SedoTreepoint-Seminar Dhaka 2014-1

Download as pdf or txt
Download as pdf or txt
You are on page 1of 188

www.sedo-treepoint.

com
www.sedo-treepoint.com
Author/Speaker: Mr. Herbert Guebeli
04. April 2012 - page 1:

Page 1
Ecology meets Economy

Seminar Dhaka 2014 / Part 1


Herbert Guebeli
www.sedo-treepoint.com

History of SEDO TREEPOINT


Page 2

• 1978 SEDO GmbH was founded in.


• 1987 TREEPOINT AG was founded.
• 1990 SEDO became part of BARCO.
• 1997 TREEPOINT & BARCO SEDO started cooperation.
• 2000 TREEPOINT and BARCO SEDO decided to develop
a common product line until ITMA 2003 / ITMA 2007.
• 2004 TREEPOINT became integrated into BARCO.
• 2007 SEDO and TREEPOINT merged to Sedo-Treepoint.
1. Introduction: Sedo Treepoint www.sedo-treepoint.com
Page 3

Page 3

• Since 1978, we globally develop and supply integrated systems for the
textile finishing industry.
• We are the inventor of the first automatic dyeing machine controller and have
installed the first fully automatic dyeing mill.
• Today, we supply highly integrated system from ERP level, linking to our
MES systems, to the machine floor. We offer solutions for process
management, color management, printing and energy management.
1. Introduction: Sedo Treepoint www.sedo-treepoint.com
Page 4

Page 4

• Our customers are the textile dyeing and finishing industry, textile dyeing and
finishing machine builders, dye stuff manufacturers, the apparel industry,
leather industry, paint industry and institutes.
• Our products and support help customers optimizing their production.
• At present, we focus on green textile technology, delivering the best
available technology to reduce energy consumption,
chemical use and waste water.
1. Introduction: Sedo Treepoint www.sedo-treepoint.com
Page 5

High Lights Page 5

• Sedo Treepoint GmbH


• More than 40 employees
• Worldwide presence
• Group of companies with Savio Spa., Loepfe, BMSvision

– Headquarter in Germany
– R&D in Germany and Switzerland
– Offices in Germany, Switzerland, Belgium, Italy, UK, USA, India, Singapore, Brazil
and China
– A dedicated team with experts from multiple areas
– Multidisciplinary: Electronics, IT, automation, colorimetric, textile finishing, energy
management
– Cooperation with innovative partners (Datacolor, Minolta, X-rite, Mathis, …)
– Consultant customer for textile dyeing, printing and finishing.
– Long term projects with open dialogs and special solutions (Sika, Clariant, Coats,
Milliken, Vorwerk, etc. )
1. Introduction: Sedo Treepoint www.sedo-treepoint.com
Page 6

Global company Page 6

• Worldwide network with offices, distributors and agents.


• Mayor growth in the last years in China, Taiwan, India, Bangladesh, Thailand,
Indonesia, Vietnam, Brazil…
1. Introduction: Sedo Treepoint www.sedo-treepoint.com
Page 7

System integration Page 7

From ERP with


SedoExpert

and MES systems with


SedoMaster
EnergyMaster
ColorMaster
PrintMaster

to machine
control and
data
acquisition
Sedomat
1. Introduction: Sedo Treepoint www.sedo-treepoint.com
Page 8

We can help you to optimize processes: Page 8

• Machine controllers, PLC’s, I/O ´modules and sensors for machine

• Central systems, monitoring and data acquisition


1. Introduction: Sedo Treepoint www.sedo-treepoint.com
Page 9

We can help you to optimize processes: Page 9

• Recipe and color management software for laboratory and production

• Energy Management
1. Introduction: Sedo Treepoint www.sedo-treepoint.com
Page 10

We can help you to optimize processes: Page 10

• Quality control systems for lab and production


1. Introduction: Complete integration of vertical textile production www.sedo-treepoint.com
Page 11

Complete integration by Sedo Treepoint as part of the Savio Group Page 11


www.sedo-treepoint.com

Saving Potentials
Page 12

Topics: Ecology meets Economy

Saving potentials:
1. A complete solution for dye house automation
2. Saving potential trough material control
3. Color management integrated in process management
4. Dye machine automation and intelligent process
management.
5. Energy management and resources optimization
www.sedo-treepoint.com

Saving Potential 1
Page 13

Saving Potential 1:

A complete solution for dye house


automation
www.sedo-treepoint.com

Market: Most important relations


Page 14

Our main Customers:


Dyeing, Printing Machine
Finishing

Garment SEDO
Customer TREEPOINT
Apparel

SEDO
Dyes &
TREEPOINT Chemicals
www.sedo-treepoint.com

Optimization today
Page 15

Todays Island
solution

Many people
coordinate
and optimize
independent
www.sedo-treepoint.com

Smart Technology / Optimization potential


Page 16

Smart
Technology
integrates
all different
subsystem
www.sedo-treepoint.com

Sedo Treepoint - the complete solution


Page 17
1. Introduction: Sedo Treepoint www.sedo-treepoint.com
Page 18

System integration Page 18

From ERP with


SedoExpert

and MES systems with


SedoMaster
EnergyMaster
ColorMaster
PrintMaster

to machine
control and
data
acquisition
Sedomat
www.sedo-treepoint.com

Which areas we have to control?


Page 19
www.sedo-treepoint.com

Control it all
Page 20

There are three main areas for quality control in production:

• Material:
• the material itself
• its preparation (pre treatment)

• Recipe:
• color matching
• Lab dispensing and Lab dyeing
• Recipe and process formulation
• checking dyestuff conformity
• correct dye liquor preparation

• Process:
• Lab to Bulk Recipe transfer
• Process formulation / selection
• process control
www.sedo-treepoint.com

Saving Potential 2
Page 21

Saving Potential 2:

Saving potential trough material


control
www.sedo-treepoint.com

Control it all
Page 22

There are three main areas for quality control in production:

• Material:
• the material itself
• its preparation (pre treatment)

• Recipe:
• color matching
• Lab dispensing and Lab dyeing
• Recipe and process formulation
• checking dyestuff conformity
• correct dye liquor preparation

• Process:
• Lab to Bulk Recipe transfer
• Process formulation / selection
• process control
www.sedo-treepoint.com

Material Control
Page 23

Morapex
www.sedo-treepoint.com

Function of Morapex
Page 24

Parameters:
• temperature
• pressure
• volume
• speed
• size of fabric
www.sedo-treepoint.com

What to analyze?
Page 25

Immediate information before dyeing / printing:

• pH measurement (in 2 minutes)


• residual alkali, acids and salts
• residual peroxides,
• residual size
• conductivity
www.sedo-treepoint.com

What to analyze?
Page 26

Immediate information after dyeing / printing:

• controlled wash procedure


• pH measurement
• wash fastness
• water fastness
• residuals on fabric
www.sedo-treepoint.com

Wash fastness with Morapex


Page 27

Wash fastness according


Morapex method:

• in 2 minutes on the wet fabric

Wash fastness according


Standard method:

• 1 hour washing 60°C in wash liquor


www.sedo-treepoint.com

Core-alkali control with Morapex


Page 28

Situation: Cut through a fiber

Morapex method:
• immediately after production
measured pH in extract was 8 -
9.

Standard method:
• immediately after production
the measured pH was around 7.
After few weeks on same fabric
the measured pH was 8 - 9.
www.sedo-treepoint.com

Formaldimeter
Page 29

• Two most commonly used test methods are supported:


– Free Formaldehyde / Jap. Law 112 and EN ISO 14184-1
– Released Formaldehyde / AATCC and SHIRLEY II

• Approved by MARKS&SPENCER for “In house test”


• Easy to handle
• Good reproducibility
www.sedo-treepoint.com

Morapex A and S
Page 30

• Morapex A can be used for all


water soluble substances.
Temperature range up to 95°C,
at pH values between 3 – 10.

• Morapex S can be used for all


of the chemicals which can be
extracted by means of water
or solvents. Temperature
range up to 150 °C.
www.sedo-treepoint.com

Saving Potential 3
Page 31

Saving Potential 3:

Color management integrated in


process management
www.sedo-treepoint.com

Control it all
Page 32

There are three main areas for quality control in production:

• Material:
• the material itself
• its preparation (pre treatment)

• Recipe:
• color matching
• Lab dispensing and Lab dyeing
• Recipe and process formulation
• checking dyestuff conformity
• correct dye liquor preparation

• Process:
• Lab to Bulk Recipe transfer
• Process formulation / selection
• process control
www.sedo-treepoint.com

Recipe Control
Page 33
www.sedo-treepoint.com

ColorMaster laboratory system


Page 34

CM3600d
System consist of

• Spectrophotometer
• high precision
• inter instrument agreement

CM2600d
www.sedo-treepoint.com

ColorMaster - Recipe formulation


Page 35

System consist of:

• Minolta spectrophotometer
• high precision
• inter instrument agreement

• Recipe formulation
• recipe management
• synthesis
www.sedo-treepoint.com

ColorMaster - Standard shades


Page 36
www.sedo-treepoint.com

ColorMaster – Analyze Recipe


Page 37
www.sedo-treepoint.com

ColorMaster - Quality control


Page 38

System consist of:

• Minolta spectrophotometer
• high precision
• inter instrument agreement

• Recipe formulation
• recipe management
• synthesis

• Quality control
• pass/fail
• statistics
www.sedo-treepoint.com

ColorMaster – Database structure


Page 39
www.sedo-treepoint.com

ColorMaster – Batch statistics


Page 40
www.sedo-treepoint.com

ColorMaster – Statistic / Lab graph


Page 41
www.sedo-treepoint.com

Flex dye liquor control


Page 42
www.sedo-treepoint.com

Check Dye Liquor bevor dyeing


Page 43

Material
Final Fabric
Dye Process

Dye Liquor

Pass/Fail Flex Pass/Fail CCM


www.sedo-treepoint.com

Function of Flex
Page 44

Steps to control the dye liquor:


• calibrate all dyestuffs
• enter the recipe (import from ColorMaster)
• take sample and measure prepared dye liquor
www.sedo-treepoint.com

Function of Flex
Page 45
www.sedo-treepoint.com

Function of Flex
Page 46
www.sedo-treepoint.com

Function of Flex
Page 47
www.sedo-treepoint.com

Function of Flex
Page 48
www.sedo-treepoint.com

Function of Flex
Page 49
www.sedo-treepoint.com

Function of Flex
Page 50
www.sedo-treepoint.com

Advantages of Flex
Page 51

1. pass/fail - evaluation
2. correction proposals

Eliminate errors before dyeing, therefore:

• reduce off shade dyeing - reduce repair


• reduce cost
• increase efficiency
• increase quality
• improved Lab-Production transfer
www.sedo-treepoint.com

Typical dye liquor errors in praxis


Page 52

Sources of errors % before after


FLEX FLEX

lot to lot delivery variation +/- 3% + -

humidity influence > 10% -- ++

Lab: weighing/dosing ? - +

Production: weighing/dosing
manual ? + -
automatic ..3% - +

Calculation, writing, exchange ? -- ++

contamination ? - +
diverse
www.sedo-treepoint.com

Improve Lab – Production transfer


Page 53

Dyestuff Dyestuff
Delivery Stock

2 3
Material flow
1

Dye Stock Stock Lab Lab


in Lab Solution Dispensing Dyeing

Information flow

Stock in Dye Liquor Production


Production Preparation Dyeing

4
www.sedo-treepoint.com

Some practical experience


Page 54
www.sedo-treepoint.com

Dissolving dyestuff
Page 55
www.sedo-treepoint.com

Transfer dissolved dyes to tank


Page 56
www.sedo-treepoint.com

Final dye liquor prepared in tank


Page 57
www.sedo-treepoint.com

Take a sample for checking


Page 58
www.sedo-treepoint.com

Take a sample for checking


Page 59
www.sedo-treepoint.com

Select recipe
Page 60
www.sedo-treepoint.com

Machine takes small amount to analyze


Page 61
www.sedo-treepoint.com

Prepare optimized dilution to analyze


Page 62
www.sedo-treepoint.com

Prepare optimized dilution to analyze


Page 63
www.sedo-treepoint.com

Measure the sample


Page 64
www.sedo-treepoint.com

Measure the sample


Page 65
www.sedo-treepoint.com

Automatic leaning process after measurement


Page 66
www.sedo-treepoint.com

Analyze result
Page 67
www.sedo-treepoint.com

Calculate correction if needed


Page 68
www.sedo-treepoint.com

Prepare correction
Page 69
www.sedo-treepoint.com

Check after correction again


Page 70
www.sedo-treepoint.com

Prepare material for production


Page 71
www.sedo-treepoint.com

Start production
Page 72
www.sedo-treepoint.com

After dyeing
Page 73
www.sedo-treepoint.com

Saving Potential 4
Page 74

Saving Potential 4:

Dye machine automation and


intelligent process management.
www.sedo-treepoint.com

Control it all
Page 75

There are three main areas for quality control in production:

• Material:
• the material itself
• its preparation (pre treatment)

• Recipe:
• color matching
• Lab dispensing and Lab dyeing
• Recipe and process formulation
• checking dyestuff conformity
• correct dye liquor preparation

• Process:
• Lab to Bulk Recipe transfer
• Process formulation / selection
• process control
www.sedo-treepoint.com

Sedomat process controller for dyeing machine


Page 76
www.sedo-treepoint.com

Sedomat Touch-Screen controllers


Page 77

Sedomat 5500

Sedomat 1800

Sedomat 2500
www.sedo-treepoint.com

Controller types
Page 78

Sedomat 1800

Display: 5,7“ TFT, color, 640 x 480 pixels,


Touch Screen
Internal I/Os: max. 24 digital inputs
max. 32 digital outputs
max. 2 analog inputs (PT100)
max. 3 analog inputs (0-20 mA)
max. 2 analog inputs (counter)
max. 4 analog outputs (0-20 mA)
External I/Os: ---
Size: 258.5 x 216 x 67 mm (L x H x D)
Features: 2 x independent step-by-step control
windows
www.sedo-treepoint.com

Controllers types
Page 79

Sedomat 2500

Display : 6,4“ TFT, color, 640 x 480 pixels,


Touch screen
Internal I/Os: max. 48 digital inputs
max. 48 digital outputs
max. 4 analog inputs (PT100)
max. 4 analog inputs (0-20 mA)
max. 4 analog inputs (counter)
max. 8 analog outputs (0-20 mA)
External I/Os: Profi 16 / Profi 32  Profibus DP
Size: 258.5 x 216 x 155 mm (L x H x D)
Features: 3 x independent step-by-step control
windows
www.sedo-treepoint.com

Controllers types
Page 80

Sedomat 5500

Display : 12,1“ TFT, color, 800 x 600 pixels,


Touch Screen
Interne I/Os: max. 48 digital inputs
max. 48 digital outputs
max. 4 analog inputs (PT100)
max. 4 analog inputs (0-20 mA)
max. 4 analog inputs (counter)
max. 8 analog outputs (0-20 mA)
External I/Os: Profi 16 / Profi 32  Profibus DP
Size: 390 x 320 x 175 mm (L x H x D)
Properties: 4 x independent step-by-step control
windows
www.sedo-treepoint.com

Controller interfaces and expansions


Page 81

Profibus DP Ethernet 2x USB

24V DC

RS232 Serial interfaces keyboard/mouse


www.sedo-treepoint.com

Logging functions
Page 82

• Batch history

– Extended logging possibilities for temperature curves, functions, times, alarms, etc.
www.sedo-treepoint.com

Independent control windows


Page 83

• Flexible program controller

– Independent step-by-step control windows

– Each control window consists of a sequence of functions


(task’s like filling, heating, etc.) that are executed

– As many as required functions (vertical) are in each step


window possible

– Batch overlapping possible by activating the parallel


function of the next batch (important for preparation call
of next batch)

– Virtually unlimited number of active parallel functions

– 27 h/day e.g. by preparing addition tank of next batch


www.sedo-treepoint.com

Remote control for excellent service


Page 84

The integrated web server offers secure remote service and diagnosis of the
Sedomat Touch-Screen controller
www.sedo-treepoint.com

Total control of a modern dyehouse


Page 85

SedoMaster Client ERP ColorMaster ColorMaster Client


Server Server

database database

Ethernet
SedoMaster
editor, program transfer, Server recipe development, color control,
planboard, calendar, remote process optimization, addition
access, monitoring, link sub- calculation, cost calculation
systems database

LAN
Ethernet
M-SERVER

Sedomat Sedomat Sedomat Sedomat Sedomat Dissolving Dispensing


1500 3500/5000 1800/2500 2800 5500/5800 Solid Fluid

HT jet HT jet HT jet stenter stenter

distribution pipe
www.sedo-treepoint.com

Sedomaster standard system


Page 86

SedoMaster

Network
www.sedo-treepoint.com

Sedomaster standard system


Page 87

Basic programming
SedoMaster • dye program editor
• send/receive programs
• system management

Network
www.sedo-treepoint.com

Sedomaster standard system


Page 88

Production
SedoMaster • production planning
• calendar
• remote control

Network
www.sedo-treepoint.com

Sedomaster standard system


Page 89

Management report
SedoMaster • production control
• production reports
• batch process curves

Network
www.sedo-treepoint.com

Sedomaster link Colormaster


Page 90

SedoMaster

ColorMaster

LAN
www.sedo-treepoint.com

ColorMaster laboratory + production


Page 91

• System consist of:

• ColorMaster laboratory
• spectrophotometer
• quality control
• recipe formulation
www.sedo-treepoint.com

ColorMaster laboratory + production


Page 92

System consist of:

• ColorMaster laboratory
• spectrophotometer
• quality control
• recipe formulation

• ColorMaster production
• relational database
• process optimization
• order administration
www.sedo-treepoint.com

ColorMaster process optimization


Page 93

Typical dyeing process for PES

reduction hot acidificatio


dispersion dyeing clear rinsing n

Z1
T3

A1
A1 A2 T2

Z1
T1
T1
T1
A1

T1

A1: dispersing agent A1: NaOH T1: temp. A1: acid


moisten agent hydrosulfite Z1: time T1: temp.
acetic acid T1: temp.
A2: dispersion dyestuff Z1: time
T1: start temperature
T2: raise temperature
T3: dyeing temperature
Z1: dyeing time
www.sedo-treepoint.com

ColorMaster treatment rules


Page 94

If-than-else rules

reduction acidification
for treatments clear
• reduction clear
• acidification

If total recipe dyestuff A1

concentration is < 1 % Z1
T1
than 0 (don‘t apply)
A1
else 1 (apply reduction clear)
T1

A1: NaOH A1: acid


hydrosulfite T1: temp.
T1: temp.
Z1: time
www.sedo-treepoint.com

ColorMaster parameter rules


Page 95

If-than-else rules

dispersion dyeing for parameter


• dyeing time
Z1
T3
If total recipe dyestuff
A1 A2 T2 concentration is < 1 %
than 30 (minutes)
T1 else 45 (minutes)

A1: dispersing agent


moisten agent
acetic acid
A2: dispersion dyestuff
T1: start temperature
T2: raise temperature
T3: dyeing temperature
Z1: dyeing time
www.sedo-treepoint.com

ColorMaster treatments + parameter


Page 96

Optimized process for dyestuff concentration = 0,8 %

hot
dispersion dyeing rinsing

Z1 time and cost


T3
saving

A1 A2 T2

T1
T1

A1: dispersing agent T1: temp.


moisten agent Z1: time
acetic acid
A2: dispersion dyestuff
T1: start temperature
T2: raise temperature
T3: dyeing temperature
Z1: dyeing time
www.sedo-treepoint.com

ColorMaster product rules


Page 97

If-than-else rules

dispersion dyeing for products


• dispersing agent
Z1
T3 • moisten agent
• acetic acid
A1 A2 T2
If total recipe dyestuff
T1 concentration is < 1 %
than 1 g/l (dispersing agent)
else 1,5 g/l (dispersing agent)

A1: dispersing agent


moisten agent
acetic acid
A2: dispersion dyestuff
T1: start temperature
T2: raise temperature
T3: dyeing temperature
Z1: dyeing time
www.sedo-treepoint.com

Implement central color management ColorMaster including process optimization


Page 98

Case Study:
Company in China optimized water consumption by SedoMaster and
ColorMaster within 6 month they were able to reduce water consumption
by 50%.

In past processes were simple


optimized according colors in light,
middle and dark shades. Now
processes are divided according
different criteria’s in dozens or
even hundreds of process variation.
All optimizations are done
automatically without user
intervention.
www.sedo-treepoint.com

ColorMaster production
Page 99
www.sedo-treepoint.com

ColorMaster production
Page 100
www.sedo-treepoint.com

ColorMaster batch ticket


Page 101

batch text

liquid ratio

treatments

products

parameters
www.sedo-treepoint.com

ColorMaster Integration
Page 102

Laboratory Production

Color Matching SedoMaster

Lab Dosing Flex Dye Liquor Control


www.sedo-treepoint.com

SedoMaster MES Dyeing and Finishing


Page 103

Basic System
Configuration Editor Program transfer

Advanced System
Expert System
Planboard Calender

Remote Access Monitoring

Link
Planning/Routing Link ERP system
Colormatching
Options

Inventory Dyestuff Weighing Dyestuff


and Chemicals and Chemicals
www.sedo-treepoint.com

Planboard: Batch moved to mach. #07


Page 104
www.sedo-treepoint.com

Report of stop reasons


Page 105

Stop reasons

Change of batch
8%
Production
35% 23% interference
Change of quality

13% no fabric
4% 8% 9%
Machine test run
www.sedo-treepoint.com

SedoMaster Report
Page 106
www.sedo-treepoint.com

Sedomaster link weighing station


Page 107

SedoMaster

ColorMaster

Weighing

LAN
www.sedo-treepoint.com

Sedomaster link dispensing station


Page 108

SedoMaster

ColorMaster

Weighing

Dispensing SM2500
LAN
www.sedo-treepoint.com

Sedomat process controller for dispensing system


Page 109
www.sedo-treepoint.com

Sedomaster batch flow


Page 110

SedoMaster
SedoMaster batch flow www.sedo-treepoint.com
Page 111

Page 111

HOST

SedoMaster

batch scheduling
data import from HOST system
SedoMaster batch flow www.sedo-treepoint.com
Page 112

Page 112

ColorMaster

SedoMaster

batch scheduling on specific machine


with production recipe request
SedoMaster batch flow www.sedo-treepoint.com
Page 113

Page 113

ColorMaster

SedoMaster

optimized production recipe


with treatments, parameter
and preparations
SedoMaster batch flow www.sedo-treepoint.com
Page 114

Page 114

SedoMaster

create dyeing program


reservation of dyestuff + chemicals
orders for weighing + dispensing
SedoMaster batch flow www.sedo-treepoint.com
Page 115

Page 115

dyestuff type and quantity


for check weighing

SedoMaster

Weighing station
SedoMaster batch flow www.sedo-treepoint.com
Page 116

Page 116

register actual amount of dyestuff

SedoMaster

update dyestuff
Weighing station
inventory
SedoMaster batch flow www.sedo-treepoint.com
Page 117

Page 117

send optimized dyeing program


to Sedomat controller
start process

SedoMaster

Machine
SedoMaster batch flow www.sedo-treepoint.com
Page 118

Page 118

program call 1. prepare chemical

SedoMaster

Machine
SedoMaster batch flow www.sedo-treepoint.com
Page 119

Page 119

send 1. preparation with


batch- and machine no.
products and amounts

SedoMaster

Dispenser for liquids

Machine
SedoMaster batch flow www.sedo-treepoint.com
Page 120

Page 120

acknowledge 1. preparation with


batch- and machine no.
products and actual amounts

Actualize
inventory

SedoMaster

Dispenser for liquids

Machine
SedoMaster batch flow www.sedo-treepoint.com
Page 121

Page 121

step acknowledgement 1. preparation


transfer preparation tank to machine

SedoMaster

Dispenser for liquids

Machine
SedoMaster batch flow www.sedo-treepoint.com
Page 122

Page 122

complete automatic batch flow with


call and acknowledgement
of preparations
between the systems

Dispenser for powder

SedoMaster

Dispenser for liquids Weighing station

Machine
SedoMaster batch flow www.sedo-treepoint.com
Page 123

Page 123

HOST

SedoMaster

batch finished
export batch data to HOST system
www.sedo-treepoint.com

Automatic process for dyeing and finishing


Page 124

HOST

Dyestuff Dissolving ColorMaster Spectro

SedoMaster

Chemical Dispensing Weighing Scale

SM5500
www.sedo-treepoint.com

Plug’n’Play
Page 125

Sedomat 1800 Sedomat 2500 Sedomat 5500


www.sedo-treepoint.com

Introduction Plug’n’Play
Page 126

• Saves costs through easy setting into operation


by local technician.
– For machine retrofits
– New machines

• No pre-defined wiring: flexible configuration of


I/O‘s
?
• Profibus interface enables connection of existing
Profibus devices
• Big function library for max. 5 tanks + machine
• Connection to central systems
(SedoMaster/ColorMaster) possible.
www.sedo-treepoint.com

Example 1: Simple Jet dye machine


Page 127

Configuration:
1. Basic configuration
2. I/O-configuration
3. Tune values configuration

Example 1: Simple Jet dye machine

+ 1x preparation tank
www.sedo-treepoint.com

Example 2: advanced yarn dye machine


Page 128

Example 2: advanced Yarn dye machine

+ 1x Stock tank
+ 2x Preparation tank
+ 2x Dye kitchen tank
www.sedo-treepoint.com

SedoMonitor Central system


Page 129

Fulfill targets:
SedoMonitor
• Easy to install
• Easy to use
• Low cost
www.sedo-treepoint.com

Sedo Monitor – General Machine Overview


Page 130

Overview of all machines with batch status, program


state, active batch/functions/alarms/operator calls
www.sedo-treepoint.com

Sedo Monitor – Machine Monitoring


Page 131

• The Machine Monitoring program offers an overview of the


actual status of all connected machines including:
– Machine Status
– Active Alarms
– Active Operator Calls
– Machine Name
– Current Batch Status
– Current Batch Number
– Active Process
– Active Functions
www.sedo-treepoint.com

Sedo Monitor – Copy Programs


Page 132

• A backup can be made of all programs from all connected


controllers on a PC. For security, this backup is very important.
• Programs can be easily copied from one controller to another
controller. No need to copy via memory stick.
www.sedo-treepoint.com

Saving Potential 5
Page 133

Saving Potential 5:

Energy management and resources


optimization
www.sedo-treepoint.com

EnergyMaster
Page 134
www.sedo-treepoint.com

EnergyManagement
Page 135

Objectives of manufacturing companies

• Ecologic production:
• Lower emissions (Environmental protection)
• Energy optimized

• Cost reduction
www.sedo-treepoint.com

The textile finishing process


Page 136

Compressed air
Electricity Steam

Energy

Raw material Manufacturing Finished product


process

Auxiliaries

Water Dyestuff Chemicals


www.sedo-treepoint.com

The textile finishing process


Page 137

• Manufacturing process:

• Process:
– Chemicals
– dyestuff SedoMaster / ColorMaster
– Water

• Raw material:
• Personnel:
ERP
• Maintenance:
– Personnel cost
– Spare parts

• Energy and Resources: ?


www.sedo-treepoint.com

The textile finishing process


Page 138

• Manufacturing process:

• Process:
– Chemicals
– dyestuff SedoMaster / ColorMaster
– Water

• Raw material:
• Personnel:
ERP
• Maintenance:
– Personnel cost
– Spare parts

• Energy and Resources: EnergyMaster


www.sedo-treepoint.com

Few typical questions about consumptions


Page 139

• What is our consumption ?


• What department consumes more / less?
• What causes / is our peak consumption?
• What about our power factor (cos phi)?
• What is our base load (no production)?
• What are abnormal consumptions and when do they occur?
• What is the energy consumption for manufacturing 1 article or for an
order?
• What article is best produced on what machine?
• What is the manufacturing cost per kilogram or per meter?
• What is the energy saving potential in textile finishing?
• ….
www.sedo-treepoint.com

EnergyMaster
Page 140

The importance of energy saving

• Makes the company less dependant of changes in energy prices


• Energy costs generally represent the third largest variable cost (after
materials and direct labor)
• Energy costs typically represent 4-12% of turnover
• Savings in energy costs translate directly to the bottom line as a 1:1
increase in profit
• Lowering company’s carbon footprint (CO2-emission)
• Good energy management can reduce energy cost by
– 10 % for spinning and weaving mills
– 25 % for dyeing and finishing plants
www.sedo-treepoint.com

Map your saving potentials !


Page 141

• Each company is different


• Some energy saving investments cost little money
• Some energy saving investments cost big money
• Base the investment plan on saving potential (ROI)

Measure Analyse Plan


www.sedo-treepoint.com

EnergyMaster: Monitoring, Targeting & Reporting


Page 142

EnergyMaster : Reducing energy costs by Monitoring, Targeting & Reporting

•Monitoring :
– Data collection and analysis: production data as well as energy consumption data
– Requires the metering of energy consumption
– Calculation of performance ratios : relationship between energy consumption and production
output

•Targeting :
– setting targets based on internal or external benchmarks
– Set targets in function of production output

•Reporting:
– Translate the collected data into readable reports
– Needed to take actions for improvement
www.sedo-treepoint.com

EnergyMaster: the concept


Page 143

Consumption logging in dye house and finishing (Department based)

Sedomat
Sedomat

Auch Dampf, Außentemperatur,…

On an individual machine, data logging is generally limited to active power (kW),


reactive power (kVAr) and water counter
www.sedo-treepoint.com

Energy Monitoring: typical analysis reports


Page 144

• Performance Characteristic Line (PCL):


– Relation between energy consumption and production output (per plant, per
department, per machine,…)
– Base load: the energy consumption when there is no production = intersection
point of PCL with the Y-axis
– Process load: energy consumption per unit of production output (kWh/meter,
kWh/kg,…)= slope of the PCL
• Specific Energy Consumption (SEC) as function of time:
– Shows the evolution of energy consumption per unit of production as function of
time
• Counter reports:
– Charts showing the energy usage as recorded by each meter
• Consumption reports:
– Energy consumption by department, machine,…
• Actual consumption vs. Budget :
– Cusum (Cumulative Sum of differences- chart)
www.sedo-treepoint.com

Case study: Concordia Textiles (B)


Page 145

• Concordia Textiles in Waregem, Belgium is a large producer of synthetic


fabrics and a long time customer of Sedo Treepoint.
• Concordia successfully implemented EnergyMaster in their dyeing and
finishing operation.
• Energy consumption is one of the most important factors in the cost of finishing
a fabric.
• Concordia has full automated all dyeing machines
• SedoMaster is used as dye house management system for the batch dyeing
machines as well as for the finishing machines.
• SedoMaster is linked to the color management system and to the dispensers.

• Concordia has full control over all processes.

• With EnergyMaster the consumption of power, steam, gas and water is now
also logged in the database of the SedoMaster system.
www.sedo-treepoint.com

Concordia Textiles: Complete integration finishing


Page 146

Colormatchine clients Colormatching HOST


Server Server

Power meters:
Manual registration
Database Database

Ethernet SedoMaster
12 SedoMaster Clients
Server

SedoMaster
Database

LAN

Ethernet

M-SERVER

Sedomat Sedomat Sedomat Sedomat Sedomat Dispenser Dispenser


3500 3500 3500 5800 5800 Solids Liquids

Distribution pipes
Concordia: Cabling measuring points via Profibus www.sedo-treepoint.com
Page 147

Page 147
Boilerroom
PROFIBUS •2xGas
•2xP steam
ETHERNET •2xwater
•1xconductivity

SedoMaster
Server
www.sedo-treepoint.com

Concordia Textiles: Complete integration finishing


Page 148

Colormatchine clients Colormatching HOST


Server Server
Energy:
•Main power panel
•Preparation
Profibus
Database Database •Weaving
•Jet dye house
•Jigger dye house
Sedomat
12 SedoMaster Clients Ethernet SedoMaster
5800
•Beam dye house
Server
•Finishing
•Boiler room
SedoMaster EnergyMaster
Database Database
Gas
Steam
Compressed air
LAN
Conductivity
Ethernet Different
temperatures
M-SERVER

Sedomat Sedomat Sedomat Sedomat Sedomat Dispenser Dispenser


3500 3500 3500 5800 5800 Solids Liquids

Distribution pipes
www.sedo-treepoint.com

EnergyMaster: But also reports on the Sedomat display


Page 149

• Examples on 12,1 inch display of the Sedomat 5500 :


www.sedo-treepoint.com

EnergyMaster: Reports as Plug-In


Page 150

• Plug-In in SedoMaster:
www.sedo-treepoint.com

Example: Active energy (kWh) per substation


Page 151
www.sedo-treepoint.com

Example: Consumption report


Page 152

• Show the consumption of a specific energy resource by department. In this


example, the water consumption by department during a selected time period
is displayed in a pie chart.
• Allows to identify the “top consumers” for a selected energy resource
www.sedo-treepoint.com

Example: Water consumption per machine


Page 153
www.sedo-treepoint.com

Example: Counter report


Page 154

• Displays the readings of one or more selected energy meters as function of time. In
this example, electricity consumption (kWh) and cos phi is displayed as function of
time
• Is used to identify peak loads, base loads (energy consumption when no
production), periods of low power factor,…
www.sedo-treepoint.com

Example: Production report per department


Page 155
www.sedo-treepoint.com

Example: Production report per article per machine


Page 156
www.sedo-treepoint.com

Case study: Concordia Textiles (B)


Page 157

• Concordia Textiles measuring points:

– 10 Power panels with active, reactive and apparent power, frequency, cos phi,
current and voltage
– Main counter with active, reactive and apparent power, frequency and cos phi
– 46 Water counters (every single machine)
– Consumption, flow and temperature of drain water, cooling water and hot water
– Hardness and consumption of „grey“ water
– Air humidity in the boiler room
– Various temperatures (outside, Production, Laboratory, ...)
– Compressed air pressure (Compressor outlet)
– Gas consumption: different boilers
– Steam pressure and conductivity

– In total, 224 counter elements are processed in EnergyMaster.


Part of these counter elements are imported from the ERP system like e.g.
personnel cost

– All external measuring devices are connected over a Profibus network (over
1.300 m).
www.sedo-treepoint.com

Summary Saving Potential


Page 158

Summary Saving potentials :


• manage and upgrade
– Hardware / Software maintenances
– Know How maintenances

• Use more “Brainware”


The biggest saving potential in future
www.sedo-treepoint.com

About our Group in textile field


Page 159
www.sedo-treepoint.com

Page 160

Our GROUP
8 plants spread in 6 Countries worldwide.
1350 employees. 450 million Euro Turnover.
www.sedo-treepoint.com

Page 161

Products covering
Spinning – Weaving – Dyeing/Finishing
SAVIO PRESENTATION

162
SAVIO MACCHINE TESSILI - ITALY

SAVIO MACCHINE TESSILI

163
SAVIO MACCHINE TESSILI S.P.A. - ITALY
AUTOMATIC WINDERS, TWO-FOR-ONE TWISTERS,
OPEN END ROTOR SPINNING FRAME
GREEN AREA: 171.000 sq. mt.
COVERED AREA: 81.000 sq. mt.
EMPLOYEES: 423

SAVIO MACCHINE TESSILI

164
SAVIO (SHANDONG) TEXTILE MACHINERY CO.,LTD. - CHINA
AUTOMATIC WINDERS, TWO-FOR-ONE TWISTERS
GREEN AREA: 30.000 sq. mt.
COVERED AREA: 18.000 sq.mt.
EMPLOYEES: 106

165
SAVIO IN CHINA

C.N.T. Ltd. - Beijing

SAVIO SHANDONG - Jining

C.N.T. Ltd. - Wuxi

C.N.T. Ltd. - Shanghai

C.N.T. Ltd. - Zhejiang

C.N.T. Ltd. - Canton

MANUFACTURING
SALES
6 SERVICE LOCATIONS
SERVICE
6 SPARE PARTS STORAGES
SPARE PART
58 LOCAL ENGINEERS

166
SAVIO INDIA LIMITED - INDIA
TWO-FOR-ONE TWISTERS GREEN AREA: 88.000 sq. mt.
COVERED AREA: 15.000 sq. mt.
EMPLOYEES: 174

167
SAVIO IN INDIA

Ludhiana
Delhi - Gurgaon

Kolhapur
Guntur

SAVIO INDIA LTD - Coimbatore


Coimbatore office - Sales / Service / Spares / Show
room / Training facility
Electronic repairing station
MANUFACTURING
SALES 7 SERVICE LOCATIONS
SERVICE 5 SPARE PARTS STORAGES
SPARE PART 45 LOCAL ENGINEERS

168
Products portfolio

Winders

Two-for-one
twisters

Open-End

169
LOEPFE PRESENTATION
Welcome to LOEPFE

OVER 55 YEARS
MASTERS IN TEXTILE QUALITY CONTROL
A success story – Made in Switzerland
www.loepfe.com | info@loepfe.com 171
Your reliable Partner

 SWISS made
 ISO certified
 know-how of over 55 years
 highly innovative
 worldwide service net

www.loepfe.com | info@loepfe.com 172


Spinning Solutions
YARNMASTER ®
 fully digital, modular
yarn clearing system
 online laboratory functions
and foreign fiber detection
 exclusive (option):
online monitoring of
Surface Index SFI

www.loepfe.com | info@loepfe.com 173


Weaving Solutions

WEFTMASTER ® - Monitoring and control of the weft insertion

1 – Knot detectors 4 – Thermo cutters


monitor all knot-type thickenings separate and fuse synthetic fabrics

2 – Filling stop motions 5 – Short weft detector


acquire every filling break monitors the weft insertion
into the last phase

2 – Yarn stop motions


monitors the running yarn

3 – Filling brakes 4
make possible a minimum
filling yarn tension 3
2
thanks to the optimally 1
controlled brake time

www.loepfe.com | info@loepfe.com 174


Partners

www.loepfe.com | info@loepfe.com 175


BELGIAN MONITORING SYSTEMS PRESENTATION
Belgian Monitoring Systems: The Company

• Originally part of the BARCO group ( Belgian American Radio


Corporation, founded in Poperinge, Belgium, in 1934)

• International company, headquartered in Wevelgem, Belgium, with a


global presence

• BMS company established in 2007 as carve out from Barco group

• Now part of Savio Technologies group, Italy

KORTRIJK

WeaveMaster 1 2009
Page 177
BMS : Activities

• Sensors & machine controls


• Spinning
• Weaving
• Dyeing & Finishing

• MES Systems
– Plastics
– Textiles
– Metal
– Pharma
– Packaging
– Energy Monitoring
WeaveMaster 1 2009
Page 178
PlantMaster : some references

WeaveMaster 1 2009
Page 179
MES Systems for the textile industry

• WeaveMaster: Monitoring, reporting and scheduling


for the weaving industry

• KnitMaster: Monitoring, reporting and scheduling for


the knitting industry

• SpinMaster : Monitoring, reporting and scheduling


for the spinning mill

• QualiMaster: fabric inspection systems for weaving


and knitting.

WeaveMaster 1 2009
Page 180
Traceability

WeaveMaster 1 2009
Page 181
Sensors for weaving
Cyclops

-Automatic on loom inspection


-Stop the loom in case of quality risk
-Automatic “piece map” at end of piece
-No more manual inspection required
-Detects all weaving defects in plain fabric
-Massive reduction of “2nd quality”

KFD : Kinky Filling Detector

-Detection of “loops” on air jet looms


-Stop the loom in case of “too many” loops
-Fit for all types of air jet looms

WeaveMaster 1 2009
Page 182
EnergyMaster
The battle against energy waste
in
the textile industry

Page 183
EnergyMaster: the concept

WeaveMaster 1 2009
Page 184
EnergyMaster : benefits

• EnergyMaster is a module of the MES systems


(WeaveMaster, SpinMaster, SedoMaster).
• EnergyMaster can be installed stand alone
• Real Time measurement of the consumption
• User friendly reporting tool
• Measures all types of energy consumption
• Pinpoints the large consumers
• Delivers objective information for the energy
savings program of the company
• Assures easy follow up of taken saving
measurements

WeaveMaster 1 2009
Page 185
Benefits for our customers

All BMS solutions result in :

Increased efficiency
Improved quailty
Shorter production lead times
Reduced work in process

Higher profits!!

WeaveMaster 1 2009
Page 186
www.sedo-treepoint.com

Contact
Page 187

Head office:
Sedo Treepoint GmbH, Germany Sedo Treepoint, Belgium
belgium@sedo-treepoint.com
Neuwies 1, D-35794 Mengerskirchen
Phone: + 49 6476 31-0 Sedo Treepoint, China
china@sedo-treepoint.com
sedo@sedo-treepoint.com
www.sedo-treepoint.com Sedo Treepoint, India
india@sedo-treepoint.com

Sedo Treepoint, Italy


italy@sedo-treepoint.com
Sedo Treepoint, Switzerland
Phone: + 41 43 488 11 88 Sedo Treepoint, Singapore
singapore@sedo-treepoint.com
switzerland@sedo-treepoint.com
Sedo Treepoint, USA
usa@sedo-treepoint.com
www.sedo-treepoint.com

Discussion
Page 188

Thank you for your attention!

Your questions and suggestions are welcome!

You might also like