How to Innovate Jigger Dyeing Machines

The jigger dyeing machine is a batch wise dyeing process equipment. Highly favored by dyeing and finishing enterprises for its suitability for small-batch, multi-variety production, dyeing facilities typically possess anywhere from several units to over a hundred.

Industry Background and Innovation Drivers

In recent years, water intake standards in the dyeing and finishing industry have restricted the application of high-liquor-ratio jet dyeing machines in immersion processes. Furthermore, new market access conditions for printing and dyeing stipulate that “batch dyeing equipment must achieve a liquor ratio below 1:8 (1:10 for silk and wool dyeing)”. Consequently, jig dyeing machines, with their typical liquor ratio around 1:3, show a growing trend of replacing jet dyeing machines. This presents both an opportunity and a test for jigger machine manufacturers. It is crucial to innovate jigger machines to contribute to product enhancement, energy conservation, and emission reduction for dyeing and finishing enterprises. The following discussion explores how to innovate jigger dyeing machines.

Market Status and Price Paradox of Jigger Dyeing Machine

Current market prices for jigger dyeing machines vary significantly. While the adage “you get what you pay for” holds, the practical differences in process applicability, product quality, and production cost between machines costing tens of thousands versus hundreds of thousands of RMB per unit must be evaluated. This requires comparison across multiple factors: production efficiency, first-pass success rate, presence of batch-to-batch shade variation, side-to-center shade variation, lot-to-lot difference, and consumption of water, electricity, steam, dyes, and auxiliaries, as well as finished product quality. If the performance, cost, and quality delivered by a ¥60,000-70,000 machine are not significantly inferior to those of a ¥300,000 machine, it indicates fundamental flaws in the overall design or process application of jigger machines.
JIgger dyeing machine in FYI
High-priced jigger machines in the market are often promoted as “giant” units with 1400 mm diameter rolls, typically featuring dual-frequency conversion (or servo drive), constant linear speed, constant tension, and PLC control. However, production practice reveals that rolls exceeding 1200 mm diameter are rarely used. The reason is simple: larger diameters increase the risk of end-to-end and side-to-center shade variation, forcing manufacturers to sacrifice processing efficiency and increase batch numbers to avoid defective cloth. In theory, maintaining a fixed micro-speed difference between unwinding and winding should ensure constant tension. If overall tension is controllable and the fabric maintains uniform pickup during winding, end-to-end and side-to-center shade variation should not occur. The market’s “peculiar phenomenon” – buyers unwilling to invest in “high-end” jigger machines, preferring cheaper models for lower-grade textiles – indeed suggests problems with high-end machine technology. Buyers are price-sensitive based on quality, and their choices are mostly rational.
This “peculiar phenomenon” is undesirable. It hinders textile quality improvement and promotes excessive production of low-to-medium grade textiles, which harms the sustainable development of the dyeing and finishing industry. How can “high-end” jigger machines be innovatively redesigned to produce high-quality textiles while conserving energy and reducing emissions?

Innovative Solution

It is reported that patented tension control technology conforming to the winding mechanical characteristic curve is available for direct application in jigger machine innovation. This mechatronic device features:
A direct diameter measurement sensor. Mechanical memory function during stops for easy restart at process speed. Standard, mature electronic sensors with high output precision, waterproofing, heat resistance, and anti-interference. An excitation board designed according to the roll build-up during jigger processing, generating the characteristic curve Uk = f(D). This controls constant unwinding/winding linear speed while maintaining controllable tension.
The original author of this article is Chen Liqiu. If there is any infringement, please contact fyie@hkdowell.com

Comments

Post a Comment

Popular posts from this blog

Fiber Fineness and Tenacity Test

Image
  Test methods explanation We have tested 5 fiber samples using two solutions to test fiber fineness and tenacity: Solution 1 and solution 2. Solution 1 We use YG002C measured the fiber diameter, and YG005S tested the break force and extension. The fiber density is converted to denier from diameter using the formula. Then use the break force divide the density to get the tenacity. Please move to TABLE 1 to view the test result. We have attached YG002C parameter sheet in Appendix 1 and YG005S parameter sheets in Appendix 2. Solution 2 We use ZK100F measured the fiber density, and YG005X tested the break force, extension, and tenacity. Please move to TABLE 2 to view the test result. We have attached ZK100F parameter sheet in Appendix 3 and YG005X parameter sheet in Appendix 4. A better solution for fiber density and tenacity testing  We also have a YG005XD AUTOMATIC FIBER TENSILE AND FINENESS TEST SYSTEM, which has integrated function of ZK100F and YG005X; it is equipped wi...
Read more

Selection of materials for jigger dyeing machine parts

Image
In the textile industry, the jigger dyeing machine is a key textile printing and dyeing equipment. The selection of its main manufacturing material has a vital impact on the performance, durability, and dyeing effect of the equipment. Stainless steel is one of the most commonly used materials in modern dye jigger manufacturing, especially 304 and 316L. Material selection for each component of the jigger dyeing machine The jigger dyeing machine is composed of a frame, an electric control cabinet, a vessel/top cover, a circulation system, a dye bath, a main roller, a guide roller, a tension frame, an additional tank, a debatching device, and other parts. More details about jigger dyeing machine in our company No contact with dye solution ​ For parts that are not in contact with the dye solution, the main consideration when choosing the manufacturing material is the use environment of the equipment. Generally speaking, the environment of the dyeing factory is harsh. We recommend using 304...
Read more

Definition and Classification of Yarn Spinning

Image
  What is yarn spinning Yarn spinning is the technique of making yarn from fibers. The fibers can be wool, cotton or other natural materials, or they can be synthetic. Spinning produces a yarn that can then be used to make fabric. Types of yarn spinning Spinning can take numerous forms, but they all have the same goal: to transform fibers into yarn. Some varieties of spinning are more popular than others, but each has its own set of benefits. Woolen and cotton are the two most common forms of spinning. The process of converting raw wool into yarn is known as spinning. The yarn is generally thick and heavy since it is spun on a spinning wheel. Cotton spinning is the transformation of raw cotton into yarn. The yarn is generally thin and light, and it is spun on a spinning wheel or spinning jenny. There are also additional styles of spinning that are less common but have their own advantages. The process of converting raw silk into yarn is known as silk spinning. The yarn is generally...
Read more