controlled motors with brake current return provide a considerably shorter braking distance compared with hydraulic

•. Loading/unloading device

for crease-free loading/unloading of the fabric (Option)

JIGGER DYEING MACHINE

1. Based on experience and developments in industry and controller technology, the Thies-Jigger is developed

2. Suitable for processing fabric at atmospheric temperatures of up to 98°C and in HT execution up to 143°C, this Jigger is especially recommended for the treatment of crease sensitive, permeable and non-permeable articles in open width form, offering optimum flexibility for the finishing of all modern fibres and blends.

3. Incorporating innovations in step less tension and material speed control and with an economical dye trough designed for uniform dyeing in short liquor ratio conditions.

4 An industrial PC, proven in the exhaust dyeing industry, including PLC and a fabric rope monitoring system is used for the complete machine control, ensuring the maintenance of optimum processing conditions.

Jigger dyeing machine

Based on experience and developments in industry and controller technology, the Thies-Jigger is developed Suitable for processing fabric at atmospheric

temperatures of up to 98°C and in HT execution up to 143°C, this Jigger is especially recommended for the treatment of crease sensitive, permeable and

non-permeable articles in open width form, offering optimum flexibility for the finishing of all modern fibres and blends Incorporating innovations in step less tension and material speed control and with an economical dye trough designed for uniform dyeing in short liquor ratio conditions.

An industrial PC, proven in the exhaust dyeing industry, including PLC and a fabric rope monitoring system is used for the complete machine control, ensuring the maintenance of optimum processing conditions.

These machines have been used for a long time to treat medium-size lots of woven with an

open-width exhaust dyeing process The fabric moves while the liquor stands still, except for the very latest machines, which are also equipped with a circulation pump The fabric pieces are sewn together tail-to-head, forming a sort of “ribbon” At the head and at the tail of the ribbon two cloths are added (4–5 m long) to allow the regular dyeing of the whole pieces, also leaving the machine drawn-in once the dyeing process has come to an end The assembled pieces are taken down from a roll, pass through the liquor (they are kept in the correct position by means of transport cylinders and a tension equaliser, which avoids the formation of wrinkles) The fabric is then wound on a takeup roll until the dyeing process has ended The piece through speed and tensions are adjusted by special devices to avoid any change in dimensional stability, above all when treating lightweight fabrics and/or delicate fibres

Jiggers Theory

The maximum diameter of the roller can be 1,450 mm with a width of the piece of cloth ranging between 1,400 and 3,600 mm The piece through speed is adjusted between 30 and 150 m/min and kept constant during the whole operation Also the tension must be constant and

it can be adjusted between 0 and 60 kg Since the passage time is very short, dyeing occurs above all on the fabric wound on the rolls The composition of the liquor absorbed must be as uniform as possible on the whole width and length of the fabric piece; for big lots, many additions may be necessary to avoid the so-called head-tail defects Lightweight fabrics (viscose, nylon) that are stretched excessively during the takeup step can show “shading” defects Jiggers work with a quite low liquor ratio (from 1:1 to 1:6).Together with standard atmospheric systems, builders also offer HT jiggers inside autoclaves working at high pressure Jiggers are suitable for dyeing all type of fibres

6

Jiggers Theory

1. Direct drive of the main rollers via frequency controlled three-phase motors with brake drive current return (energy saving)

2. A dye trough design ensuring minimum possible liquor ratio

3. Fabric rope monitoring control system for precise calculation and control of the fabric speed and tension

4. Uniform dyeing conditions in the dye trough, independent of the batch size

5. Water meter for controlled rinsing

6. Dosing of dyes and chemicals dependent on the fabric length passing through the dye bath

7. Addition pressure pump for shading corrections and dosing

8. On the HT-Jigger dosing under pressure possible

9. External pump and heat exchanger ensure uniform liquor heating and circulation

10. Sidewise displacement of the main batch roller

11. Analogue level for dyeing kier

12. Floor level track system*

13. Easy maintenance

Significant innovations in the process technology ensure modern utilization

1. Integrated fabric transfer system with spreader for crease-free loading/unloading of the fabric

2. Centre driven frequency controlled motor drive for loading/unloading of the fabric from and to an A-frame

3. Function “Salt dissolving” with electric stirrer and automatic brine transfer into the kier

4. Self cleaning liquor filter

5. Chamber roof heating

6. Spraying device in the dye trough for intensive rinsing of the fabric

7. Moisture extraction device used in the unloading process

8. Chamber roof cleaning spray

9. Automation of the loading/unloading port*

Options:

Fig: Atmospheric jigger dyeing machine

1. Slow start/stop.

2. Trough is entirely built in stainless steel AISI 316

3. The door of machine pneumatically lifted & lowered

4. To observe inside of the machine large windows are provided

5. The doors and windows are sealed with special gasket against steam escape

6. To prevent dripping of condensate there are steam coils in the hood

7. Dye liquor circulation by means of pump this circuit is used for better leveled dyeing or switching the flow on the spray pipes for more efficient washing or raising

8. Dye liquor filter outside the machine with large filtering surface

9. Service tank for dye stuffs & chemicals

10. Semi or fully automatic with microprocessor (optional)

Technical characteristic:

This machine is for the jig dyeing at high temperature and high pressure conditions of all types of thick, thin fabrics, Terylene, chemical fiber and real silk fabrics Under normal temperature and pressure conditions, it can replace common jigs to dye all types of natural silk, rayon and polyamide fiber The machine

is reasonably structured, with good safety and capacity, easy to maintain

High-temperature High-pressure Auto jig

1. Jigs exert considerable lengthwise tension on the fabric and are more suitable for the dyeing of woven than knitted fabrics.

2. In textile preparation due to the swelling and dissolution of size, which makes the fabric slippery and unstable in roll form

3. The low liquor ratio makes washing-off difficult

4. There is little mechanical action in a jig machine and it is less suitable where vigorous scouring is required before dyeing

5. Moiré effects or water marks may arise on some acetate and nylon fabrics because of pressure flattening the structure of the rolled

fabric

Limitations of Jigger Dyeing

Some critical problems related to the conventional jigger dyeing machines ( which are minimized in the modern day machines) The major problems are side-to-centre color variations, called listing, and lengthways color variations, called ending.

Other problems are

1. Temperature control from side-to-side and end-to-end of the roll

2. Tension control from end-to-end

3. Constant speed control from end-to-end

4. Prevention of creases

5. Prevention of air

problems related to the conventional jigger dyeing machines

NOTE : but have limited application on fabrics which are tension sensitive such as crepes , flat crepes , knits , net fabrics and elastomeric warps etc.

Some wovens are conveniently dyed on jigger are ,

MAXI Hydraulic Type Jumbo Jigger Machine

SWR1400 Large-Size Jig Dyeing Machine

HD618 Constant Temperature Dye Jigger

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

Maintenance:

1 Yarn Manufacturing Technology

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