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Automation in the dyeing laboratory and its influence on accuracy in batch dyeing Hazel N Harvey and James Park Dymatecs Ltd. 25 Long Furrow Industrial Estate, East Goscote, Leicester LE7 8XJ Accurate laboratory dyeing techniques that correlate with bulk processing are essential if cost-effective coloration processes are to be established. This will result in the ability to utilise successfully blind dyeing techniques, which will assist in giving the desired quick response to the market and ensure that the material {s ‘right first time’. The laboratory dyeing activity has often been criticised by the practical dyer and reasons for this are discussed. Methods of improving laboratory accuracy are reviewed together with several recent developments in laboratory automation. The advantages and disadvantages of the latter are considered. Finally an approach to automation, developed by the authors. that is likely t0 be of value to the smaller dyeing laboratory is presented. INTRODUCTION Laboratory dyeing is a major function of any successful ‘commercial dyeing venture. The functions of the dyehouse laboratory have been admirably described by Thompson [1], and can be summarised as: (a) The evaluation and selection of dyes and dyebath additives together with the development of appropr ate application techniques (b) The preparation of databases for computer match prediction (€) The matching of shades for bulk production, Adequate laboratory dyeing services are undoubtedly required if the dyer is to be successful and meet all the ‘matching criteria demanded by the customer. Le. {a} Material on-shade and non-metameric {b) Level application (c). Satisfactory fastness properties (a) Satisfactory physical properties (@} Total processing (including coloration) within cost budget (Delivery on time ‘The dyer incurs severe financial penalties if he is unable to obtain reproducible dyeing, either as a result of poor laboratory dyeing or through deficiencies in bulk dyeing procedure (Table 1) TABLE 1 ‘Comparison of process costs Relative Technique cost Blind dyeing 100 No-adaition dyeing 105, Dyeing plus addition 130 Increasing commercial pressures, the need forefficient, short, robust and reproducible dyeing processes, often in conjunction with automation, have increased the impor- tance of the laboratory function, and in the modern dyehouse the laboratory should be considered as the nerve centte. High-quality laboratory dyeing allows blind dyeing techniques to be employed (Figure 1), Preparation ‘of catabases pence dyeabity | < J check | N ‘evaluation Figure 1 ~ Procedural routes involuing laboratory dyeing ‘Whether laboratory dyeing can be omitted through the adoption of computer matching depends to some extent on the philosophy of the individual dyehouse. In practice there are two altemative views but both depend on the availability of accurately prepared databases. The frst is the ideal approach in which all the potential variables. such ‘as water quality, dve strength and substrate dyeability. are correlated to the primary database. This approach re- ‘quites.a great deal of laboratory work including correlation diyeings, but it gives a high quality of prediction and allows for the application of such predictions directly to bulk «dyeing, The second approach is the “match of the day’ approach illustrated in Figure 2. This requires ess labora- tory work for determining the correlations and testing. but it is unlikely that the predictions resulting can be used rectly in bulk dyeing, USDC Volume 105 May/June 1989 207 1. | Prectet win primary database atry out laboratory dyeing under curent condtions (sub- oi sate, wale, dye. et) @ oy ‘o @ ‘Match of the day. which may be ‘alstactory for tanstor to buk dvecty, of Satisfactory for vanster attr visual correction, oF Satistaclory for vansfr alter computer correction, or Satistactory for Vanster after computer correction further laboratory dyeing | Figure 2 ~ "Match of the day’ option to calour matching, showing that matches may oniy seldom be directly transferable 10 bulk, but on the other hand calls for less laboratory effort REPRODUCIBILITY To obtain reproducible dyeing, whether this is on a laboratory, pilot plant or bulk scale, many factors in the dyeing process must be controlled or measured: ~ Quality of water supply Preparation of substrate Dyeability of substrate Weight of substrate ‘Weighing of dyes and chemicals, Dispensing method for dyes and chemicals Selection of dyes Standardisation of dyes Moisture content of dyes Moisture content of substrate at weighing Dyebath additives Liquor ratio pH of dyebath Machine flow and reversal sequence Time/temperature profile Sumner concluded 2} that inaccuracies in weighing and. measuring were the major source of off-shade batches. ACCURACY OF LABORATORY DYEING Litlle quantitative data have been published on the accu- racy of laboratory dyeing methods, and criticisms have been expressed about the reproducibility of laboratory dyeing on the grounds summarised in Figure 3 [3] and Table 2 [4 Many practical dyers presumably agree with this data since traditionally their firstaction is to subtract 10 to 15% from the quantities given in laboratory recipes before proceeding to bulk dyeing, This i, of course, counterpro- ductive since in most instances at least one addition is needed when the subtracted quantities (or more) have tobe subsequently added to the batch dyeing. To achieve a satisfactory service from the laboratory in any of the functions already mentioned. two conditions must be met: {@) The laboratory dyeing procedure must correlate with bulk practice (@) Accuracy of weighing and measuring must be of a high order in both the laboratory and the dyehouse. Table 208 JSDC Volume 105 May/June 1989 3 summarises the limits of accuracy that must be imposed if reproducibility to an accuracy of one AE {UPC 79) unit is to be obtained. Duplicate dyeings "O (0.5 MacAdam units Figure 3 ~ Variation in dyeings (Derby): dyeings 1-10 were ‘made simultaneously by using a standard formula under carefully controlfed conditions Inasurveyof dyehouses. it issurprising how many of he factors lsted in the section on reproducibility are different in the laboratory and the works. Those most commonly found at variance are listed below: ~ Water suppiy used Different substrates - Source of due sample Dye application method Liquor ratio pH of dyebath, Time/temperature profile Method of assessing shade, TABLE 2 Variations in dyeing (Brockes) Corresponding dye conen, diflerences 0) ANLAB (40) units Industial tolerances 12 First trials of computer prediction Under good conditions Under poor conditions 23 10-20 30 oF more fardware/software Satisfactory Database preparation Main source of ertor Laboratory weighing procedure TABLE 3 Morsture content of dye ture content of substrate hing of substrate Weighing of dyes. ausiliaries and chemicals Dye standardisation pH of dyebath tunis ‘As an example, the differences in the laboratory water supply and the works supply in one particular location alone gave a colour difference of AE = 3 between dveings, as determined using the JPC 79 equation Having correlated all the above variables. it is then necessary to obtain accuracy in measuring and weighing Dye solutions and dispersions must be prepared accurately using precision balanices, approved dissolving/dispersing techniques and high-quality glassware for make-up. When using traditional techniques this requires balances capable of weighing to the accuracy of 0.001 or 0.0001 of agram ‘a magnetic strivrer and a hot plate. The substrate for dyeing must also be weighed accu: rately. The dyebaths ate then prepared accurately from solutions of the necessary strength. The use of "pea shooter’ pipettes has been criticised [5] and these inade- quacies increase when ‘sawnroff' versions are employed in, fained hands. However, adequate and satisfactory results and good reproducibility can be obtained from the traditional approach if staff are properly trained. AUTOMATION IN LABORATORY DYEING Arrecent development in the automation of the traditional approach to laboratory dyeing has taken place. Firstly the dye is weighed on a balance interfaced with a personel computer (PC). When the approximate weight required is achieved, the PC instructs thal the required amount of solvent be added to a weighing flask (Figure 4). Then recipes held in a computer can be automatically prepared Jn a unit holding a large number of solutions prepared by the above equipment. The weight of the substrate is fed to the computer and automatic recipe calculation is included in the lunetion (Figure 5). Equipment of this type has been developed by a number of companies (see Appendix). The systems have a number of advantages and disadvantages, as are listed below. Advantages Good accuracy with less qualified staff Improved speed ~ 25% time required compared to manual methods Labour saving ~ 50 reduction advantages ~ Dye preparation and dispensing units requiring a lot of spac Many dyes have a short shell-ie in solution or disper sion form High cost of both units Requires minimum preparation of 50 dyebaths per hour to be cost effective Figure 4 ~ ICS-Gain Dyemaster Many dyehouses are unable to justify the capital exper diture of approximately £60.000 on such equipment. Ir addition, it has been shown that many of the solutions and, dispersions with a short shelf-life can, after only a few hours storage. introduce a colour difference of between three and five AE units into the dyeing, However, for large organisations that use only 2 relatively few dyes and where solutions are used rapidly and replaced such a system can give a short pay-back period in addition to improved. accuracy. JSDC Volume 105 May/June 1989 209 Figure 5 ~ Automated dispensing unit This is indicated in Table 4, based on two dyehouse operations in the USA, ‘TABLE 4 Cost advantages Company scenario Production 2000 tonnes per week Dyehouse laboratory staff 27 technicians on three shifts Dyes 808% of produetion from six dyes Laboratory dyeing capacity 4000 per week Installation of laboratory dispensing unit Cost £60,000 Effect Reduction of staff by six Pay-back, An alternative approach, especially for the smaller laboratory, isto use electronic pipettes (Figure 6) at a cost of around £500 each [6},Itis possible with such apparatus torepeat dyeing toacolour difference of 0.2 SE units (JPC 79 formula) with untrained technicians. An intermediate approach is to introduce a further PC into the system, this being interfaced with a balance for Weighing substrates. Recipes loaded into the PC are then calculated in terms of quantities of dye solution required based on the weight of substrate. This option allows freedom in both substrate weight used, which need not be restricted to exactly 5 or 10 g pieces, and the strength of dye solutions prepared Whilst all three methods described depend on auto: mated dye preparation equipment, the latter two use manual dispensing methods and the EDP can be utilised to advantage, TOTAL LABORATORY AUTOMATION The automation of the !wo most important areas in laboratory dveing has been described above. Total auto” 210 JSDC Volume 105 May/June 1989 Figure 6 ~ Electronic dispensing pipette (EDP) ‘mation is now possible but, of course, at a cost. Perhaps only the larger laboratories can afford to consider this, some of the areas involved are CAM/CAD/colour specifier shade selection ~ Computer colour matching = Dye storage facility — Weighing booth ~ Solution preparation ~ Automated dispensin, ~ Robot trolley Dyeing (controlled machine/MPI) — Computer quality control of dyeing/correction, Major developmentsin this area have occurred in Japan (7]. including the use of robotics to move dyeing tubes to the machine. Whether or not multiproduct injection techniques are required in the laboratory is debatable, especially since dyeing technology is moving to the use of alkin’ techniques, TABLE 5 Productivity comparison (8 h shift) Dyeings per Level of automation technician Fully automated 44 Automated solution preparation + EDP 40 TABLE 6 Limits of accuracy Matching tolerances Substrate variability in dyeing Varability in water supply Instability of dye solution Alispersion Computer prediction Variation in weighing of 5 Repeat knitting or card-wrapping for assessment Batch levelness Repeatability in bull. Laboratory dyeing reproduebility Spectrophotometer reproducibility We ourselves have developed a system that offers advantagesin cost to the smaller laboratory or where fewer dyes are used: the procedure is: 1. Dye is weighed in an extraction booth on PC-moni- tored balance and portion of solvent added 2. The material is transferred for pasting to magnetic stirrer/hot plate 3. PC instructs that the remainder of solvent be added to make up to the required volume 4, An electronic pipette is used for dispensing ‘The productivity of a fully automated laboratory com- pared with that from a laboratory employing such a small system is shoum in Table 5. Iris also worth considering the limits of accuracy that can now be achieved inthe dyeing process, and these are outlined in Table 6. ‘CONCLUSION “The era of the automated dyeing laboratory has arrived and itis now possible to carry out dyeings to a high level of accuracy with relatively unskilled staff, This wil increase the reproducibility of dyeing when the accuracy obtained 's linked with laboratory methods that correlate with the bulk process. Blind dyeing techniques can them be achieved, giving reduced costs with a quick response and ‘material that is ‘right fist time’. However, asis customary with all forms of automation, careful costelfectiveness studies are required to determine what level of automation can be justified in ermsof an appropriate pay-back period. SE UPC 79) = most end uses 10 ~ tight tolerances 03-05 ~ aeryle 0.15 ‘wool 15 = bulked c 4.0 30 3.0-5.0 ~ typical 25-30 = optimum <10 25 01s 02 02 ~ trained operative with class A pipette 0.8 ~ untrained operative swith EDP 02 REFERENCES, TM Thompson, ‘Duvaowse lboratony practice (Bradford: SDC. 1983 2 HE Summer, ISDC., 92 (1976) 84 4 RE Derty. Color technology inthe textile industry’ Resear ‘Triangle Park, USA; AATCC. 1983) 7 4. A Brockes, “Color technology in the textile industry’ Resear ‘Tranale Park, USA, AATCC, 1983) 177 5, Gaunt, JSDC, 108 (1987) 225, 6. HIN Harvey ane d Park, IS.D.C.. 104 (1988) 138, 7. ‘Flexible dyeing lhoraton” (Sumitomo Chemical Co, Led 1988} APPENDIX Makes and country of origin of automated dispens- ing units Color Agent Systems, Japan CIR aly Daika, Japan Excom, Japan Emori Shoji. Japan ICS-Gain. UK and Taiwan Ishizaka Shoji. Japan Kurabo, Japan Nippo Kayaku, Japan Sakata Shokai, Japan Sumitomo. Japan Technorama, kaly Toyobo, Japan ‘Tsuyakin Koavo, Japan JSDC Volume 105 May/June 1989 211

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