NZ Denim Ltd.
Pad Steam
Document No : NZDL_Pad Steam_SOP_2019/01
Author Tanvir Mahmud
Document Owner NZ Denim Ltd
Approvals :
Standard Operating Procedure (SOP)
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PAD Steam Machine
1.0 Introduction of Machine
Name of the machine : Saga Pad Steam machine
Country of origin : China
Manufacturer : Jiangsu Saga Textile Machinery Co. Ltd.
Model no : LMH924-200
1.1 Machine Setting
Pad steam machine can be set up in two ways:
1.2 For Washing
Machine Parameters Set-up Value
Padding unit Not applicable
Steamer Depends on quality 60°-105°C
Wash chamber Continue- 8 chamber
Chemical Dosing Depend on quality
Steam Pressure 2.5-4.5 boma.
Temperature 70°C-98°C
Air pressure 3-5 bar
Exhaust Auto
Speed Setting 30-50 Min/M depends on Quality
1.3 For Dyeing
Machine Parameters Set-up Value
Padding unite 1.0 Left and 1.0 Right side (Depends on
shade)
Steamer 60°-103°C
Wash chamber 05 Chamber for Light shade 9 Chamber for
Medium to Deep shade
Chemical Dosing Depend on shade
Acid dosing Auto (Ph: 4-6)
Steam Pressure 2.5-4.5 bar.
Temperature 60°C-98°C
Air pressure 3-5
Exhaust Auto
Speed 20-50 Min/M (Depends on Shade)
2.0 Introduction of the Process
Pad steam is a machine where different processes are done. Such as de-sizing
wash, only wash and over dyeing.
3.0 Description of Machine
This machine is combined with main 4 units.
Dosing pump- 02
Colour/chemical mixing tank-02
3.1 Padding Unit
The padding unit of pad steam machine is used generally for dyeing or chemical
padding. There is a pair of padders that’s both sides can control pressure with
hydraulic pump.
3.2 Steamer
During dyeing to ensure adequate time and temperature for colour padded fabric
fixation, steam is supplied in steamer. During chemical padding steamer is used
for other purposes.
3.3 Washer Chamber
There are 8 washer chambers in pad steam machine. All these chambers’
temperature can be measured separately. In the number 1 chamber
soaping/washing chemical is applied and in the number 8 chamber acetic acid is
applied. In every chamber water can be flowed.
3.4 Drying
This unit is used to dry up fabrics. There are 30 cylinders in 3 rows in the machine
that heat up by steam. Manually as per quality requirements different
temperature can be applied at them.
3.5 Dosing Pump
There are 2 dosing pumps in the machine. Of which one is used for chemical
dosing and another one acid dosing to control PH.
3.6 Description of Tanks
In this machine there are 2 tanks to prepare dyes and other chemicals. Both tanks
have the capacity of 1200 litters.
3.7 Dyes and Chemical Mixing
At first according to recipe from store or from own chemical area dyes and
chemicals need to collect weighing properly. For dyes and chemicals, both have to
be mixed with hot water and mixed properly using a mixing motor in the tank.
Then the fabric waiting to be padding should be inserted in the machine on the
trolley and a batcher on the other side.
4.0 Process Requirements
4.1 Key Accessories
While the machine is on the following accessories
(1) Scissors
(2) Measurement tape
4.2 Material/ Chemicals used
(1) Acitic acid
(2) Reducer BP
(3) Colsul Black
(4) Polywet HTS-70
(5) Caustic soda
(6) Sequestering agent
5.0 Safety and Warning
When processing and handling dyes and chemicals wear protective gloves and
goggles. While the machine is on do not touch padders, batching point, steam
dryer and steam chamber. When switching on electricity wear plastic shoes and
have rubber mat underneath. Do not wear loose clothing.
6.0 Operation Procedure
6.1 Manpower
Operation process of dying process includes following people:
Operator
Asst. Operator
Helper
6.2 To Do Checklist before Production and Machine Set Up
Ensuring there is electrical main power in the machine.
Ensuring airline got correct air pressure.
Ensuring panel board does not show red danger sign, if there is red sign
then fix it.
Steam chamber, water chamber, dry cylinder and steam valve should be
ready and should have correct temperature.
Switch on the machine when all ready.
6.3 Parameters to Check and Fix
At first main supply valve has to be opened followed by setting chambers,
steamers, dryers and temperature and finally start the machine. Then the
following parameters have to be followed:
Correct speed has to be set.
Water flow has to be opened.
Chemical dosing has to be checked.
PH has to be checked.
Shade has to be checked.
6.4 Fault Checking
During the process the operator will keep checking for different faults such as dry
stain, drop, chemical spot, crease mark, casting, uneven shade, tailing etc.
7.0 Q.C Sample test
After wash one meter sample is cut from each 1000 meter of the Batch. Then it is
sent to QC Lab where the sample is tested for different specification or Specified
by the customer like wash fastness, listing, water fastness, light fastness, Rubbing,
Shrinkage etc.
8.0 Cleanliness
On daily and weekly basis the following cleanliness has to be observed:
Clean the surrounding of the machine before the start of every shift.
After every batch of fabric is processed, steamer, chambers, padders and
dryers have to be cleaned.
After every batch of fabric is processed wash chambers have to be cleaned.
9.0 Applicable forms and Documents
The necessary forms and documents for pad steam M/C are listed below:
1) Process Batch card
2) Daily dyeing report
3) Machine downtime report
4) Identification sticker
5) Daily lab test report or QC Sheet
6) Program register of pad steam machine.
