How a continuous range works
The cloth passes through the range without stopping. First it is padded with dye liquor and squeezed. Then it is dried, and the dye is fixed by heat or steam. Last, it is washed and dried again.
For polyester with disperse dyes, the fixing step is thermosol: a hot air oven at high temperature for a short time. For cotton with reactive dyes, the fixing is by pad-steam or by baking.
When it makes sense
A continuous range pays off on long runs of few shades. One shade can run for tens of thousands of meters with little change in color along the roll.
It does not suit short runs and frequent color changes. Each change wastes cloth and time. For small lots with many shades, a jigger is more flexible.
Typical process data
| Item | Typical range | Note |
|---|---|---|
| Line speed | About 40 to 60 m/min | Depends on fabric and oven length |
| Wet pick-up (dyeing) | 50 to 80% | Cotton about 55 to 70%, polyester-cotton about 45 to 50%, viscose about 85 to 95% |
| Thermosol (disperse dye) | About 180 to 280 °C, 15 to 30 s | Polyester and blends |
| Pad-steam (reactive dye) | About 101 to 103 °C, 60 to 120 s | Cotton and cellulosic |
| Baking (reactive dye) | About 130 to 160 °C, 2 to 5 min | Pad-dry-bake |
| Fabric | Woven cotton, polyester-cotton, polyester, linen | Knit fabric needs a different design |
Typical ranges from published process data, not machine ratings. Line layout and ratings are set in the quotation.
How to choose
Work out the monthly meters per shade. Long runs justify the line. Short runs do not.
State the fiber and dye class. They set the fixing section: thermosol oven, steamer or bake oven.
Give the widest fabric and the target speed. They set the padder, the dryer and the oven length.
Ask about the washing section. Reactive dyes need several wash boxes and good counter-flow water.
Frequently asked questions
Do you supply the complete line?
Yes. We supply the padder, dryer, thermosol or steam section and the washing range as one line, matched in width and speed.
Can I use my existing stenter as the thermosol oven?
Sometimes. The oven must reach the temperature and have the dwell time. Send the stenter details and we will check.
What do I send for a quote?
Fabric type and weight, widest fabric, dye class, target speed or daily meters, heat source, and destination country.
