Has anyone standardized a quick pre-dye risk check for reactive dyeing that operators follow? We cut re-dyes 28% by locking out the chemical feed during crew change, confirming inline pH 6.2 ±0.1 and a 40°C hold before the first salt addition, but I’m looking for a one-page checklist or training sheet we can post at each jet — happy to share ours in return?
We added a 15‑sec conductivity check at the jet before the first salt shot — verify incoming water <120 µS/cm and confirm the salt bump matches the theoretical rise; it’s caught feed errors and valve crossovers (cheap smoke alarm for the bath)… We also require a quick “no cationic residue” swatch test with a cationic spot‑dye drip on the wet prep fabric — any halo and the lot gets a hot scour rinse before dye. Happy to swap a “one-page checklist”; do you track hardness inline or only per-shift beaker?
We’ve had good luck with a fast load-mass check: weigh the wet lot on the carrier pre-fill and let the PLC auto-recalc liquor ratio/salt/alkali if it’s off by >3% — underfills were skewing the first salt hit. @ethanross75 do you allow LR edits on the HMI or lock to recipe?
30-sec alkali feed check with a handheld refractometer before the ‘40°C hold.’ If carbonate, do a quick density check?