Name: Dye Production Optimization Software: Process and Ticket
Brand: Datacolor
Availability: InStock

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.

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

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, Windows 10 & 11

Datacolor PROCESS Product Brochure (English)

Visit the FAQ Hub to Get All of Your Questions Answered

See how my peers are using the Datacolor

How do I test a Mettler scale in Datacolor Weigh?

The attached document contains the Mettler scale SICS communications protocol and how to test the scale using the HyperTerminal program.

What scales are supported in Datacolor Weigh?

See attached document for the list of scales supported in Datacolor Weigh software.

Datacolor Process takes a long time to open a list of records.

Datacolor Process uses a set of local look up tables to speed up the opening of screens. Occasionally these sets of look up tables can become corrupted slowing the software and so need resetting. Follow the procedure in the attached document to reset the tables.

How do I switch on the adapt concentration column in a recipe?

Follow the instructions in the attached procedure.

How to change the bath volume inside a recipe template.

In Job ticket, it is not possible to change the volume in Operation. But it is possible to introduce a factor in the Recipe Template call-off.

The call-off volume will be equal to the dyelot volume multiplied by this factor. See attached document.

How do you adapt recipes as a function of liquor ratio?

The quantities of dyestuffs must be modified following rules that are specific to each dyestuff. In this example, the adaptation depends on the liquor ratio, but it can be adapted to other variables.

The attached document has been written for Datacolor Process v.2.1. Since Datacolor Process 2.2, it is possible to add parameters to each dyestuff record and even formulas (see IP2 TN011 – Quantity related to each dye.doc). With this new feature, you can simplify the following procedure by including the dyestuff factor calculation directly in the dyestuff record.

Use of the coupled machines feature in Datacolor Process

In Datacolor Process or ITMProcess, it is not possible to create a dyelot that uses two or more machines at the same time. You have to create a virtual machine that has the total volume of the machines you want to couple. See attached document.

How can we select all dyelots containing 45 and order them?

“select * from Dyelot where dyelot_Id like ’%45%’ order by dyelot_id”

How to select unit with a rule

Units cannot be selected by a formula but, however, it is possible to introduce rules to select units.

Problem:

Dyes quantities less than 10g must be expressed as a volume of a stock solution at 100% or 10%.

Solution:

As formulas cannot be introduced to select a unit, we will introduce in the dye operation two dyes lines, one with a unit expressed as a volume and the other with a unit expressed as a weight.

To avoid from displaying twice a dye (one time for each unit), we will introduce a formula that sets quantity to zero when the unit is the wrong one. As the dyes quantities should not be definitively modified by these formulas, formulas will be set as ‘display only’.

See attached document.

How can we manage 2 volumes in a batch?

Use the function ChangePickup

example: IN CASE OF… THEN ChangePickup(ValueOf(’Newvolume’))

Use of the report option, Dyes parameters and auxiliaries

This report is useful to check the information you introduce in dyestuffs, in tab ’Dyestuff’ tables ’Parameters’ and ’Auxiliaries’. See attached document.

How to enable and disable a dyelot in Datacolor Process or ITMProcess.

See attached document for procedure.

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