Automatic Dye Weighing

Spectrum has a ColorService dye and chemical dispensing system. The powder dye weighing system is capable of weighing 0.01 gram of dye with excellent accuracy. Liquid chemicals are also weighed with exceptional accuracy by a separate liquid dispensing unit. The products are then automatically dissolved and sent to the machine's add tank. Chemical quantities are automatically supplied to dispensing by the formula management and machine control systems. This process reduces possible mistakes made by manual entry of data.

Automated Dye Control

Spectrum has designed and installed an automation system. This software was completed "in house", and thus, Spectrum has the flexibility to rapidly adapt to changing processes and customer needs. Programmable Logic Controllers (PLCs) handle immediate machine processes while traditional PC-based programming software handles the user interface, data manipulation and reporting. The result ensures the reliability of PLCs for individual machine control combined with the power of desktop computers for data handling.

The primary feature of this system is a built-in monitoring system. An array of alarms alert supervisors if any part of the process does not proceed as requested. Any exceptions are stored in databases for reporting purposes and analysis. This ensures that every lot is processed to optimize quality and efficiency. Dye machine automation links the dye formulation data with the machine procedures and the dye/chemical dispensing system, providing maximum efficiency.

Winding Technology

Spectrum uses the latest technology in winding yarns after dyeing. The most important step has been the installation of Murata precision winders. By combining our knowledge with Murata, Spectrum has designed a unique winder for dyed yarn packages to assure maximum efficiency to our customer's specifications. The computerized, automated process provides maximum flexibility.

Other benefits include:

• The ability to produce the highest quality wound yarn. Cone wound packages that are consistent in tension, wax application, weight and diameter. Package sizes up to 7 lb.
• Cleaner yarn due to:
  • - Controlled environment.
  • - Less lint and contamination.
  • - Less handling.
  • - Yarn cleared of defects using a Peyer Clearing Head.
• Knotless yarn.
• Stronger yarn due to a straight winding path.
• Alandale enclosures create a separate room for each individual winder to prevent color contamination.