Balancing of machines for complete process house :Part-6 Finishing (Softener application)

For finishing purpose stenter machine (4 chambers) will be used and fabric will be given softening treatment.

Machine working speed: 40 m/min, M/c utilization= 80%

Total production per shift (8 hours or 480 min)= (speed x utilization x 480)/100

= (40 x 80 x 480)/100 = 15,350 meter

Total fabric to be dyed= 50,000/-

15,350 meter fabric treated in 8 hours

50,000 meter…………= (8 x 50,000)/15,350 = Approx 26 h

Balancing of machines for complete process house :Part-7 Finishing (Zero-Zero)

For this purpose one Sanforizing (zero-zero) is needed to dimensionally stabilize cotton fabric.

Machine working speed: 40 m/min, M/c utilization= 80%

Total production per shift (8 hours or 480 min)= (speed x utilization x 480)/100

= (40 x 80 x 480)/100 = 15,350 meter

Total fabric to be dyed= 50,000/-

15,350 meter fabric to be preshrunked in 8 hours

50,000 meter…………= (8 x 50,000)/15,350 = Approx 26 h

Balancing of machines for complete process house :Part-5 Dyeing

For this purpose one CDR (Continuous Dyeing Range - Open width) is required

Machine working speed: 40 m/min, M/c utilization= 75%

Total production per shift (8 hours or 480 min)= (speed x utilization x 480)/100

= (40 x 75 x 480)/100 = 14,400 meter

Total fabric to be dyed= 50,000/-

14,400 meter fabric treated in 8 hours

50,000 meter…………= (8 x 50,000)/14,400 = Approx 28 h

Balancing of machines for complete process house :Part-4 Mercerization

For this purpose one Mercerizing machine (chain type) is required.

Machine working speed: 40 m/min, M/c utilization= 75%

Total production per shift (8 hours or 480 min)= (speed x utilization x 480)/100

= (40 x 75 x 480)/100 = 14,400 meter

Total fabric to be mercerized= 50,000/-

14,400 meter fabric treated in 8 hours

50,000 meter…………= (8 x 50,000)/14,400 = Approx 28 hrs

Balancing of machines for complete process house :Part-3 Scouring and Bleaching

For this purpose one Pre-treatment Range (PTR) is required.

Machine working speed: 60 m/min, M/c utilization= 80%

Total production per shift (8 hours or 480 min)= (speed x utilization x 480)/100

= (60 x 80 x 480)/100 = 23,040 meter

Total fabric to be pretreated= 50,000/-

23,040 meter fabric treated in 8 hours

50,000 meter…………= (8 x 50,000)/23040 = 17.36 hrs

Balancing of machines for complete process house :Part-2 Processing on  Singeing cum desizing machine

This will be used to remove protruding fibre from the surface of fabric by singeing process followed by  desizing of fabric.

Let Machine working speed: 120 m/min, M/c utilization= 75%

Total production per shift (8 hours or 480 min)= (speed x utilization x 480)/100

= (120 x 75 x 480)/100 = 43,200 meter

Total fabric to be singed and desized= 50,000/-

43200 meter processed in 8 hours

For 50,000 meter = (8 x 50,000)/43200 = 9.25 hours

Balancing of machines for complete process house :Part-1 (Introduction)

•      Machine balancing is a most important part of any process house to run production smoothly.

•      Let us take example of dyeing of 50,000 meter 100% cotton medium weigh quality (150 gsm) fabric to understand this

Process flow:

To start it, let us have following process flow:

Grey cotton fabric------Singeing & Desizing------Scouring------Bleaching-------mercerizing-----dyeing-----finishing----finish folding

Let us have following type of machines to carry out processing of 100% cotton fabric:

•      Singeing cum Desizing

•      Scouring & Bleaching (Pretreatment renage-PTR)

•      Mercerizing

•      Continuous dyeing range (CDR)

•      Softening & Drying on stenter

•      Sanforzing (Zero-zero)