Modification on plain loom for Denim

The following is the proposed modification on plain loom for weaving denim. The main problem of running denim on plain loom is the presence of width wide faults, problems of a strong beatup and prevention of starting marks among others.

How to make Indigo solution

In a tank of 1000 liters:
a. take 400 litres of water (soft)
b. add setamol ws--> 4 g/l (stirring) ( dispersing solution)
c. Add 100 kg of Indigo ( at 1.8 % shade -see the indigo calculations- stirring)
d. add caustic soda --> stirring ( for solubilising and pH)
e. allow to cool it for 2/3 hours
f. Add hydrosulphide ( As reducing agent)
g. Make the solution to 1000 l by adding water.

If pH is fluctuating, if it is > 11.7 then hydro is added (2-3 kg), if (<11.2) then caustic is added.

For 100 kg of Indigo,
Caustic Required= 90 kg
Hydro Required= 80 kg

Indigo Calculations

For 12 ropes, at 24 m/min, of 344 ends of 14000 m length of 7s count.

wt of yarn = (12*344*14000*100*453.6)/(7*840*36*2.54*1000) kg= 5000 kg

at 24 m/min, a lot of 14000 m will be completed in 14000/24 = 583.3 min

at 1.8% shade
100 kg of yarn needs--> 1.8 kg of Indigo
5000 kg of yarn needs --> 90 kg of dye

at 100 gpl
100 gms of dye = 1 lit of solution
90 kg of dye = 900 litres

900 litres should be completed in 583.3 min
1 litre would be completed in = 583.3/900= 38.8 seconds

so flow rate will be 38.8 seconds / litre

Similarly flow rate of caustic and hydro can be determined

Hydro is taken around 100 gpl
caustic is taken around 90 to 100 gpl

Indigo Calculations