Batch to Batch Shade variation in Dyeing

Question: I am getting batch-to-batch variation for the same reactive shade, in Soft Flow machine. I am using the same manufacturer’s dyes and chemicals and almost same quality of fabric. What are the reasons and how to avoid it?

Answer: Batch to batch shade variation is a general phenomena noticed almost everywhere in dye houses. There are so many factors that affect a particular dyeing operation. Please make the following checks; I hope you can eliminate 90 to 100% of the above problem.
Phase-1: Preparatory Stage.
Check the batch weight exactly for all batches. Find the exact GSM of the greige fabric and note down on your job card.
After Scouring, Bleaching and neutralization, before dyeing, take a sample, dry it, condition it and check the GSM.
Note down the difference in percentage as Scouring and bleaching loss on the job card. Compare this loss% between each batch. It should not deviate more than 2 to 3%.

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