Wet Processing

Dye Bath Dosing Pump Profile & Addition Schedule

A progressive profile peaks at n times its average rate. Size the pump on the peak, not on the average.

Dye & Stock Solution What is being metered
kg

Total dyestuff added over the profile

g/L

Strength of the made-up stock in the dosing tank

L

Working liquor in the machine

Profile The shape of the addition curve
min

Total time over which the dye is fed

n

1 is linear; above 1 feeds progressively faster toward the end

nos

How many discrete increments the controller uses

L/min

Rated delivery of the installed metering pump

Peak Dosing Rate

— L/min

The rate the pump must sustain at the end of the profile

Schedule & Pump Duty

Stock Solution to Dose
— L
Average Rate
— L/min
Pump Utilisation at Peak
— %
Shortest Dosing Time this Pump Holds
— min
First Step
— L
Last Step
— L
Last Step / First Step
— x
Delivered at Half Time
— %
Bath Concentration at End
— g/L

The profile is a power law, which is the shape almost every dosing controller implements even when its screen calls it "progressive" or numbers it one to five; if the machine uses a true logarithmic or a tabulated custom curve the peak rate will differ and only the average rate and the stock volume carry across unchanged. Peak rate is quoted at the end of the profile because that is where a power law with an exponent above one is steepest, and it is the figure that decides whether the pump can hold the curve — a pump at more than about 80 percent utilisation has nothing left for the viscosity of a cold stock solution on a winter morning. Step volumes assume the controller divides the profile into equal time slices and doses the difference in cumulative volume each slice, which is the usual implementation; a controller that instead divides into equal volume steps and varies the interval produces the same schedule read the other way round. Nothing here models levelness itself: the profile is a means of keeping strike below migration, and whether it succeeds depends on the dye, the fibre, the temperature ramp and the electrolyte, none of which appear in this calculation.

Dye Bath Dosing Pump Profile & Addition Schedule — free, with the formula and a worked example, at Textile School.