The processes of cotton knitting fabric(scouring, bleaching , dyeing and etc.) is generally carried out in the overflow machine. During the entire processing, the fabric remains in a rope-like state. The fibers constantly bend and deform in the dyeing machine, the original hydrogen bonds are constantly broken while new hydrogen bonds are constantly formed. Sometimes the newly formed hydrogen bonds cannot be fully restored, thus forming chicken claw marks and dead creases on the fabric surface.

In the single-sided fabric structure, tension of the two sides of yarn is asymmetric. After fabric is folded in one direction for a long time, it is difficult to recover. Therefore, among various structures,  especially on fabrics with less or larger weight (eg. plain weave and sweatshirt fabrics) are more prone to crease problems. The generation of creases is also closely related to yarn count and twist. The finer the yarn count and the higher the twist, the greater the possible reversal and untying of the yarn, and the more likely it is to cause crease problems.

 

 

The main process steps leading to creases: scouring and bleaching

1. The general dyeing and finishing process typically involves: fabric preparation → seam sealing → boiling and bleaching in the fabric dyeing machine → dyeing → soaping → color fixing → softening → fabric out from dyeing machine → dehydration → drying. It is commonly believed that creases mainly form in the dyeing machine. However, after rigorous experimental verification by our engineers, it has been found that most cotton knits actually develop creases during the boiling and bleaching stage, which are just not easily observable before dyeing.

 

2. Based on the years of experience of our engineers, the following types of fabric and equipments are prone to developing creases during the boiling and bleaching stage:

Fabric factors: Single-sided cotton fabrics with lighter or heavier weights (e.g., weights <150g or >300g), especially cotton spandex (with elastane) fabrics.

 

Machine factors: Compared to L-shaped overflow fabric dyeing machine, J-shaped overflow fabric dyeing machine are more prone to creating creases due to their stronger stretching force. Air-jet fabric dyeing machine, on the other hand, are less likely to cause creases because the fabric is fully blown open by high-pressure air at the nozzles, allowing the fibers to "rest" from tension, which aids in eliminating internal stress and reducing creasing issues.

 

Process factors: Fabrics that have not undergone prestretching are more prone to creasing. Fixing the fabric under high temperatures can improve fiber proximity and orientation, stabilize fiber morphology and reduce likelihood of changes occurring in dyeing machine, which is beneficial for reducing creases.

350g pure cotton knitted fabric (no creases after dyeing)

 

140g pure cotton knitted jersey (no creases after dyeing)

 

Solutions of scouring and belaching creases 

1. General Method: During boiling and bleaching, as well as dyeing, polyacrylamide-based lubricants are added. The primary role of this type of lubricating agent is to "reduce friction between fabrics and between fabrics and machinery," but it is difficult to resolve creases formed during boiling and bleaching.

 

2. Solution Proposed in This Article: To improve creases during boiling and bleaching, the following auxiliaries, processes, and operations are employed. Satisfactory results have been confirmed through applications by multiple clients.

 

Auxiliaries:

A. Preferentially select a high-concentration and highly soluble polyacrylamide-based anti-crease agent JET (non-ionic) for use in the bath. Its role is to reduce friction between fabrics and between fabrics and machinery.

B. Select new type of anti-crease softener RCE (non-ionic). Its role is to impart good softness and smoothness to the fabric itself, as well as to provide level dyeing properties. 

The combined use of these two auxiliaries is the core of this method.

 

Process:

Reduce the heating rate; the focus is on reducing the cooling rate, with an optimal range of 1.0 to 1.5°C/min.

 

Operations:

Before entering the dyeing machine, the gray fabric should be placed in an area with high humidity in workshop to allow for sufficient moisture regain. During moisture regain, the fibers undergo some swelling, and internal stresses are partially eliminated, which is conducive to reducing creases. After the gray fabric is loosened, it should be allowed to freely pass through a J-shaped trough, while simultaneously being pressed by a press roll or stretched by rollers, which is conducive to eliminating internal stresses and reducing creases.

 

3.Process example

Before boiling and bleaching, add refining permeant, etc., anti-wrinkle agent JET and anti-wrinkle softening agent RCE in the bath, do not heating firstly, cycle for 20 minutes after entering the cloth, so that the grey cloth is fully moistened and the auxiliary agent fully reacts with the fabric fiber. If bleaching is required, caustic soda and hydrogen peroxide can be added before heating. Reduce the rate of heating; Especially to reduce the cooling rate, generally 1.0 ~ 1.5℃/min is better; And it must be completely cooled to 50 ° C to discharge the liquid for dyeing.

 

Other items to prevent creases

1. In order to prevent the generation of creases, it is recommended to add polyacrylamide type lubricant - JET in the bath during dyeing, and reduce the cooling rate.

2. When dehydrating and dry cloth, open width rolling water dry cloth can be used, which not only improves the efficiency of dry cloth, but also helps to solve the problem of creasing. 

3. When stacking cloth, it is recommended that the weight should not be too large and the time should not be too long, especially when the wet cloth is stored.

4. If it is cotton rack (with spandex) fabric using this solution can not completely solve the crease problem, you can consider the presetting process. 

 

5. Generally, the slight crease can be solved by the setting machine, and the stubborn can be returned to the cylinder washing water, gradually heating up to 85 ° C, gradually cooling down to 50 ° C process test repair, or can be re-shaped by steam in the industrial drying machine, which can be repaired according to their respective equipment and crease conditions.

Textile dyeing machines are industrial equipment designed for the dyeing or coloring process of textiles. Dyeing is a critical step in the textile manufacturing industry, where dyes are applied to fabrics, yarns, or fibers to achieve the desired color or pattern.

 

I. Market Research

1. Market Size and Growth Trends

According to the latest report by QYResearch, “Global Textile Dyeing Machine Market Report 2023-2029,” it is expected that the global textile dyeing machine market will reach $1.37 billion by 2029, with a compound annual growth rate (CAGR) of 4.2% in the coming years. This indicates that the textile dyeing machine market will experience steady growth over the next few years.

 

2. Development Trends

Digitalization and Automation: With the continuous development of artificial intelligence, big data and other technologies, the textile dyeing machine industry is gradually moving towards digitalization and automation. The application of intelligent equipment not only improves production efficiency but also reduces production costs and enhances product quality.

 

Environmental Sustainability: With the increasing global awareness of environmental protection, eco-friendly solutions have become a mainstream trend in the textile dyeing machine industry. Major companies are adopting environmentally friendly production technologies and materials to achieve sustainable development.

 

Customization and Personalization: As consumer demand becomes more diverse, personalized and customized textile products are increasingly favored. Textile dyeing machine companies need to offer a variety of products and services to meet consumers' individual needs.

*knitted fabric dyeing machine

 

3.Potential Growth Drivers

Sustained Market Demand: With the global economic recovery and the improvement in consumer purchasing power, the demand for textiles continues to rise, providing significant growth opportunities for the textile dyeing machine market.

 

Emerging Markets: Emerging markets in Southeast Asia, Africa, and other regions offer vast growth potential for the textile dyeing machine industry.

 

Technological Innovations: New dyeing technologies such as digital dyeing and smart dyeing are constantly emerging, bringing new development opportunities to the textile dyeing machine market.

 

4. Potential Challenges

Environmental Pressure: With the tightening of environmental regulations, textile dyeing machine companies need to increase investments in environmental protection and improve the eco-friendliness of their products.

 

International Trade Barriers: Green trade barriers are becoming a significant factor limiting textile exports, requiring the textile dyeing machine industry to focus on green production.

 

Intense Market Competition: The domestic and international markets are highly competitive, requiring textile dyeing machine companies to continuously improve product quality and technological capabilities to stay ahead of the competition.

 

II. Industry Competitor Analysis

1. Major Manufacturers

Globally, leading manufacturers of textile dyeing machines include COSMOTEX, Gargo Corporation, Sclavos, Texfab, Thies, Chemtax, M/s Exolloys Engineering, Capto, and Loris Bellini. The top three companies account for approximately 54.9% of the market share.

 

2. Strategic Positioning and Competitive Advantages

Large Multinational Companies: These companies typically possess strong R&D capabilities and advanced technological expertise, allowing them to produce high-end, intelligent dyeing machines. They enjoy significant global market share and brand recognition. These companies focus on technological innovation and product quality, continuously introducing advanced dyeing machine models that meet market demands.

 

Small and Medium-Sized Local Enterprises: Compared to large multinational companies, small and medium-sized local enterprises also occupy a certain share of the textile dyeing machine market. They typically serve local markets by offering flexible production methods and personalized services.

 

3. Competitive Disadvantages

Some small and medium-sized enterprises lack sufficient investment in R&D and product innovation, resulting in weaker product competitiveness.

Some companies lack an international perspective and brand influence, making it difficult to secure a dominant position in the global market.

*small capacity fabric dyeing machine

 

III. Supply Chain Structure Analysis

1. Supply Chain Efficiency

The textile dyeing machine industry’s supply chain includes raw material suppliers, component manufacturers, machine manufacturers, distributors, and end users. Currently, there is a high degree of collaboration and coordination between different supply chain stages, leading to overall high efficiency.

 

2. Potential Bottlenecks

Raw Material Supply: The supply of some critical raw materials may be affected by market fluctuations, trade policies, and other factors, potentially leading to bottlenecks in the supply chain.

 

Technological Innovation: Technological innovation is a key driver of industry development, but some enterprises' insufficient investment in R&D may slow the overall improvement of supply chain technology.

 

IV. R&D Progress and Technological Innovation

1. New Dyeing Technologies

Emerging technologies such as digital dyeing and smart dyeing are creating new opportunities for the textile dyeing machine industry. These technologies not only improve dyeing efficiency and product quality but also reduce energy consumption and pollutant emissions.

 

2. Intelligent Production Lines

Intelligent production lines are an important development direction for the textile dyeing machine industry. By integrating smart equipment, companies can automate and optimize the production process, leveraging big data and cloud computing technologies to enable real-time analysis and processing of production data, thus improving production efficiency and product quality.

 

3. Application of New Materials

The development and application of new materials, such as functional fibers, smart fibers, and eco-friendly fibers, provide more possibilities for the textile dyeing machine industry, driving innovation and development.

*hank yarn spray dyeing machine

 

V. Regulatory and Policy Environment Analysis

1. Environmental Regulations

With increasing global environmental awareness, governments worldwide are strengthening the formulation and enforcement of environmental regulations. Textile dyeing machine companies must comply with these regulations, increasing their environmental investments and improving the eco-friendliness of their products.

 

2. Industrial Policies

During the “14th Five-Year Plan” period, national policies are placing higher demands on ecological civilization construction. The "3060" carbon neutrality goal will push the printing and dyeing industry to adopt more proactive and practical measures, such as technological innovation and pollutant control, to improve energy and resource efficiency, reduce pollutants, and achieve a balance between economic, ecological, and social benefits.

 

3. International Trade Policies

The rise of international trade protectionism and green trade barriers has impacted the export of textile dyeing machines. Companies need to closely monitor changes in international trade policies, strengthen international trade cooperation, and improve their products' international competitiveness.

The textile dyeing machine industry is expected to maintain steady growth in the coming years. However, it also faces many challenges. Companies need to continually enhance their technological innovation capabilities and product quality, adapt to changes in market demand, expand their market share and achieve sustainable development.

 

There are numerous factors that influence the quality of dyed products, chief among them being equipment, dyes and chemicals, processes (procedures, formulations, conditions)  and operational factors. Occasionally, defects in dyeing can also arise due to chance occurrences. Therefore, when analyzing the root causes of quality issues, it's imperative to consider all aspects thoroughly to pinpoint the actual cause, allowing for resolution and prevention of recurring issues. According experience, product quality control measures can be implemented.

 

In this context, let's delve primarily into the impact of dyeing equipment on the quality of dyed products.

 

To achieve superior dyed products, not only must suitable dyes be selected based on the type of fiber and fabric, but also must appropriate textile dyeing machine be paired with customized and rational dyeing processes. Despite advancements in production technology and the continuous improvement of dyeing machinery, quality issues stemming from equipment are still not entirely avoidable.

The primary concern related to yarn dyeing machine and fabric dyeing machine is its operational stability, efactors such as machine speed, drying condition, temperature ramp-up and ramp-down rate, and pressure control. When these parameters are tightly controlled, the dyeing and finishing machinery can ensure consistent color reproduction and reproducibility.

 

Textile dyeing machine pivotal role in achieving even dyeing. To this end, the following requirements are crucial:

 

1. **Strong Dyeing Process Adaptability**: dyeing machine must be capable of accommodating a wide range of process parameters like temperature, pressure, speed, and treatment time, as well as adjustment to dyestuff and chemical, ensuring compatibility with new processes and technologies. This ensures uniform dyeing and meets other quality standards.

 

2. **High Automation Level**: Automated detection and adjustment of key process parameters minimize human errors, enhancing precision control. This ensures the repeatability of processes and stabilizes product quality.

 

3. **Versatility for Multi Processing**: Given the limited resources in dyeing plant and ever-changing market demands,  fabric and yarn dyeing equipment should be versatile, allowing for cost-effective processing of various fabric and yarn types while maintaining dyeing uniformity and meeting other quality criteria.

 

4. **Low-Tension or Loose Running**: Tension is a significant factor affecting dyeing evenness. High or uneven tension can easily lead to quality issues. Hence, dyeing equipment should operate with minimal or uniform tension, preferably in a loose-running mode. It is related with the design of dyeing machine structure.

In addition to the processes and operations defined, the color matching and dyeing levelness of products are intimately tied to the dyeing equipment chosen. The selected equipment must cater to the requirements of various dyeing processes, handle diverse product types, produce high-quality outputs, and be safe, durable, economical, high-speed, efficient, continuous, automated, low-energy consuming and environmentally friendly. In essence, the equipment must guarantee the quality of dyed product.