Inline Color Measurement Solutions for Assessing Color of Denim Yarn

Color plays a vital role in the denim industry, contributing significantly to the creation of distinct and stylish clothing pieces. Whether it's classic blues or more vibrant shades, color adds character and visual appeal to denim garments. Nonetheless, maintaining consistent color in the denim industry comes with its share of challenges.?

One of the major obstacles revolves around ensuring that denim yarn matches the intended color, a key factor in achieving a cohesive final product. To address this, an inline color control solution steps in, evaluating the color of yarn post-dyeing to identify any deviations. This allows for the sorting of yarn based on its shade before shipping.

In this article, we'll explore these challenges, discuss the advantages of using an inline color solution, and introduce X-rite’s ERX130 spectrophotometer—an exceptional inline color measurement solution that sets a high standard for accuracy in the market.

The Challenges of Color Management in the Denim Industry

Denim yarn must be on-color to create a seamless and cohesive final garment. A variation in color can disrupt the overall aesthetic appeal and impact the quality of the finished garment.

Yet color consistency is a challenge for denim yarn manufacturers for a variety of reasons. Some of the most common challenges include:

• Each individual fiber is subjected to dyeing with indigo pigments and multiple dyes, essential for achieving the desired hue.
• The process of indigo dyeing introduces varying color tones to denim yarn owing to disparities in the reducing agents utilized.
• Numerous parameters within the dyeing machinery exert influence on color, encompassing dye concentration, chemical composition, temperature, and the duration of immersion in the dye bath.
• The color of denim yarn might undergo alterations upon drying.
• Denim dyeing facilities are compelled to align with sustainability initiatives, adding an extra layer of complexity to the process.

The Solution: Inline Color Control Solution

An inline color control system is capable of overseeing the color quality of denim yarn throughout various stages of the dyeing process. The non-contact ERX130 spectrophotometer is positioned either above the rope on a rope dyeing machine at a distance of 300mm (11.8") or? above the fibers on a slasher machine on a moving beam to distinguish color variances in cross direction.

Spotting a measurement field of 90mm (3.5"), the ERX130 consistently captures readings and transmits color data via quality control software. This empowers operators to promptly implement corrective measures and uphold ISO compliance by tracking color variations.

The process is quite simple:

Slasher Dyeing:?

• At the outset of the machine, the fibers are measure as they are still singlefibers next to each other.
• Positioned at a traversing beam over the yarn web, the ERX 130 records color measurements on the yarn, covering the range from the center to the left and right sides.
• The measurement data is transmitted to the QC software, enabling operators to assess uniformity and adjust contact pressure on the padder rollers. This adjustment facilitates the removal of excessive dye, thus regulating color control.

Rope Dyeing:

• Following dyeing, individual denim fibers are combined into a bundle. In some instances, small strings might necessitate further combination to form a larger measurement area.
• The ERX130 is affixed above the rope, capturing color measurements
• Thanks to itslarge measuring spot, the ERX130 captures multiple fibers, thereby providing a reliable measured value.
• Measurement data is relayed to the QC software, empowering operators to appraise color consistency and categorize yarn based on shade.

Final QC:

• Denim color can also be affected by fixing, washing, and drying processes. Consequently, color assessment can be conducted anew prior to shipment.
• Placed on an inspection table, the ERX130 performs spot measurements.
• Measurement data is communicated to the QC software, allowing operators to gauge color consistency and implement corrective actions before the items are dispatched.

What Results Can You Expect from Implementing an Inline Color Measurement Solution?

By adopting an inline solution like X-Rite's ERX130 Spectrophotometer, denim manufacturers can realize the following benefits:

• Decrease start-up and shade transition times by 20-50%
• Identify quality enhancements at an earlier stage, leading to a 25-35% improvement
• Minimize waste production by 20-50%
• Maintain comprehensive process documentation compliant with ISO 9001 standards
• Make progress towards achieving sustainability objectives

Conclusion

X-Rite's ERX130 Spectrophotometer is a game-changer for denim manufacturers, empowering them to enhance efficiency, quality, and environmental responsibility. By embracing this solution, the denim industry can harmonize color consistency, streamline processes, and make strides toward a more sustainable future.