In the process of semi-continuous dyeing that consists of pad-batch,
pad-jig, pad-roll the fabric is first impregnated with the dye-liquor in,
what is called a padding machine. Then it is subjected to batch wise
treatment in a jigger. It could also be stored with a slow rotation for many
hours. In the pad-batch this treatment is done at room temperature while in
pad-roll it is done at increased temperature by employing a heating chamber.
This helps in fixation of the dyes on to the fibre. After this fixation
process, the material in full width is thoroughly cleansed and rinsed in
continuous washing machines. There is only one point of difference between
Continuous and semi-continuous dyeing process is that in semi-continuous
dyeing, the dye is applied continuously by a padding. The fixation and
washing remaining discontinuous. Liquor Ratio in semi-continuous dyeing is
not of much importance and is not taken as a parameter. One of the widely
used techniques for semi-continuous dyeing process is the Pad Batch Dyeing a
schematic diagram is given here for the semi-continuous dyeing process.
The following table shows some of the important machineries for
semi-continuous and continuous dyeing processes.
| Make up |
Process |
Equipment |
| Woven and Knitted Fabric, tufted carpet |
Rope |
Continous |
Padding Machine for Piece in rope form |
| Open width |
Semi Continous |
Pad batch (or carp-o-roll for carpet) |
Padding Machine+ Washing Machine |
| Pad batch (or carp-o-roll for carpet) |
Padding Machine+ Washing Machine |
|
Pad -jig |
Padding Machine+ Jigger+ Washing Machine |
| Continous |
Pad stream |
Padding Machine+ Steamer+ Washing Machine |
| Pad Dry |
Padding Machine+ Stenter frame+ Washing Machine |
Pad Batch Dyeing is one of the widely used technique for
semi-continuous dyeing process. It is mainly used in the dyeing of
cellulosic fibre like cotton or viscose (knit and woven fabric) with
reactive dyes. Pad batch dyeing is a textile dyeing process that offers some
unique advantages in the form of versatility, simplicity, and flexibility
and a substantial reduction in capital investment for equipment. It is
primarily a cold method that is the reason why it is sometimes referred to
as the cold pad batch dyeing.
The technique or process used in pad-batch dyeing starts
with saturating first the prepared fabric with pre-mixed dye liquor. Then it
is passed through rollers. The rollers, or padders, effectively forces the
dyestuff into the fabric. In the process, excess dye solution is also
removed. After removal of excess dye stuff the fabric is subsequently "batched".
This batching is done by either storing it in rolls or in boxes. It takes a
minimum of 4-12 hours. The batches are generally enclosed by plastic films.
This prevents absorption of carbon dioxide and water evaporation. Finally as
the reaction is complete the fabrics are washed. This is done by becks,
beams, or any other washing devices.