Experiment no.

: 01

Experiment Name: Application of Computer in Textile Wet Processing

Introduction: The efficient working of textile processing and manufacturing are greatly depend
on automation that requires the application of computer in textiles specially Wet processing
Industry. The quantitative and qualitative product is produced by applying technically developed
features in machineries by using computer which assist in production with required quality. The
technical features developed in modern textile wet processing machineries by using automation,
electronic controlling system & computer assistance.

Computers are extensively used in wet processing in the textile industry to improve process
control, increase efficiency, and reduce waste. The application of computers in wet processing can
be broadly classified into three categories: process control, data analysis, and simulation.

Dyeing Machine program: https://www.youtube.com/watch?app=desktop&v=gd3mbeACcN8

Auto dispensing: https://www.youtube.com/watch?v=6GYw3FIxMBk

ETP: https://www.youtube.com/watch?v=Zwhv0NTROf0

Fig: Application of Computer in Textile Wet Processing

The application of computer controlling system in textile wet processing machines has the
advantages:
 ● Increase in quality and productivity of the processing material.
● Process control parameters are controlled by it, also chances of breakdown in machine also
reduces.

For an example if the dye solution level in the trough of the dye padder is reduced it is sensed by
the pressure transducer which gives activation signal to the dosing pump of the dye liquor due to
which the dye level is maintained and chances of colour variation in the batch decreases and
continuous production can be obtained.

If we consider the application of computer in textile wet processing the application can
mainly be categorized as bellow

A. Applications of computer in testing equipment for textile wet processing.

B. Applications of computer in process machineries for textile wet processing.
C. Applications of computer in process management for textile wet processing.
D. Applications of computer in overall process management for textile wet processing.

Computer Aided Testing Equipment in Textile Wet Processing

There are some testing equipments that are used in wet processing laboratory they are,

1. Spectrophotometer
2. Data color
3. Buffer Calculator
4. Different kinds of computer aided fastness tester.
1. Spectrophotometer

Spectrophotometer usually used in textile to measure the efficiency of dyeing and k/s value ect.it
is used in the quantitative measurement of the reflection or transmission properties of a material
as a function of wavelength. It is more specific than the general term electromagnetic spectroscopy
in that spectrophotometry deals with visible light, near-ultraviolet, and near-infrared, but does not
cover time-resolved spectroscopic techniques.
 Fig: Spectrophotometer

Spectrophotometry involves the use of a spectrophotometer. A spectrophotometer is a photometer

that can measure intensity as a function of the light source wavelength. Important features of
spectrophotometers are spectral bandwidth and linear range of absorption or reflectance
measurement.

2. Datacolor

In testing laboratory it can be used to match color recipe before going to bulk production. With
increasing pressure for smaller production lots, shorter time to market and intricate blends, the
only way to optimize time, recipe development and production is to have a broad knowledge base
taken directly from dyers themselves. Datacolor process is a unique software solution that uses the
knowledge of the experts in your company to help you manage dyeing recipes and entire processes.
It automatically creates or specifies the best production recipe for any color, dyed on a specific
fabric and for a particular customer.

3. Buffer calculator

It is used to calculate the amount of acids/alkali required to maintain a proper buffer solution for
the use.

4. Different kinds of computer aided fastness tester

Fastness properties of fabrics should be tested accurately for the production. For that computer
assistance are taken for better results. Few testers are as bellow,

AATCC Rotary Crockmeter, automated pilling (automated pilling Ici Pilling Testing
Machine (TSE-A010)) and abrasion tester, automated percpirometer etc.

Many more applications are there in the testing lab of wet processing as an example to test the
fabric quality there are few more computer aided machines.the application of computer is day by
day increasing in various places with the improvement of technologies and almost everywhere
computer assistance can be used for correct results.

Computer Aided Process Machineries in Textile Wet Processing

In textile wet processing there are many pretreatments processes are carried out before sending the
fabric to the dyeing and printing sections. As an examples singeing where optimum temperature
required, scouring, bleaching, mercerization where ample amount of tension required which can
be maintained by applying automation or computer assistance. After than that fabrics sent to
dyeing and printing section.

⮚ For dyeing sections

For dyeing procedure, the accuracy of process is required for a proper dyeing process there are
some machineries which comes with computer assistance in the machine for a better performance.
There are some dyeing machines which has software that work independently after the command
that is made by the operator. Digital monitor with information of m;l ratio, chemical ratio, machine
speed, temperature, pressure etc criteria can be maintained for better dyeing effect.

⮚ Computer match prediction for fluorescent dyes by neural networks

Fluorescent dyes present difficulties for match prediction due to their variable excitation and
emission characteristics, which depend on a variety of factors. An empirical approach is therefore
favoured, such as that used in the artificial neural network method. In this paper, the production of
a database with four acid dyes (two fluorescent and two non-fluorescent) is described, along with
the large number of mixtures dyeings that were carried out. The data were used to construct a
network connecting reflectance values with concentrations in formulations. The results show that,
although time consuming, this approach is viable and accurate.

⮚ Datacolor

During the bulk production accurate formulation of recipes datacolor also used.

⮚ Ultrasonic-assisted wet processing

Ultrasound reduces processing time and energy consumption, maintains or improves product
quality, and reduces the use of auxiliary chemicals. In essence, the use of ultrasound for dyeing
will use electricity to replace expensive thermal energy and chemicals, which have to be treated
in waste water.

Bubbling phenomenon, Ultrasound energy is sound waves with frequencies above 20,000
oscillations per second, which is above the upper limit of human hearing. In liquid, these high-
frequency waves cause the formation of microscopic bubbles, or cavitations. They also cause
insignificant heating of the liquid. Ultrasound causes cavitational bubbles to form in liquid. When
the bubbles collapse, they generate tiny but powerful shock waves. We needed to agitate the border
layer of liquid to get the liquor through the barrier more quickly, and these shock waves seemed
like the perfect stirring mechanism.

Ultrasonic wave also can be used to increase the amorphous reasons in fabric to better the dye
uptake.

For printing section

This process can be divided into two parts one preparation part and two is to applying the print
paste on the fabric.

Preparation:

Designing: It is done by as followings;

Photoshop

Before the application of printing on fabrics there is a necessity of an appropriate designing which
was used to be done manually now a days can be done accurately with necessary information like
repeat size, number of colors etc. with the help of Photoshop.

Computer Aided Design (CAD)

CAD is an electronic system which is used for designing new products or part of a product or
altering the existing products or replacing the entire product done manually. CAD is used by the
designer to design different geometric shapes with the help of graphics software. The CAD system
has been built up from the Graphical User Interface with NURBS geometry and boundary
representation data via a geometric modeling kernel. The graphics system provided by the CAD
allows designers to create electronic images that can be portrayed into two- or three-dimensional
solid component which can be rotated or scaled or transformed as it is viewed.

Screen preparation: In the past the screen preparation was a quite a difficult task and was time
consuming as well and accuracy was not achieved. Now a day’s glass fiber used as screen, and
galvano, laqour screen etc. made by computer assistance.
 Fig: Galvano screen
Galvano Screen Printing: https://www.youtube.com/watch?v=Gyp7eB7D1nY

Printing process

Digital textile printing, often referred to as direct to garment printing, DTG printing, and digital
garment printing is a process of printing on textiles and garments using specialized or modified
inkjet technology. Inkjet printing on fabric is also possible with an inkjet printer by using fabric
sheets with a removable paper backing. Today major inkjet technology manufacturers can offer
specialized products designed for direct printing on textiles, not only for sampling but also for
bulk production. Burnout effect can be brought or plasma technology, laser technology can be
also used for printing.
 Fig: Digital printing Machine

Digital Printing: https://www.youtube.com/watch?v=eeUDnikKBCY

Process Management in Wet Processing

Computer Integrated manufacturing (CIM) uses computers to control the entire production process
that involves engineering, production, marketing and all the support functions of a manufacturing
enterprise. In the traditional business paradigm, the company is assumed as an island, i.e., an
independent and self-operating entity. As a company is a part of a broader matrix of business
systems composed of customers, suppliers, products and global information, it leads to integration
along different axes, namely geographical and functional. Its main objective is streamlining the
process of manufacturing and integrating it with all the other business functions such as financing,
marketing and accounting. To eliminate the wastage, basic manufacturing functions as well as
materials handling and inventory control can be simulated by computers. Nowadays there are
many simulation software’s available. The elements of CIM system include manufacturing
planning and control, manufacturing engineering, manufacturing processes and indirect elements
such as sales order processing and finance and accounting. Manufacturing planning and control
includes shop floor control, inventory control etc., Manufacturing engineering includes
CAD/CAM, CAPP etc.; Manufacturing process includes robots, material handling systems etc.
Computer Aided Manufacturing

This is the component of the CIM that directly deals with manufacturing operations. The computer
systems are used by the manufacturers because they are accurate and also easily adaptable. They
also provide easy access to data storage and cost effective, high quality production. CAM makes
use of the computer-based software tools to assist the engineers for manufacturing or prototyping
the product components.

● Computer helps to compute how long a machine will work and what would be the amount of
production that the machine will give by that time.
● During the manufacturing there are automatic system which can identify the fault in process
and can guide to solve the problems

Computer Aided Process Planning

As process planning involves determining sequence of individual manufacturing operations

needed to produce a given part or product, CAPP must be capable of understanding and analyzing
the characteristics of the part of a product, possessing multiple knowledge about the tools and their
characteristics, possess the capability of analyzing the inter dependencies between the part, the
process involved, quality of the product and cost of the product.

Overall Process Monitoring & Managing

Process monitoring is one of the most important part of synchronization of the process. In the
textile industry, some of the complex activities such as process monitoring, management and
planning makes used of knowledge based expert system, where human experts are scarce.

Enterprise Resource Planning (ERP)

ERP is the latest high-end solution provided by information technology for business application.
Globalization has led to increase in competition and quality awareness and therefore it has become
very important for the textile industry of Bangladesh to integrate itself with information technology
to survive. To sustain competitive advantage, companies must re-examine and fine-tune their
business processes to deliver high quality goods at very low costs. ERP is an integrated system
that allows information to enter at a single point in process & updates a single shared database for
all functions that directly or indirectly depend on this information. ERP solutions came into
existence in corporate world due to various problems faced in Management Information System
(MIS), Integrated Information System (IIS), Executive Information System (EIS), Corporate
Information System (CIS), Enterprise Wide System (EWS), and Material Requirement Planning
(MRP), Manufacturing Resource Planning (MRP II). This paper deals with the functions of ERP,
Necessity and benefits of ERP system. Challenges of aligning ERP with textile processes,
taxonomy of textile ERP system, Development of ERP system, Existing ERP systems, ERP
system providers, ERP system Implementation, simply to understand – ERP system organizes all
of the company’s information into one centralized system, which is always available.

Fig: ERP Plan

Through ERP in Wet Process We can make a synchronized relation between the production floor
for monitoring and inventories, fabrics, dyes that are consumed and wasted and also the market
conditions.

Conclusion

The use of computers is the demand of the developed technologies. In the last couple of decades,
automation has taken place in all the processes involving textile manufacturing i.e wet processing,
resulting in enormous gains in productivity and efficiency. In our wet processing sector of textile,
it is very important to have well-prepared/pretreated fabric which is aided by the application of
computer more precisely. Another most important and can be called as the main part of dyeing
process is to match the color or to have appropriate shade of color which also assisted by computer
i.g datacolor, spectrophotometer etc. And at last assuring the quality of materials also done by
computer.