Textile Engineering
Wet Processing
52 interactive Wet Processing tools. Every one shows its formula, a worked example and the standards it follows.
Professional tools
Full costing sheets, booking schedules and project appraisals. Enter your own figures and see the headline result before you buy.
- Air, Sea or Split: Late Shipment Expedite Sheet Worth of Choosing Style by Style
- Brownfield Expansion: What the Next Increment Costs Shared Plant the Proposal Forces
- Built Into the Fibre or Applied to the Cloth: What Protection Costs Over a Life What Moving to the Cheapest Protection Saves
- Buyer Chargeback: Contest, Fix or Accept Recoverable a Year
- Buyer Cost to Serve & Development Recovery Net Margin After Serving the Book
- Buyer Quotation Generator Order Value
- Buyer Terms & Effective Price Comparison Best Offer, Once Its Terms Are Paid For
- Buyer Test Plan & Laboratory Budget Laboratory Cost for the Range
52
tools
Wet Processing
Advanced Colour Physics & Wet Processing · Denim Manufacturing & Specialized Wet Processing · Dyeing, Printing, Color Management & Chemical Control · Specialized Chemistry & Advanced Dye Physics · +1 more
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Advanced Colour Physics & Wet Processing 7
- Dye Compatibility, Strike Rate & Half-Dyeing Time Tool Compares two dyes in one bath using first-order exhaustion kinetics: exhaustion reached by each at the dyeing time, the gap between them that drives unlevelness, a compatibility index from their half-dyeing times, and the time the slower dye needs. Exhaustion Gap at Cut-off pp
- Garment Wash Liquor Ratio & Enzyme Dosing Calculator Scales a lab garment-wash recipe to a production machine by holding dose on weight of goods constant: batch weight, bath volume, the production dose in grams per litre, total enzyme per load and water per garment. Production Enzyme Dose g/L
- Indigo Rope Dyeing Oxidation & Immersion Calculator Sets the dip and sky sequence on an indigo rope range: immersion time per trough, skying time available between dips, whether that meets the oxidation the dye needs, and the total time the rope spends in the range. Oxidation Adequacy %
- Kubelka-Munk K/S Colour Formulation Predictor Converts spectrophotometer reflectance into Kubelka-Munk K/S, separates the substrate contribution, derives the unit K/S per percent of dye and solves the concentration needed to reach a target reflectance. Sample K/S
- Ozone Bleaching Dose & Exposure Time Calculator Sizes an ozone denim bleaching cycle: ozone supplied over the exposure, the fraction consumed at the working utilisation, dose per kilogram of garments, generator energy and the off-gas load the destruct unit has to handle. Ozone Dose g/kg
- Pad-Thermosol Sublimation Loss Calculator Estimates disperse dye lost to sublimation during pad-thermosol curing of polyester: the temperature-corrected loss rate, the share of dye sublimed away over the dwell, and the dye actually retained on the cloth. Sublimation Loss %
- Supercritical CO₂ Dyeing Pressure & Solubility Modeler Models a supercritical CO₂ dyeing vessel: disperse dye solubility by the Chrastil density correlation, dye dissolved per pass, passes needed for the recipe, CO₂ charge mass, the equivalent liquor ratio and the reduced pressure and temperature. Dye Solubility in CO₂ g/L
Denim Manufacturing & Specialized Wet Processing 8
- The Cheapest Route to a Denim Wash Premium Takes the wash-down a recipe actually reaches and finds the cheapest combination of processes that reaches the same one, inside the tensile loss the fabric will take and the water the plant is allowed. Prices what an inherited recipe is costing, what the brand's restricted-substance list is costing, and what one more point of fabric strength would be worth to the laundry. What the Recipe on the Card Is Costing cost/yr
- Denim Skewness & Leg Twist Correction Calculator Converts a measured weft offset into skew percentage and angle, then solves the additional skew needed to cancel the residual leg twist a wash produces, with the weft offset the finishing range must set. Required Skew Angle °
- Indigo Build-Up Across a Dip-Nip Sequence Turns bath concentration, wet pick-up and per-dip fixation into the indigo each box deposits, accumulates it across the sequence, and reports the dips or the concentration a target depth needs along with indigo consumption per tonne of warp. Indigo on Yarn % owf
- Indigo Vat Redox & Hydrosulfite Dosing Calculator Converts measured redox potential and pH deficits in an indigo vat into hydrosulfite and caustic top-up doses, in both concentration and total mass, with the hydrosulfite to indigo ratio the vat is holding. Hydrosulfite to Add kg
- Laser Denim Fading Energy & Tensile Loss Predictor Converts laser power, scan speed and line spacing into surface energy density, predicts the tensile loss it causes, and reports the energy budget and pass count still available before the fabric falls below its minimum strength. Surface Energy Density J/cm²
- Mercerisation Caustic Baumé & Dwell Time Calculator Converts a Baumé hydrometer reading into caustic specific gravity, percentage and grams per litre, then checks the dwell time the range actually delivers at the running speed against what the swelling reaction needs. Caustic Concentration g/L
- PP Spray Neutralisation Bisulfite Dosing Calculator Sizes the sodium bisulfite dose that stops a potassium permanganate spray: stoichiometric requirement from the redox mass ratio, working dose after safety excess and product purity, bath concentration and consumption per garment. Bisulfite to Charge g
- Stone Wash Pumice Load & Attrition Cost Calculator Sizes a stone wash load: fabric weight, pumice weight at the working ratio, the combined load against machine capacity, and the stone lost to attrition each cycle with its cost per garment. Pumice Load kg
Dyeing, Printing, Color Management & Chemical Control 18
- Dyeing Route Economics: Which Machine for This Lot Premium Costs the same lot down every dyeing route the house owns, separating what each route costs to start from what it costs to run. Reports the lot size band over which each route is the cheapest, so the answer becomes a routing rule rather than a single verdict, and prices what running the lot on the fastest machine costs when that is not the cheapest one. Cost of Routing This Lot to the Fastest Machine cost
- Rotary or Digital: Where the Two Cost Lines Actually Cross Premium Routes a print book design by design instead of by a rule of thumb. Rotary is almost all fixed cost — a screen per colour per colourway, strike-offs, setup and washdown — so its cost per metre falls with length and never stops. Digital is almost all variable, and its ink scales with coverage rather than with run length. The two lines cross, and where they cross moves with the colour count, the number of colourways and the coverage, so a house carrying one crossover figure is right about the design it came from and wrong about the rest of the book. Saving From Routing Each Design cost
- The Express Lane: How Much Can Be Sold Before It Stops Being Express Premium Works out how much of a plant can be sold as priority work before the priority stops meaning anything, using the waiting times of a two-class queue rather than a scheduling rule of thumb. Reports the largest express share that keeps the promised lead time, what the standard book pays for it, the premium being charged today for a service that is not being delivered, and the lead time that could honestly be promised instead. Premium Charged a Year for a Promise Not Kept cost/yr
- What a Colour Costs Before Any Cloth Is Dyed, and the Lot That Absorbs It Premium Costs a colour card colour by colour, separating the recipe cost that scales with the cloth from the lab dips, approvals and changeover that do not, and reports the absorbed cost per kilogram, the margin each colour actually earns, and the lot size at which a losing colour breaks even. Blended Margin on the Range %
- Colour Measurement Uncertainty & Tolerance Guard Band Combines spectrophotometer drift, repeatability and inter-instrument agreement in quadrature into an expanded uncertainty, subtracts it from the shade tolerance as a guard band, and reports which of the three terms is actually consuming the tolerance. Usable Shade Latitude dE
- Counter-Current Washing Range: Stages, Wash Ratio & Water Evaluates a continuous washing range as the counter-current cascade it is: computes the wash ratio, the impurity left on the cloth after a given number of boxes at a stated stage efficiency, the same water spent as independent baths for comparison, the boxes a target actually needs and the least water the boxes already built could run on. Impurity Left on Cloth %
- Digital Textile Printing Ink Consumption, Purge Waste & Cost Builds ink consumption from drop physics - resolution, pass count, coverage and drop volume - into millilitres and grams per square metre, then adds the purge and maintenance ink that never reaches the fabric and costs it per square metre. Ink on the Fabric mL/m2
- Dye Bath Dosing Pump Profile & Addition Schedule Converts a linear or progressive dosing profile into the stock volume, the average and peak metering rates, the per-step addition schedule and the shortest dosing time the installed pump can actually hold, so the profile that is programmed is the profile that runs. Peak Dosing Rate L/min
- Dye Strength Assay, Dosing Correction & Stock Yield Corrects a recipe dose for the assayed strength of the lot actually in the store, and reports the depth shortfall an uncorrected recipe carries, the extra dye each batch consumes, the batches the stock will really make and the value of the strength deficit. Corrected Dose % owf
- Dyebath Exhaustion Kinetics & Cycle Time Fit Fits the Cegarra-Puente rate constant from a single measured exhaustion point, then returns half-dyeing time, the times to reach 95 and 99 percent of equilibrium, the exhaustion the programmed cycle will actually reach and the dye left in the bath when it stops. Exhaustion at End of Cycle %
- Dyeing Machine Fill Ratio & Part-Load Penalty Compares a batch against the vessel it is loaded into, holding the machine to its minimum circulating volume, and returns the effective liquor ratio, the chemical overdose that part-loading forces, the salt wasted per batch and the smallest batch that still runs at the design ratio. Effective Liquor Ratio :1
- Polyester Oligomer Deposition Risk & Safe Drop Temperature Models cyclic trimer released from polyester during high-temperature dyeing against what the cooling bath can still dissolve, returning the mass at risk of depositing on fabric and machine and the drop temperature above which nothing crystallises out. Safe Drop Temperature degC
- Reactive Dyeing Salt, Alkali & Carbonate Buffer Capacity Applies Henderson-Hasselbalch to the bicarbonate-carbonate step to give the carbonate fraction at a target pH, computes the Van Slyke buffer capacity the soda ash dose provides, and compares it against the acid released by dye hydrolysis and by the substrate. Soda Ash to Charge kg
- Reactive Wash-Off Dilution Series & Water Demand Treats reactive wash-off as the geometric dilution series it is: computes the unfixed dye left after dyeing, the fixed fraction each rinse removes, the residual after a given number of baths, the baths actually needed to reach a target and the absurd single-bath liquor ratio that would match them. Residual Unfixed Dye ppm
- Screen Volume, Paste Deposit & Squeegee-Shear Viscosity Derives screen open area and theoretical paste volume from mesh count and thread diameter, converts it into wet pick-up, dry deposit and dye applied per square metre, and gives the apparent viscosity a power-law paste has at squeegee shear rather than at rest. Wet Paste Pick-Up g/m2
- Special Index of Metamerism Across Illuminants Separates metamerism from a plain shade mismatch by taking the colour difference under incandescent and fluorescent illuminants net of the residual difference under the reference, and reports the index, the margin against a limit and how many illuminants fail. Worst Metamerism Index dE
- Sublimation Transfer Yield & Ink Waste Models sublimation transfer as a saturating time-temperature dose, returning the efficiency a given press cycle achieves against the ceiling, the ink transferred and left on the paper, and what the residue costs per square metre. Transfer Efficiency %
- Thermosol Fixation Dose & Line Speed Limit Converts oven length, line speed and curing temperature into the fixation dose actually delivered against a reference time-temperature point, separates the heat-up seconds that fix nothing, and returns the maximum line speed that still completes fixation. Fixation Dose Delivered %
Specialized Chemistry & Advanced Dye Physics 5
- Cationic Cotton Reagent Dosing & Zeta Potential Calculates the chemistry for salt-free reactive dyeing of cotton: CHPTAC reagent and caustic charges for a batch, reagent actually fixed on the fibre, resulting zeta potential and degree of substitution, and the salt the route avoids. Treated Zeta Potential mV
- Fluorescent Brightener Whiteness Index Saturation Limit Prevents optical brightener overdosing: CIE whiteness index at the current dose, the dose that maximises whiteness, the peak whiteness available, points of whiteness given away by overdosing, dose excess and reagent wasted per batch. CIE Whiteness Index W
- Microcapsule Rupture Force & Payload Release Calculator Calculates the mechanics of fragrance and phase-change microcapsules in fabric: single-capsule rupture force and pressure, the ratio against applied rubbing pressure, capsules burst per rub, payload released and the number of rubs to exhaust the garment. Single Capsule Rupture Force µN
- Photochromic Dye UV Activation & Reversal Time Modeler Predicts colour-change apparel behaviour: activation rate from UV irradiance, colour developed and saturation reached over an exposure, the temperature-corrected reversal half-life, residual colour after moving indoors and time to clear below a visible threshold. Colour Developed ΔE
- Superhydrophobic Finish Contact Angle & Roll-off Predictor Models the lotus effect on treated fabric: Cassie-Baxter apparent contact angle from solid fraction, the competing Wenzel state, droplet radius and adhesion force from contact angle hysteresis, and the surface tilt at which a drop rolls off. Apparent Contact Angle °
Wet Processing (Dyeing & Printing) 14
- What to Do With a Batch That Comes Out Off Shade Premium Works out the first move on an off-shade batch by looking forward to the last attempt the cloth will survive rather than at the cost of this one. Prices topping up, stripping and re-dyeing, submitting the shade for approval and downgrading against each other, band by band, and reports what the habit of always topping up first is costing where the shade is worst. What the Right First Move Is Worth cost/yr
- Boiler Steam Requirement for Dyeing Batches Calculates the thermal energy and saturated steam needed to raise a dye bath and its fabric load to process temperature, and the heating time a given boiler capacity will take to get there. Steam per Batch kg
- Cellulase Biopolishing: Activity, Weight Loss & Strength Converts an enzyme dose and declared activity into units per kilogram of fabric, derates them for temperature and pH away from optimum, and returns the saturating weight loss, the strength it costs and the time a target weight loss actually needs. Weight Loss %
- Continuous Dyeing Range Dosing Pump Rate Calculator Synchronises chemical dosing to fabric speed on a continuous dyeing range, converting line speed, width, fabric weight and wet pick-up into litres per hour of liquor and the pump setting in millilitres per minute. Liquor Demand L/h
- Dye Exhaustion & Fixation Percentage Calculator Separates dye exhaustion from true fixation using bath concentrations before dyeing, after dyeing and after soaping, exposing how much dye was absorbed but never covalently fixed. Exhaustion %
- Dyeing Recipe & Bulk Dosing Calculator Scales a laboratory dyeing recipe to bulk, converting shade percentage on weight of fabric into kilograms of dye and grams per litre of salt and alkali into batch quantities, with a correction for commercial dye strength. Dye Required kg
- Fabric pH Neutralization Acid Dosing Calculator Calculates the volume of acid needed to bring an alkaline bath down to a target pH after scouring or reactive dyeing, from bath volume, current pH and acid normality. Acid Required L
- Lab Dip & Shade Matching Adjustment Tool Corrects an off-shade lab dip by scaling dye concentration against the measured colour strength from a spectrophotometer, and reports the Delta E position against the agreed commercial tolerance. Corrected Concentration % owf
- Liquor Ratio (MLR) & Water Consumption Calculator Converts batch weight and material to liquor ratio into dye bath volume, then totals the water drawn across the dye bath and every rinse fill, with the cost per batch and per kilogram of fabric. Dye Bath Volume L
- Mercerisation Baume, NaOH Concentration & Barium Activity Number Converts a mercerising liquor between degrees Baume, specific gravity, per cent sodium hydroxide by weight and grams per litre, computes the caustic carried on the goods at a given wet pickup, and turns AATCC 89 barium hydroxide titration figures into the barium activity number. Sodium Hydroxide % w/w
- Pad-Batch Dyeing Pick-up Calculator Determines wet pick-up on a padder from dry and wet sample weights, then converts it into liquor and dye required for the full batch and the resulting depth of shade on weight of fabric. Wet Pick-up %
- Rotary Printing Repeat Size to Screen Matcher Checks whether a design repeat divides exactly into a rotary screen circumference, and returns the adjusted repeat size that will print seamlessly along with the distortion that adjustment introduces. Seamless Repeat Size mm
- Scouring Weight Loss & Peroxide Bleaching Bath Recipe Calculates cotton scouring weight loss from non-cellulosic content and scouring efficiency, then builds the hydrogen peroxide bleach bath: bath volume from the liquor ratio, litres of commercial peroxide at its actual strength and density, available active oxygen, caustic and stabiliser charges, and the alkali to peroxide ratio. Total Preparation Weight Loss %
- Screen Printing Colour Paste Consumption Estimator Estimates print paste consumption for a run from fabric area, design coverage and the paste pick-up of the screen mesh, giving kilograms per colour, per metre and for the whole order. Total Paste Required kg
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