Product quality and energy consumption optimisation of dyeing fixing process by steaming through DOE analysis: a cotton case study

Simultaneous improvement of product’s quality and process’ energy performances of dyeing fixing on cotton fabrics is studied in this work. A full factorial design, starting from factor’s ranges currently in use by textile industrial operators, was settled following design of experiments guidelines, resulting in a two-factor (team flow rate and steaming time) and three-level experimental plan, including three repetitions of the central point. Both analysis of variance and best subset analysis were carried in order to establish the real effectiveness of each independent variable. Analyses point out the high influence of steaming time, while the one of the steam rate is negligible, which leads to the opportunity of producing the best quality fabrics at the lowest level of steam rate, maintaining the time under the traditionally employed one. These results if properly applied to an industrial size equipment, can be translated in consistent energy and, consequently, and economical savings.