A.T.E.’s continuous dosing system to eliminate variations in CPB dyeing
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A.T.E. Enterprises' continuous dosing system addresses inconsistencies in dyeing processes, specifically the critical 1:4 chemical to dye ratio in cold pad batch dyeing. By employing synchronized pumps regulated by a PLC and real-time feedback from flow meters, the system ensures precise dosing without manual intervention, leading to uniform fabric tones. Benefits include automatic regulation, overflow prevention, and consistent dyeing results.
A.T.E.’s continuous dosing system to eliminate variations in CPB dyeing
- 1. A.T.E. Enterprises Private Limited A-19 CTS 689, Veera Desai Road, Andheri (West), Mumbai - 400 053, India T: +91 22 6676 6100 E: automation@ategroup.com W: www.ategroup.com Application note A.T.E.’s continuous dosing system to eliminate variations in CPB dyeing Problem In the cold pad batch (CPB) dyeing process, it is vital to maintain the exact 1:4 ratio of chemical to dye to produce a dyed fabric that is uniform in tone and hue. Conventional systems designed to maintain this 1:4 ratio consist of a two-part metering pump in which the colour and chemical are dispensed based on the total liquor replenished into the trough. However, due to the absence of a feedback loop, it is not possible to consistently maintain the chemical to dye ratio of 1:4, affecting the fabric in tone and hue and leading to depth variation along the length of the fabric dyed. Solution A.T.E.’s continuous dosing system eliminates this variability in the chemical to dye ratio through tight synchronisation between the two pumps with the help of a PLC and feedback from the flow meter.
- 2. As shown in the diagram above, both the dye and chemical pumps are regulated through a feedback system that receives real time input from individual flow meters. Thus, the ratio is kept constant by controlling the speed of the chemical pump with help of a VFD (variable frequency drive) that is in sync with a dye pump. Even a small change in the flow of the dye pump is sensed and the chemical pump will act quickly to keep the ratio constant. Benefits: Level sensor feedback from the trough ensures that there is no overflow of liquor No manual intervention required; pumps are automatically regulated as long as the dosing station or the fabric transport is switched on Actual dosing feedback is received from the flowmeters and is compared and corrected continuously with the set point threshold, thus ensuring consistent dyeing results