I. Daily Cleaning: The Foundation for Unobstructed System Operation
Cleanliness is the first line of defense against fabric clogging and uneven dyeing.
After each dyeing cycle, the screens and filters must be cleaned, especially when producing medium-length fiber or polyester filament fabrics, as impurities can easily clog pipes and affect dye liquor circulation. Recommendations:
For medium-length fiber fabrics, brush the filters once per shift; For polyester filament fabrics, clean them at least once a day; During cleaning, add a suitable amount of waste cloth to the tank and use high-speed water flow to flush the nozzles and "dead corners" of the circulation system, improving cleaning effectiveness.
For dark-to-light or whitening processes, a thorough tank cleaning is essential: Use 4-6 kg of 98% caustic soda and 1-2 kg of detergent, keep at 130℃ for 60-90 minutes, and only after high-temperature discharge can the machine be used for light-colored production.
II. Lubrication and Tightening: Ensuring Smooth Mechanical Operation
Lubrication of mechanical parts is crucial for maintaining equipment flexibility.
Monthly application of high-temperature lubricating oil to friction components such as bearings, gears, and guide roller shaft seats is necessary to prevent dry friction-induced wear or overheating. If grease emulsification or water leakage is observed, the components should be replaced immediately, and the sealing problem investigated.
The tension of V-belts also needs to be checked regularly to maintain proper tension and prevent slippage or breakage.
Weekly inspection of bolts and connectors is required, especially at the cylinder-to-pipe interface, to prevent vibration-induced leaks.
III. Instrumentation and Sealing Management: Ensuring Safety and Accuracy
In high-temperature and high-pressure environments, the performance of instruments and seals directly affects production safety.
Pressure gauges, temperature sensors, and safety valves must be calibrated regularly, ideally quarterly, to ensure accurate and reliable data.
Aging or deformation of sealing rings (gaskets) can easily lead to air or liquid leaks, causing cylinder differential pressure or energy waste. Any leaks should be replaced immediately.
Tempered glass observation windows must never be wiped with a damp cloth at high temperatures to prevent shattering due to excessive temperature differences, which could cause a safety accident.
IV. Thermal System Maintenance: Improving Temperature Control Efficiency
Slow heating/cooling is a common problem, often caused by scale buildup in the heat exchange system or valve malfunctions.
Regularly check if the steam pressure meets standards, clean the steam trap to prevent blockage, and ensure smooth condensate drainage.
The cooling water system should be kept below 25℃ to avoid difficulty in cooling due to excessively high water temperatures. If a significant decrease in the heating rate is observed, check the heat exchanger for scale buildup and clean it promptly.
V. Chemical Residue Control: Avoiding Cross-Contamination
Dyes, oligomers, calcium salts, and other deposits can adhere to the inner wall of the tank, affecting subsequent dyeing results.
Choose the cleaning method based on the deposit composition:
Oligomers: Can be cleaned with NaOH or acidic sulfite detergent; adding a carrier helps dissolve them.
Alkaline scale and calcium salts: It is recommended to use TF-105F tank cleaner, which does not contain strong acids, to avoid corroding the stainless steel inner wall.
Coagulated dyes and greases: Use sodium hydrosulfite + liquid alkali + emulsifier for reduction cleaning.
