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Production Formula Scale-Up

PRODUCT OVERVIEW: Production Scale-Up scales lab or standard formulas up to production quantities with computer and printer. It prints procedure sheets and captures inventory dye and chemical usage data. These programs are designed for continuous dye ranges running single fiber or blend fabrics. They handle up to two dye pads and two chemical mixes per dye range.

This system manages formula storage and retrieval with inventory tracking. It runs on a central computer and can have other computers networked to it. A single local printer can be used or a remote printer in the drug room.

SYSTEM SETUP: This system contains programs to maintain the following files:

1. Dye class file
2. Dye file
3. Chemical file
4. Formula file
5. Procedure (chemical) file
6. Pickup data file

The chemical procedure file contains a set of range instructions printed for each procedure. These programs set up the basic data needed and each has associated listing programs. These listings contain all the associated data and provide a convenient way to maintain an accurate list of currently used production formulas. Dye concentration changes made during the dyeing of a lot can be saved. This insures the most up-to-date actual formula is available for use or upload to other systems.

Reports and listings can be easily modified to provide whatever information is needed by a particular dyehouse operation.

SYSTEM OPERATION: Once the basic data is entered normal daily processing consists of:

1. Scale-up a lot
2. Complete a lot
3. Weekly dump report
4. Lot pickup report
5. Lot file purge (automated)

The scale-up process takes a stored formula and procedure and creates a complete list of dyes and chemicals needed to dye a lot. Dyer's starting (before adds) formula sheets are printed and handed out. Chemical mix sheets for all of the reduction and oxidation baths are printed and distributed.

Stored strength factors (normally 100%) are used for each dye. This facilitates easy switching between single and double strength pasts or adjusting for off strength batches. Formula usage counts and last use dates are maintained for enhanced data reporting. Dye usage and last use data are also captured.

The number of mixes used and the number of gallons of dye dumped are captured. The captured data facilitates an accurate record of the true dye and chemical usage for each lot processed. This information provides the data necessary to calculate processing costs that include all materials for a lot. This is much more accurate than having to use average waste estimates as lot wastes can vary widely. This ensures the dyer is fully aware of his costs and consumptions.

SYSTEM INTEGRATION: The stored data can be transferred to other systems ensuring highly accurate, real-time consumption data is available. Information can be passed to the finishing department for coordination of dyeing and finishing of lots.

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