Dyeing, Printing, Color Management & Chemical Control

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 %