Lab to bulk shade variation in terry towel fabric for RFT dyeing

摘要

The purpose of this study was to reproduce a sample in the lab, to develop a recipe for large scale production and for Right First Time (RFT) dyeing of terry towel. A study of lab to bulk variation was used to identify material, method and important parameters to meet customer demands. Reproduction and reprocessing of material adds manufacturing cost and in the entire bulk, mechanical and physical properties are adversely affected. The performance of the fabric is also changed, as its viscoelastic behaviour is affected, depending upon the parameters of the wet processing. This study was aimed at standardising the mechanical and geometrical properties of the terry towel to obtain RFT fabric.To combat lab to bulk variation in exhaust dyeing operations, processors have adopted the RFT concept, to ensure the reproducibility of shades that may be marginally affected variations in dye-bath chemistry and auxiliary concentration. Critical actions taken to improve lab to bulk consistency are a means whereby cost reduction can be obtained to counteract the pressures being increasingly encountered by the textile coloration sector. In this project, it was also concluded that, due to the lack of knowledge about RFT dyeing and the prevalence of manual operation, desired RFT outcomes are not being achieved. This study gave successful results as compared to the conventional fabric dyeing process in a textile unit, so that a roadmap can be adopted for any wet process, with cost savings and a bottom line benefit.