Leather hides are given different colour and texture as per customer requirements. Colour is sprayed on the leather using a spray gun. This colour has a standard formula of making, with definite proportion of various chemicals mixed in sequence.
The chemicals required for making the dye, are stored in small drums with capacity 15-20 kgs. All these chemicals are water-based chemicals in liquid form with different viscosities. All these chemicals are mixed together in a rotating drum to form the colour which is then sprayed on the leather hides using a spray gun. Leather requires 5- 6 layers of different chemical mixes coated using spray gun at different intervals and each coat having different formula and proportion.
Currently, an operator picks up the required chemical from the storage area and weighs as per the chemical formulation requirement mentioned in the SAP system and fed into the rotating drum to make the colour.
This task of picking up chemicals from the storage area, weighing and feeding, is manual in nature and is not efficient as it is prone to errors. Operators tend to miss out a chemical or change the order of feeding chemicals and thereby changing the chemical composition of the colour. This might go unnoticed until the colour is sprayed on the leather. This may lead to rejection of the whole batch of leather hides incurring losses. Therefore, we need an automated process of colour making. This automated process should fulfill the following requirements: