Inovation in Dyeng - This
Inovation in Dyeng - This
Inovation in Dyeng - This
Dyes
Man Power
Chemicals
Energy Water
Machinery
Dyeing Components
It has been estimated that in a standard cotton dyeing process Bleaching, washing and rinsing
USES
* 70% of the total time * 80% of the water * 90% of the energy
eco master
eco master
3.30
1:12
1:10
1:8
1:8
1:5
Steam Consumption
SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT
1.485
SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT SALT
1:20
1:15
1:10
1:8
1:5
Liquor Ratio
Chemical Usage
RINSEtronic
RINSEtronic automatically calculates the correct rinsing producedure to arrive at a bath residual salt content of less than 1g/l only necessary to enter the salt concentration & the dept of shade in the dye program Result : Shorter cycle time Lower water consumption Reduced effluent
RINSEtronic
2 to 5% reactive dye stuff
variable
Old system
RINSEtronic system
pH-TRONIC
A system for pH controlled dyeing. The function pH-TRONIC enables pH adjustment following the pH-gradient and at the same time setting the required machine temperature. The control system consists of a pH measuring point and a chemicals dosing unit, which incorporates a dosing valve for linkage to an existing pressure ring main or alternatively equipped with appropriate dosing pumps.
Result : Higher First Time Right rate Easy handle of pH New / different dye procedure (especially in PA dyeing)
pH-TRONIC
pH measure and regulating system for pH controlled dyeing Stationary or mobile Re-cooler
pH-FiT
A system for pH controlled dyeing with a fully automated cleaning and calibration of the pH-electrodes. The modern pH-FiT Fuzzy-integrated-Technology enables pH adjustment following the pH-gradient and at the same time setting the required machine temperature. The control system consists of a pH measuring point and a chemicals dosing unit, which incorporates a dosing valve for linkage to an existing pressure ring main or alternatively equipped with appropriate dosing pumps.
Result : Higher First Time Right rate Easy handle of pH no operator needed for cleaning and calibration of the probes New / different dye procedure (especially in PA dyeing)
pH-FiT
pH measure and regulating system for pH controlled dyeing Fully automated calibration of the probes Stationary or mobile Re-cooler Developed by DyStar, SETEX and Thies
Media r ( . to red )
Fe
2+
e
waste water
e
Dyestu f f ( reduced)
Sal t
dyed f re ib
Fe
3+
Media r ( . to ox ) Cathode
Dyestu f f ( reduced)
dyed f re ib
Dyebath
Dyebath
- 200 mV 9A 20 C
Time Redox pot ia ent l [mV] Cel cur l rent [A ] Te mpera ure t [ C]
e lect lys ro is ce l l
lquor i used
Reduct. clearing
Dithionite Caustic soda
4 140 g
150 l
9 160 g 55 %
1 000 l
16 240 g 75 %
2 000 l
21 440 g 80 %
2 000 l
Only process chemicals considered; Discharge in the EC technique approx. 15% of the liquor volume.
eco-bloc quattro
Dye up to 4 colours at a time in one machine Kier combinations 1 + 1 + 1 + 1 = 4 colours 2 + 2 = 2 colours 3 + 1 = 2 colours 4 = 1 colour 4 or 6 packages per kier batch reduction
eco-bloc X
HT-Jigger Tiro
developed by: &
Woven fabric All exhaust dyeing processes Fabrics with low length wise stretch Very light to very heavy qualities Special treatments (open width scouring)
All substrates Crease sensitive fabrics Impermeable fabrics Varying batch sizes Large fabric widths
Fabric tension: Speed: Fabric width, max. Roller width, max. Roller diameter: Roller batch dia.: Fabric height:
5 to 70 kg/cm 10 to 150 m/min 3800 mm 4000 mm 270 mm 1000 or 1230 mm (dependent on the type of m/c) 365 or 475 mm (dependent on the type of m/c)
Technical Advantages: A Fabric Rope Controller automatically calculates the r.p.m. ensuring exact fabric speed and tension providing excellent dye penetration. Automatic sampling point selection. Direct drive of the main rollers by frequency controlled motors with brake current return provide a considerably shorter braking distance compared with hydraulic drives.
Automatic dosing of dyes and auxiliaries depending on the fabric length passing through the bath provides excellent reproducibility. High efficiency external pump unit and heat exchanger ensure controlled and even flow throughout the system. Constant dyeing conditions in the economical trough for varying batch sizes (55-100% loading capacity; water meter required).
ecoMaster
Multi Contact Dyeing
CCR Combined Cooling and Rising 100% Stock tank Power drain & fill Automatic filter Water meter Liquor Ratio 1:5 pH FiT Analogue Dosing Analogue levels Vario chamber RINSE tronic
ecoMaster
Features
Multi Contact Dyeing & rinsing using dual nozzles Liquor ratio 1:4.5 - 1:5 RINSEtronic rinsing system reduces process time and water consumption Winch speed up to 400 m/min Liquor ratio reduced by new sump and pump configuration Standard step filter
ecoMaster
eco-soft PLUS Process water (25C. 60 C) Cooling water Effluent Steam Electrical Power Time 46 litres 0,00 44 litres 2.24 kg/kg 0.1 kW 5.8 hrs
ecoMaster 34.5 litres 0,00 32 litres 1.92 kg/kg 0.12 kW 4.83 hrs
soft TRD DS XL
Especially suiteable for surface senstive and light weight fabrics Double rope design Liquor ratio starts from 1:8 Fabric speed up to 600 m/min Operating temperature up to 140C 1-4 chambers per machine. Option of chamber isolation and coupling of two machines Chamber configurations 2 x 75 kg = 150 kg/tube 2 x 100 kg = 200 kg/tube 2 x 125 kg = 250 kg/tube 2 x 150 kg = 300 kg/tube
soft TRD DS XL
new internal chamber design compact machine design short fabric circulation and flooded fabric transport
lower liquor ratio minimal floor space requirement gentle handle of fabric
Luft-roto plus
Developed by: &
Luft-roto plus
==> reasonable liquor ratio ==> smooth fabric transport ==> minimised mechanical stress ==> improved opening and therefore better folding of the fabric ==> gentle plaiting into the fabric chamber ==> flexible application
Luft-roto plus
==> faster bath changes ==> possibility of preparation of the next dye bath ==> low set-up times ==> cooling water used as rinse water ==> very good cleaning effect ==> saving of rinse baths ==> pump operation during bath change ==> time saving
CCR Function
Rapid drain
Luft-roto plus
Temp C
Te mp.-time -c urve
LR 1:6
LR 1:6
LR 1:6
40
50
60
70
80
90
100
110
120
130 140
150
160
170
180 190
200
210
220
230
240 250
260
270
280
290 300
310
320
time in min.
Conventional process
Temp C
Te mp.-time -c urve
LR 1:6
LR 1:6
LR 1:6
40
50
60
70
80
90
100
110
120
130 140
150
160
170
180 190
200
210
220
230
240 250
260
270
280
290 300
310
320
time in min.
Conventional process
Consumption data
Temp C
Te mp.-time -c urve
LR 1:4,5
LR 1:3,7
LR 1:4,5
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
time in min.
A x g/l auxiliaries B x % dyestuff 1/2 amount of salt C x g/l Soda 1/2 amount of salt
Temp C
Te mp.-time -c urve
LR 1:4,5
LR 1:3,7
LR 1:4,5
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
time in min.
Developed by
&
Consumption data: Process water: 28 - 35 l/kg - 40 % Cooling water:1,4 - 1,8 l/kg Steam: 3,3 - 4,0 kg/kg - 30 % Electricity: 0,16 - 0,22 kWh/kg Enhanced dyeing process
no saving no saving
Consumption data
Volumetric dosing of Liquid Chemicals Modular extension 10, 20 ....... Low level inlet Integrated manual dispensing option Low maintenance
Liquid Chemicals
Liquid Chemicals
Option of varying capacities - 20 to 80 products Dust Extraction system One or more scales Automatic product retrieval Interface to OrgaTEX
Powder Dyes
CAPACITIES - 100, 200, 300, 600 litres OPTIONS : - Hot water preparation station - Water blending valve
Powder Dyes
Weighing
Temp C
140 120 100 80 60 40 20 0 0 20 40 60 80
100 120 140 160 180 200 220 240 260 280 300 320
Time in minutes
N S
T 737
Liquid Chemicals
Dye Stuffs
Powder Chemicals
T 737
T 737
t t
SN
T 737
Server
Colour Matching
Dye Store
DKSH Group
Melbourne, Australia
Marinco, Chemcolour
Auckland, New Zealand