Course code: TEX4215
Course title: Application of Computer in WPT
Automation In Jigger Machine
Presented by
Muhammad Sohel Rana Presented to
171-112-0-155
Md.Azharul Islam
Shafat Ahmed Bin Kamal
171-115-0-155 Lecturer,
Shah Mohammad Arman Ome
171-123-0-155
Department of TE,
Shahin Mohammad Nasimul Haque BUFT
171-126-0-155
Md.Al Amin
171-130-0-155
Jigger Dyeing Machine
Jigg or jigger dyeing machine is one of the oldest dyeing machines used
for cloth dyeing operations. Jigger machine is suitable for dyeing of woven
fabrics, up to boiling temperature without any creasing. Jigs exert
considerable lengthwise tension on the fabric and are more suitable for the
dyeing of woven than knitted fabrics. Since the fabric is handled in open-
width, a jig is very suitable for fabrics which crease when dyed in rope
form.
Types of JIgger dyeing machine
● Types of jigger dyeing machines
● There are mainly two types of jigger dyeing machine
● One is open jigger dyeing machine and
● Other is closed jigger dyeing machine
Parts of Jigger Machine
Parts of Jigger Machine
Take up and Let off rollers:
These are two stainless steel rollers, running in external bearings with
mechanical seals to take up and let off the fabric rolls.
Parts of Jigger Machine
Trough:
Dyeing trough has a special high efficiency design allowing constant and controlled liquor ratio
dyeing and high efficiency washing with minimum liquor content. The intended liquor ratio is
minimum 1:4.
Stainless steel compartment:
The machine consists of an enclosed stainless steel compartment with 6 mm thick sides. This
compartment has inclined doors and heated door frames, which prevent dripping of condensate
on the fabric.
Pump for liquor circulation:
Liquor circulation system consists of centrifugal pump at 2 bar pressure, internal sieve, stainless
steel piping, manual flow control valve and deflector system for even liquor distribution.
Parts of Jigger Machine
Quick liquor discharge:
The Large diameter pneumatically controlled drain valve enables quick liquor discharge
allowing short change over time.
Stainless steel guiding frame:
There is one stainless steel guiding frame supported by 2 air cylinders for single
unloading, including fixed stainless steel fabric spreading bar and mechanical safety
lock.
Stainless steel side tank:
Machine is also provided with a stainless steel side tank of 300 litres capacity with
direct manual heating. The tank is equipped with sieve, manual drain valve, automatic
mixer, level sensor, re-circulation connection and rinsing rim for automatic cleaning.
Technical Feature
● Fabric tension – 5 to 70kg/Cm2
● Speed - 10 to 150m/min
● Fabric width - Max. 3800mm
● Roller width -Max. 4000mm
● Roller diameter – 270mm
● Roller batch dia-1000 to 1230mm (dependent on type
of m/c)
● Fabric height -365 or 475mm (dependent on type of
m/c)
Working Procedure:
✔The jigger consists of a trough fitted with roller known as
draw rollers arranged one along either side and
supported in metal bearing. Guide rollers and steam line
are provided in the trough.
✔The material or fabric is wound, in open width ,over
rollers standing above a shallow trough containing the
dye liquor.
✔The rollers, by rotating in clockwise and anti-clockwise
directions alternately, pull the fabric backward and
forward through the dye liquor, completely immersion
being ensured by guide rollers at the bottom of the
trough.
Working Procedure:
✔The draw roller from which the fabric is taken out is called let-
of roller while the other is called take-up roller.
✔When all the fabric passes through liquor from one roller to
the other, the passage is called an end or one turn.A number of
ends are given, during which time the fabric passes to and fro
and passes through the dye solution a number of times.
✔The number of ends given depends on several factors,
including the size of roll or batch of fabric.
✔The time required for one end usually 10 to 15 minutes and on
the depth of shade being dyed.
Advantages & Disadvantages
Advantages :
⮚ The cloth can be dyed in open width form of full width form;
⮚ Chemical and heat loses are less when compared to winch
dyeing machine;
⮚ The material to liquor ratio is 1:3 (or) 1:4 which saves
considerable amount of chemical cost and steam cost.
Disadvantages
● It exerts lot of tension in the warp direction and because of
these normally woolen, knitted fabrics, silk etc are not dyed in
jigger dyeing machine
Other problems are :
● Temperature control from side-to-side and end-to-end
of the roll;
● Tension control from end-to-end;
● Constant speed control from end-to-end;
● Prevention of creases;
● Prevention of air.
Limitations of Jigger Dyeing:
▪ Jigs exert considerable lengthwise tension on the fabric
and are more suitable for the Dyeing of woven than
knitted fabrics;
▪ In textile preparation due to the swelling and dissolution
of size, which makes the fabric slippery and unstable in
roll form.
▪ The low liquor ratio makes washing-off difficult;
▪ There is little mechanical action in a jig machine and it is
less suitable where vigorous scouring is required before
dying;
▪ Water marks may arise on some acetate and nylon fabrics
because of pressure flattening the structure of the rolled
fabric.
Expected Addition of
Automation Jiggar Machine :
● Loom data Monitor
● Pressure Monitor
● Annunciator
● Shift wise counter
● Sequence controllers
● Level Monitor
● Maintance schedule monitor
● Problem Detactors
● Auto Dosing
● Auto pH control
Automation in jigger
Automatic Temperature control :
Temperature is a crucial parameter for dyeing. A fluctuation
in temperature can cause variation in shade of the fabric.
● Fuzzy Logic temperature control system is one of them.
Artificial Neural Network system is used to control the
temperature of dye bath.
● The system reads its environmental condition and
learns from previous dyeing cycles to ensure better
control according to the fabric being dyed.
Automation in jigger
Automatic Loading Unloading
Fabric in modern jiggers are automatically loaded and
unloaded without the help of operators. Automatic loading
and unloading reduces unloading time so the fabric doesn’t
sit in the machine for the long time . Also there is no need for
human helping hands.
Automatic Drainage
After dyeing the dye bath liquor needs to be drained .If it is
left for a long time it could cause damage to the machine.To
avoid it., the liquor is drained .
Automation in jigger
Automatic Tension Control
As we know the fabrics are more vulnerable while they are wet.
And high tension can tear or deform the fabrics easily . Again
Low tension can cause crease marks and uneven shades
throughout the fabric.It newer machines The tension is
controlled automatically .Using the control panel the tension of
the fabric is set.
Automatic Speed Control
The amount of time the fabric will be in contact with the dye
bath is determined with the speed of the fabric. If the speed is
high the fabric will not have enough time for contact. On the
other hand if the speed is low then there is a chance of over
dying.The speed is set beforehand using a control panel .The
central control unit ensures a uniform speed.
Automation in jigger
Automatic Dispensing :
In conventional method the dye and other auxiliaries are weighted
and provided to the dyeing bath. This has some disadvantages
due to human errors . The recipe can not be strictly followed.But
through automatic dispensing it is possible. The machine
dispenses dye and other auxiliaries according to the recipe and
no human hands are required .
Automatic Dosing
Many Auxiliaries are needed to be dosed . Because in reactive
dyeing some auxiliaries when provided to the dye bath at once
can cause uneven shade.To avoid such completions dosing is
done.This dosing system is controlled automatically in the modern
machine.According to the recipe the dosing is done with precise
amount and in precise time.
Automation in jigger
Automatic Stop when error occurs
When the dyeing is faced with a machine error or
malfunction.The modern machines has an automatic stop
function .Which halts all the machine processes. Thus there is
less chance of fabric damage.
Maintenance indicators
The control panel helps to pinpoint the fault if there is a machine
breakdown.Also helps to keep track maintenance work.
Automation in jigger: Future Trends
● Optimizing dyeing conditions using AI technology
● IOT connecting various machine to communicate
with each other.
● Learning from previous experience to better
optimization
Integration of machine learning .
● More economical heating systems.
CONCLUSION
Automation is the current future of our world . As the 4th industrial
revolution has already started will see more implementation of automation
in the field of textiles. So getting familiar with the ongoing technological
revolution is a must to survive.
Thank you
