Lab Scale Jigger Dyeing Machine

Features & Specifications

Tradition of Jigger Machines:

Processes such as pre-treating, scouring or dyeing of textile fabrics have been carried out on jiggers from the beginning of the textile industry. Textile finishing highly benefits from this simple but efficient technology. The jigger is especially suitable for the treatment of crease-sensitive, non-permeable, very fine as well as very heavy textiles mostly made of natural fibres.

 Marjan Polymer Industries’ Lab Jigger:

Very often there are differences found in the shade when recipes are transferred from lab to bulk. In order to achieve the results in a “right-first-time” attempt, our team of technologists and engineers has developed the JD500 identically to the Jigger for large scale production. The JD500 is perfectly suitable for obtaining perfect lab recipes, which will not cause any variation in production afterwards. Furthermore, the JD500 is an outstanding alternative for sampling for your next collection. Last but not least, the JD500 is a first class option for processing narrow fabrics as well.

 The complete construction of the JD500 has been taken over from the commercial production industrial Jigger. The large inspection windows made of tempered glass allows excellent visual control of the whole process even in this laboratory version. The highly insulated glass avoids any loss of heat from inside the machine.

 Benefits:

Consistent temperature, controlled fabric tension, fabric speed and processing time, proper dyestuff/ chemicals up-take and uniform liquor ratio are some of the most important features of JD500 to deliver best quality product. The reliable control of the whole process provides optimum safety. The Jigger is economical, user-friendly and Made in Pakistan.

 Main Features Include:

• The whole Jigger machine will be fabricated with high quality materials
• Consistent fabric tension
• Consistent fabric speed
• Optimum and consistent liquor ratio
• Perfect monitoring due to large inspection windows
• High quality rollers

General Characteristics:

 Inspection Window:

The large inspection window suit best for the operator to visually monitor the whole process. The sealing of the inspection window ensures a consistent inside temperature and minimum heat loss. Inspection window is made of glass providing excellent insulation values, too. The Jigger will be equipped with process bath with toughened and laminated large glass viewing window cover. This large inspection window suit best for the operator to visually monitor the whole process and can be easily opened during certain processing conditions by a simple mechanism and locked in the closed position using a clamps or springs. The area around the processing bath will have proper over temperature control protection mechanism which protects the processes and equipment from excessive temperatures

 Liquor Trough:

The specially designed liquor trough provides an optimum and consistent liquor to dye ratio. The trough design allows economic dyeing by small-sized batches. As a result, it is flexible to respond immediately to test with small size batch and requirement. Large sized outlet drain valves enable quick liquor discharge. The system can be equally applicable as required for large and small fabric batches and also for high grade technical textile products.

 Trough Cooling Jacket:

As per requirement of Jigger machines, liquor trough will be provided with a double Jacketed tank for cooling the liquor charged inside the trough by cooling jacket coupled with the circulation tank.

Chilled Liquid Control:

The double jacket bath will be provided with manual IN and OUT ball, gate or needle valve to ensure proper manual control of tap water entered inside the jacket for controlling the liquor temperature in the trough.

Main Rollers:

Two main rollers will be mounted in the JD500 Jigger. Two other nip rolls with small diameter than the main rollers will be placed inside the dye bath to support the fabric and to provide a wide space to fabric to remain dipped into the liquor.

 Drive System:

As per requirement of Jigger machine, one or two motors will be mounted for the direct drive of the main support rollers. The two main support rollers, having special bearings at the roller’s ends. One or two variable frequency drives (as per motor’s) can be installed to ensure proper control of main rollers which enables to control fabric tension properly.

RPM:

Fabric roller speed will be controlled and mounted by ‘variable processing speed control by AC drive high quality inverter or direct through controller’. These controllers will have features of reducing or increasing rotation speed which will give complete control on speed adjustments according to application need and better stability of flow-rate modulation which in turn also allows better temperature control.

Heating:

The heating process facilitates by mounting electric heaters within liquor bath for heating the liquor. This heating system helps in proper heating of dye liquor or plain liquor in bath without rapid degradation and also uniform heating. The electric heaters with high power capacity will be mounted.

 Temperature Measurement:

The temperature within the hood and the trough area will be measured by temperature sensors. The temperature within the hood and the trough area will be measured by PT100 type temperature sensors having features of temperature range more than 100^oC.

 Temperature Control

Real time temperature indication and control will be done by making a control loop with electric heaters mounted on trough. Temperature measured by temperature sensors will be displayed by digital indicators or direct display and control by controllers.

 Fabric Tension:

Readily adjustable variable fabric tension control will be installed by mechanically restricting the free roller using an adjustable brake system. The fabric tension control ensures that the fabric batch runs straight and builds up with straight sides.

Drain:

The Jigger will be equipped with proper drain system. Proper sized valves will be mounted on JD500 to discharge liquids that contains chemicals from trough and also from circulation tank.

Agitation (mixer):

To improve the dye liquor mixing, stirrer for agitation will be installed within the liquor bath which enables to produce a turbulent flow in the bath during mixing of liquor. Thus stirrer automatically provide a mixing effect for uniform mixing or dye or any other chemical in the liquor.

Floor Mounted Stand:

JD500 will be supplied with a floor mounted Mild Steel stand coated with special coating.

Tools & Accessories:

All the required tools and accessories for operation, maintenance and cleaning will be provided along-with Jigger machine.