Quality problems like color spots and oil spots in the dye factory are the biggest headache for the management, because those issues may affect not only the delivery date and output, and in the case of bad solution, there will be compensation and other problems. The following is the experience and solution that we summarize in long-term production practice, and we'd like to share with everybody here.
If you want to solve the problem of color spots and oil spots, you should distinguish color spots and oil spots first, and then find the root cause of the problems, and according to actual situation analyze the problems and find the solution. Among them, the color spots include colored flowers, color points and color spots, while the oil spots include silicon oil spots, wet wipe spots and oligomer deposition spots. The causes of different manifestations are different, and the solutions are also different.
Color spots can be divided into dark spots, light spots and alkali spots. The dark spots were mainly caused by the fact that the fabric oil stains had not been cleaned before the pretreatment, and the color and luster of the oil stains were dark during dyeing. Or too much foam in dyeing bath, and foam and the mixture of flower sweater, dye on the fabric; Or dye agglutination in different circumstances and become dark spots or water quality calcium magnesium ions too much with dye binding to the fabric and other reasons. To be targeted for treatment, such as pretreatment with Qingyuan Hongtu company's low foam high-efficiency oil removal agent HT251 for refining.
If you want to improve the water quality, choose Hongtu sequestering agent GB, which can improve the water quality while adding dispersant solubilizer to prevent dye agglutination, and timely cleaning cylinder in reproduction. Light spots are mainly from the uneven management, causing that some parts of the poor fur refuse to dye, or with refusal to dye material, or uneven mercerizing, uneven or semi-product to dry, or cloth with dissolved sodium sulphate, soda ash and other solids, or dyed before drying drops of water, or dyeing processing soft finishing with additives such as stains. Similarly, it must be targeted for treatment, such as the use of Hongtu's strong osmotic refining agent DAB to strengthen the pretreatment; Cotton pre-treatment can also be enzymatic bioremediation if the enzyme M1202 and the enzyme M1206, directly decompose impurities in the fabric. Attention must be paid to the selection of pretreatment auxiliaries and the production management must be strengthened. Alkali spots are mainly pre-treatment (such as bleaching, after the light) after the alkali removal is not clean or uniform, resulting in alkali spots, so it must strengthen the pre-treatment process of alkali removal process.
Color flowers and color dots belong to one kind of expression form of color spots. Color flower is the most common quality problem in dyeing process. The main reasons are: process formulation and operation, equipment, dye, water quality and additives, etc. If the formulation process is unreasonable or with improper operation can produce color flowers; such as after dispersing dye dyeing polyester, the temperature in hot setting machine oven is different also easy to produce the color difference or the color flower; the insufficient pump force of the rope dyeing machine is also easy to cause the color flower.
For example, dyes are easy to aggregate, with poor solubility and poor compatibility, and too sensitive to temperature and PH are easy to produce color flower and color difference. Such as poor water quality, resulting in the dye and metal ions binding or dye and impurities coagulation caused by the phenomenon of color flower and light color. It can reduce the emergence of color flower by adjusting the technology, equipment, dye and water quality, and in the meanwhile through the corresponding additives to solve the problem, such as the selection of appropriate permeant, homogenizer, chelating dispersant, PH value control agent and etc.
Among them, osmotic agent should not only consider the osmotic effect but also consider its application effect in different temperature and pH range. The non-ionic osmotic agent produced by Hongtu Company can well solve this problem. When leveling agent you must consider the effect of dispersion and dissolution of the dye, and the effect of retarding dye migration and osmosis and even the complexation of metal ions in water, and must consider its applicability, bubble PH for coloring rate influence factors. Hongtu cotton leveling agent 2022L can be used to improve the color of flowers, spots and other phenomena.
There are many reasons for the emergence of color dots, such as white dots, which may be the reason that the immature cotton does not dye, or the solid such as soda ash, Yuanming powder is stained on the cloth, causing non-dyeing parts and other reasons. Dye particles are too large or easy to coagulate and form color points; The undissolved dye enters the dye solution and sticks to the fabric to form color spots. Water quality is not good, flocculent into the vat will produce color points; Equipment is not clean: the dye tank of tar drop caused by color dots; Improper selection of additives results in dye agglutination, or there is too many additives foam and the foam and dye combine into colored foam, stained with the fabric to form color points; The auxiliaries precipitate and dye bond to the fabric and the equipment, and the agglutinates on the equipment will transfer to the fabric and cause color spots.
Oil spots which are different from the color spots result from the auxiliary agent spot that produces mainly in the finishing process. When in the process of hand feeling, the demulsification of silicone oil may cause silicon oil spots; Do dry and wet rubbing fastness lifting agent, the stability of the agent is not enough or may cause wet rubbing spots when reacting with other substances; In the dyeing and finishing process, some oligomers precipitate out and get on the oil spots formed on the cloth surface. If some factories choose non-ionic surfactant is not suitable, resulting in the turbidity point above the non-ionic surfactant itself precipitation, adsorption dyes and tar-like substances stained on fabrics and equipment, but cause quality problems. If the choice of defoaming agent is improper, the oil will float and cause dark oil spots; Some dyeing VAT cleaning and maintenance is not enough, the tar in the VAT stained on the fabric and formed a very difficult to remove the block of oil.
Oil spot is more difficult to deal with than color spot, and its risk is higher. Improper treatment may cause secondary problems, sometimes even unable to repair, and eventually scrap the cloth. Therefore, in the process of treatment, the choice of additives used is very critical. The application effect and application technology of silicon removal agents produced by different manufacturers are often very different, such as the application effect of the silicone spot stripping agent 1050E produced by Hongtu Company is very obvious. Only professional oil spot remover can be selected to remove the wet spots. The oil stain remover produced by Hongtu Company combined with special targeted technology can effectively solve the problem of wet spots in the dyeing factory. Communication and follow-up between the application engineer and the dye plant manager are also important throughout the process.