Employing the valuable knowledge of the experts in your company, Datacolor PROCESS helps you manage dye recipes and production dyeing procedures. Process parameters and auxiliary quantities are automatically adjusted based on dye quantity, customer, fabric, dye machine, and performance requirements to achieve an optimized dyeing procedure.

 

Datacolor PROCESS – Produces the most accurate and efficient production dyeing procedure through rules-based calculations for complex dyeing processes.

Datacolor TICKET – Simple dyelot tickets are produced to ensure accuracy in production dyeing.

 

Designed for:
Ideal for textile continuous and exhaust dyeing facilities seeking to improve efficiency and accuracy in their dyeing procedures.

 

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Automated Dyeing Procedures

Automated Dyeing Procedures

 

Datacolor PROCESS automatically generates the best production recipe and dyeing procedure for any color based on relevant dyeing requirements. Rules based on liquor ratio, customer, fabric, dye machine, and dyestuff quantity automatically adjust dyeing parameters and chemical amounts to eliminate dyeing errors. Temperature ramp rate and dyeing time are optimized to ensure the most efficient dyeing cycle.

Datacolor Process Automated Dyeing Procedures

Dyelot History and Recipe Correction

Datacolor Process Dyelot History and Recipe Correction

Dyelot History and Recipe Correction

 

Dyelot history and quality analysis enable proactive recipe correction to reduce dye adds. Instantly review results for previous dyelots, including all colorimetric data to identify potential production issues before costly mistakes occur. If a dyelot is off shade, connect to Datacolor MATCH TEXTILE to generate the most accurate and cost-effective correction to get the dyelot back on shade.

Advanced Production Management

Advanced Production Management

 

Datacolor PROCESS supports exhaust and continuous dyeing on any fiber type. Configure dye machines with min/max control of machine capacity, liquor ratio and pickup. Generate simple production recipes or a complete production process including recipe and process costs. Optional inventory control ensures product availability, while dyelot scheduling guarantees the most efficient use of available equipment.

Datacolor Process Advanced Production Management

Workflow Integration

Datacolor Process Workflow Integration

Workflow Integration

 

Datacolor PROCESS works seemlessly with Datacolor MATCH TEXTILE and Datacolor WEIGH to manage the entire textile dyeing process from lab to production. Designed to link with dye machine supervisor and ERP systems, customized integration modules ensure that dye and chemical quantities and process parameters are passed between systems without the need for manual re-entry of data.

Datacolor PROCESS™ software license of defined level

OPTIONAL MODULES THAT EXPAND DATACOLOR PROCESS CAPABILITIES TO
MEET INDIVIDUAL NEEDS:

 

Basic level inventory module

  • Definition of specific stock conditions (minimum and optimum amount, drum capacity) for each product and for lists of products below minimum quantity.
  • Automatic product quantity update for those production batches marked as finished, including low stock alert
  • Display of added, used and adjusted quantities
  • Display of all dyelots by specific product
  • Report of stock value with current price and predefined consumption reports

 

Advanced inventory module

  • Manages all reservations, deliveries and orders, with the ability to accommodate variations in product strength and price delivery.

 

Customized form editor module

  • Report Explorer for creation and customization of reports, including:
    • Production card customization
    • Report creation using a “wizard,” e.g. list of dyelots by machine and with additions per month; list of recipes using specific dyestuffs.
  • User-friendly tool for creation and modification of record lists, e.g. all products below stock minimum
  • Export of generated report lists into text files

 

Dyeorder module

  • Groups or splits dyelots that are dyed using the same recipe, for maximum machine capacity usage
  • Advanced formula/rules module expands the automated optimization functionality
  • Control of dyestuff combinability
  • New bath generation for continuous dyeing corrections
  • Display of total forecasted process time in temperature/time diagrams
  • Introduction of batch parameters and adaptation of chemicals and parameters
  • Calculation/optimization of production cost for different dyestuff, chemicals and
    machine operation choice.
  • Optimization of chemicals, parameters and dyestuff quantities upon a large choice of conditions, e.g. concentration, customer, machine, LR, etc.
Processor Pentium 4 2.5 GHz
Memory 2 GB
Free Hard Drive Capacity 120 GB
Video Resolution 1024 x 768 True Color
Video Memory 128 MB
CD/DVD Drive CD Writer
Diskette Drive 1.44 MB
Available Ports (1) RS-232 Serial, (3) USB
Printer Port Parallel or USB
Operating System Windows® XP Pro, SP 2
Feature Description
Dyestuff data management Input of fiber groups and affinities
Automatic creation of dyestuff names
Dyestuff exchange
Quality/Style management Input of fiber groups and affinities
Input of blends
Input of all quality specific parameters/auxiliaries for dyeing behavior
List and display of all customer or quality-specific colors and standards
Color management List of all recipes and dyelots per color
Customer management Input of customer data
Customer-specific standard labeling with specific name
Recipe and Process management Input of complete production recipes, incl. specific recipe information
Pass/Fail results of recipes to the standard can be displayed on recipe card
Storage of recipe status (theoretical, laboratory, production)
Printout of lab recipes, simple production recipes and complete production process
Recipe search via different search criteria
Automatic recipe update upon dyestuff concentration changes
Specific information like finishing type, preparation type, technical specification and “to do” date for generation of dyeing process
Creation of modular production recipes including process handling for single treatments and multiple treatments
Handling of exhaust, continuous and semi-continuous processes
Specific linked processes for production adds and re-dyes
Automatic process selection through defined rules
“If-then-else” rules that vary according to dyestuff amounts in the recipe, the affinity or dyeing machine group
Recipe evaluation based on product costs
Tank number and volume can be calculated, depending on total volume (Pad-batch)
Production management Batch ticketing: simple or advanced with additional information
Input and list of defined dyeing lots
Calculation of chemical /dye quantities for the dye kitchen
Output of simple production lots (simple batch ticket)
Output of production adds (production ticket) with additional technical information
Category creation of qualities/styles and customer
Machine management with min/max machine load, liquor ratio, etc.
Choice of dyeing machine with min/max control of machine capacity, liquor ratio, pickup etc.
Input of delivery and required date
Display of Pass/Fail results in the dyelot card
Sorting of production lots
History of production lots and production adds
Cost analysis (recipes and processes) Cost calculation of lab recipes
Production cost calculation incl.dyestuffs and chemicals
Cost comparison of different processes/cost optimization
History of production cost

Optional modules that expand Datacolor PROCESS capabilities to meet individual needs:

Module Added features
Basic level inventory module Definition of specific stock conditions (minimum and optimum amount, drum capacity) for each product and for lists of products below minimum quantity
Automatic product quantity update for those production batches marked as finished, incl. low stock alert
Display of added, used and adjusted quantities
Display of all dyelots by specific product
Report of stock value with current price and predefined consumption reports
Advanced inventory module Manages all reservations, deliveries and orders, with the ability to accommodate variations in product strength and price delivery
Customized form editor module Report Explorer for creation and customization of reports, including:
–> Production card customization
–> Report creation using a “wizard,” e.g. list of dyelots by machine and with additions per month; list of recipes using specific dyestuffs
User-friendly tool for creation and modification of record lists, e.g. all products below stock minimum
Export of generated report lists into text files
Dyeorder module Groups or splits dyelots that are dyed using the same recipe, for maximum machine capacity usage
Advanced formula/rules module expands the automated optimization functionality Control of dyestuff combinability
New bath generation for continuous dyeing corrections
Display of total forecasted process time in temperature/time diagrams
Introduction of batch parameters and adaptation of chemicals and parameters
Calculation/optimization of production cost for different dyestuff, chemicals and machine operation choice
Optimization of chemicals, parameters and dyestuff quantities upon a large choice of conditions, e.g. concentration, customer, machine, LR, etc.
Graphical Planboard Fully integrated with Datacolor PROCESS
Visual overview of machine load
Immediate visibility of planned, active and finished dyelots
Dyelots are represented graphically by the target color
Plan dyelots on any machine with verification for machine suitability
“Drag and drop” functions easily move a dyelot from one machine to another
Advanced scheduler In addition to the planboard, the scheduler allows time forecasts of the dyehouse
*(requires advanced formula module)
Real-time dyelot display
Automated planning after creation of dyelots in Datacolor PROCESS
Incorporation of offline times
Regeneration of dyelots that have been moved to another machine
Printing Module Grouping of all relevant printing recipes to be kept as one design