KIMM Develops Real-Time Dyeing Information Monitoring Technology
Reduce defects by monitoring the dyeing process in real time
Module mounted on dyeing machine, visualization of changes in dyeing variables


There are about 1,500 domestic companies in the dyeing and finishing industry, which is a major middle-stream of the textile and fashion industry, but most of them are small-scale and have low productivity. The 'Right first time' rate, which is the percentage of a color ordered by a customer that is reproduced in a single dyeing cycle in a dyeing machine, averages 80–85%, but drops to 60% or less when dyeing new colors.

The Korea Institute of Industrial Technology (KITECH) announced on the 5th that it has developed a 'real-time integrated dyeing information monitoring technology' that can reduce the occurrence of defects by measuring and controlling key variables of the dyeing process in real time.

The research team led by Group Leader Shim Jae-yoon of the Smart Textile Group has spent the past three years measuring three major dyeing variables—dye absorption rate (the rate at which dye is applied to the fabric), pH concentration, and color change—in real time with the goal of improving the dyeing success rate, and has produced an integrated module capable of visually displaying these changes in PC-based dedicated software.

Since dyeing machines have a sealed structure, it is difficult to visually check the dyeing status during operation; however, the manufactured module is connected to the machine via a separate line, allowing for the real-time extraction and analysis of the dye solution. The extracted dye solution is measured, analyzed, and stored by an IoT dyeing controller and a database system, including dye solution measurement sensors and pH sensors installed within the module. The results are visualized in the form of graphs, enabling operators to understand them easily and quickly. In addition, it is equipped with a function to monitor energy consumption, such as steam, water, and electricity, during the dyeing process and to tally the results by period.

By utilizing the developed technology, workers can accurately determine the timing of chemical injection and dyeing completion based on module analysis values, and maintain and manage dyeing conditions consistently, thereby increasing work productivity. In addition, when performing the same dyeing work, future dyeing time can be shortened by approximately 25% and post-dyeing washing time by approximately 30% compared to the conventional method, and washing water usage can be reduced by about 20%, resulting in reduced energy consumption.

Modules developed overseas can only measure individual variables such as dye adsorption rate and pH, and are manufactured on a laboratory scale, requiring additional calibration by experts for field application. However, the developed module can measure all three variables simultaneously and requires no calibration, making it advantageous for field application.

The research team has completed a demonstration test on a 50kg class dyeing machine at a pilot plant established at the Ansan Convergence Production Technology Research Institute, and plans to install the module at the business site of S Company, a textile manufacturing specialist, in the second half of this year for a pilot operation.