ITMA-2011 : Dyeing, Printing & Finishing

General observation on technology:

Emphasis on improvements in performance Carbon reduction Reduction in Water and energy consumption More attention on digital printing No real breakthrough technology

Preparatory Processes
Theme: Main focus was given on: High productivity Carbon reductions Environment friendly process Water, Chemical and Energy saving Fabric handling

BENEKS-Tubular fabric washing machine

(TBSY) Washing Machine( After Dyeing) has been developed in order to improve the efficiency of the discontinuous systems at Textile Treatment plants, as well as for savings in energy, water and time. Raw Washing (Yarn dyed etc.), Washing after Bleaching. Washing after Dyeing. Washing after Optical Brightening/Bleaching. Reductive washing. Special/Exclusive Process Washings related to plant requirements.

Parex Mather-Singeing machine for Woven & knitted fabrics

PAREX MATHER offer machines suitable for open-width singeing of woven and/or knitted fabrics. These machines use the uniquely reliable and energyefficient PAREX 5000 burner They claim Uniform flame so uniform singeing is expected Its exclusive aerodynamic flame width control ensures that only the required working width is hot. Adaptable burner position, Automatic control options Natural gas, Propane, Butane, LPG or gasoline

For woven

For Knitted

Poong Kwang Machine Co. Ltd, Korea Singeing M/c

Presented Gas singeing machine (PK-G-3-2400) for open width knit fabric. Machine exert minimum tension and give uniform singe effect Two sets of burners are provided to singe both side of the fabric Machine speed up to 100 mm/min LPG Gas consumption 10 Kg/hr

Osthoff-singe
It provides singeing machine for both knitted and woven fabric On-line control of hairiness Double jet burners for saving energy up to 50% compare to the normal burners Speed of the machine is adjusted as per the weight and type of the fabric

Benninger
Benninger has chosen several options to show carbon reductions in textile finishing. The following Carbon Hotspots are identified:
minimizing number of drying processes minimizing steam and water consumption during washing processes thanks to high efficiency washing replacing the resource intensive exhaust dyeing process by CPB dyeing

Benninger -Washer
Washing on Benninger s high efficiency TRIKOFLEX drum washer with mechanical supported front and back washing reduces the water consumption by more than 50% compared to classical washers. Simultaneously the energy required to heat up the washing water (biggest Carbon polluter) is reduced and has the biggest impact on carbon reduction. Additionally the integrated heat recovery system and the insulation of the washing box reduce also the energy requirement.

Benninger -Mercerizing m/c

Benninger shows on the ITMA a new mercerizing concept which is suitable for mercerizing cotton, but also causticizing Viscose fibres, for both woven as well as knitted fabrics. Mercerized or causticized textiles do require less chemicals and less dyestuff during the textile processing chain. Benninger s wet on wet mercerizing concept does not require a resource intensive intermediated drying stage. Consequently carbon emissions are reduced by 40%.

Poong Kwang Machine Co. Ltd, Korea Mercerizing M/c

Offered open knit mercerizing machines for width as well as tubular fabric Uniform mercerizing, preventing crease mark, edge mark, bowing and excessive elongation of fabric High quality luster, high efficient washing under minimum tension, good hand are the features claimed by the manufacturer They also offered chain type mercerizing machines

Dyeing & Printing

Theme: Major focus is Automation Shade & process control Reduced friction between fabric & metal components Water, Chemicals and energy saving Fabric handling

Obem SpA
Deals with all types of robotized dyeing and steaming machineries/plants Plants have been developed for wool, cotton, acrylic, polyester, viscose etc.

Bobbins Injection dyeing machine Laip Srl

They have also presented Bobbins Injection dyeing machine a multicolur dyeing system for yarns on cones It can handle any type of yarn wound on any type of dye house support, from cylindrical to conical. It injects four colours simultaneously from the pumping station equipped with stainless steel cylinders

Vacuum Steamer-Laip Srl

They have presented Vacuum Steamer for yarn conditioning Machine is made out of Stainless steel and produce direct steam to avoid yellowing, fading effect of yarn. Machine work at low temperature with vacuum system. Heating ceiling is provided to avoid water drops on material Full automation control panel with microprocessor is provided.

Loris Bellini S.pA, Italy

Presented APPC-LV dyeing cabinet for hanks-cotton, acrylic, wool and their blends It operate at 0.4 bar static pressure up to 110oC Low material to liquor ratio (MLR:: 1: 9-10 for mercerized cotton and 1: 12-14 for acrylic) during dyeing cycle Operating flexibility is enhanced by use of intechangeable hank loaders for dyeing hanks of different sizes and reeling circumferences

Modra Technology Pty

Presented DyeLab a dye and auxilary dispensing machine for sample yarn dyeing for carpet. It is a continuous yarn dyeing machine. After the application of dye, it is passed through steam at 100oC Steam generator and automated package winder are provided as optional accessories.

Galvanin
Offered automatic Horizontal and vertical dyeing house with automatic line for preparation of the material carrier, automatic hydro extractor line Automatic bridge crane with no limits at the number of apparatus to be served All machines are equipped with automatic opening/closing of the lid, automatic chemical dosing system, interchangeable material carrier

Alliance, France
Presented new Rotor yarn and piece dyeing machine It is claimed that there is expected saving of costs up to 50% Can be used for woven as well as knitted fabric It will enable to dye yarns (cones) together with fabric on beam in order to obtain the same colour for yarn and fabric Machine can dye fabric of wider width using one beam, narrow width fabric in two beams, one beam for narrow fabric and other for yarn (cones) dyeing or both beams for yarn (Cones) dyeing.

Flainox
Presented new Multi-Plus machine for special treatment of fabric The machine works roll to roll retaining the high efficiency of the air treatment given by the Venturi pipe Fabric is pushed at pre-settable intensity of air through a 180 meter long pipe. Consequently the treatment on the surface of fabric is very efficient, uniform, permanent, Speed goes from 5 to 50 meter/minutes It can treat cotton, silk, viscose, polyester. It is claimed saving in terms of energy and steam to contribute of CO2 emission reduction Chemical free treatment, high evaporation rate at low power consumption (35 kW), gas heating and high productivity are the main feature of Multi-Plus.

Fong s-Jumboflow (High temperature dyeing machine)

Liquor ratio: 1:4.5 to run machine Maximum fabric speed: 400 m/min. Maximum working temperature: 140 C Maximum working pressure: 3.5 bar Heating rate: 25 C~100 C average 4 C/min. 100 C~130 C average 2.5 C/min. (dry saturated steam pressure at 7 bar) Cooling rate: 130 C~100 C average 3 C/min. 100 C~85 C average

Loading up to 280 kg per tube Heat Exchanger gives the largest heating rate with minimum heat loss to the environment Multi Saving Rinsing System (MSR) shortens the dye cycle and reduces the water consumption

Then
Then has shown piece dyeing machine Lotus for sensitive fabrics and is the first long tube machine with Airflow technology. It operate with liquor ratio down to 1:2, saving water, energy and chemicals Spacer fabric, 50% spendex, anti-ballistics, parachutes, all kind of automotive textiles or functional sportswear can be dyed with this machine.

Thies
It presented iMaster H2O , a complete new design of rope dyeing machine for the processing of knit and woven goods In this machine transport winch is installed inside the kier so the cotton, synthetic fibres and their blends including articles with a high elastane content can be processed with significantly reduced elongation resulting in fabrics of improved stability and surface appearance Work comfortably on MLR:: 1:4. Complex rinsing systems combined with intelligent function for the pre and post treatment of fabric helping further reduce the total water and energy consumption.

Noseda
Presented Jigger (TJ-AT acquaZERO) The jigger work at lower MLR and the running cost is also low This includes external heat exchanger, dye kichen, dosing system, automatic flow etc,

DONG-A, Korea
They have offered iDream knit dyeing machines for atmospheric and high temperature dyeing. Working MLR::1:3.7, speed up to 350 m/min Heating rate: 5oC/min, Saturated steam pressure: 7 Bar It is claimed that it reduces process time, energy & water consumption, operating cost.

Memnun, Turkey
Presented Ecolo Jig for atmospheric and high temperature dyeing Machine speed 10-150 m/min actual speed control Electronic fabric strength, adjustable and controlled within PLC

Poong Kwang Machine Co. Ltd, Korea

They also offered compactors, compressing shrinking range, dehydrators, sanding machine and continuous washing machines for knits.

Benninger -DyePAd
Benninger come out with a continuous open width dyeing machine to reduce the liquor ratio during dyeing and finishing of knitwear in jet dyeing machines. In addition to quality benefits the continuous open width finishing process also offers savings particularly in terms of water and energy. In continuous mode, CO2 emissions can be reduced by nearly 2/3 in comparison to exhaust dyeing processes (liquor ratio of 1:7). Benninger s TRIKOFLEX bleaching and washing plants and the Benninger Ksters DyePad suit this type of application perfectly.

Bruckner, Germany
Presented continuous dyeing range (Pad-dry thermosol range The range provide colour uniformity across the width and length, no shade variation, crease free fabric with minimum energy consumption It is claimed to get 100% reproducible dyeing results For drying high energy saver IR dryer is provided, which give uniform migration-free drying, crease free material The hotflue are systematically design to provide equal pressure in upper and lower nozles

Durst, Italy
Introduced Durst Kappa 180, the new generation, fully automatic feeding in and guiding facility, high performance digital printing machine It is claimed that Durst kappa 180 is a alternative to flat bed screen printing Speed of the machine is 600sq m/ hours (over 300 running meters and outstanding quality 1056 X 600 dpi, max. printing width 195 cm. They are also offering water based printing ink (Kappa inks) for various types of printing.

Stork Prints
Present new digital textile printer Spene Speed up to 555 m2/hr Its industrial feeding system allows to use any fabric up to 1.85 meter width They also offer inks used in digital printing

DGI, Korea
Presented Fabrijet FD Pro-I digital printing machine It can print up to 9 colours with max. speed 60sqm/h (Resolution 540X360) Print width:1,850 mm

Kornit, Israel
They have offered Drop-onDemand Direct -on-Garment printer for small to mid-sized production business, online and retail shops Quick performance, easy to operate, space saving Automatic pretreatment system integrated in to the machine Printing area up to 14 X 18 Can print cotton, polyester, their blends, lycro, viscose, silk, leather etc Resolution: 600X1600 dpi

Zimmer, Austria
Presented Rotascreen SG/SU rotary screen printing machine Machine consists of Digital syncronization between screen and blanket drive guarantees printing at any speed up to 120 m/min. Individual cloth infeed systems, cloth cleaning device, printing washer with brushes and water recycling system for minimum fresh water consumption. High capacity hot-air jet dryer, Automatic colour feeding system

HAS LTDS DIS TIC LTD, Turkey

Presented Compressive shrinkage range (SHRINK-X) for processing knitted, woven and denim fabric that can put just after the stenter Cotton, cotton/lycra, viscose and their blends, silk, p/c, wool, polyamide etc can be processed

HAS LTDS DIS TIC LTD, Turkey

Presented Tubular compacting machines of FCT series Optimal compacting rate, highest dimensional stability, excellent fabric handle and longer life time of felt are the few features of the machine.

Teknik Tekstil Makine, Turkey

Presented RAM-X2 stenter machine Advanced air flow control technology, art full designed and optimum drying and heat setting performance with less consumption of energy and higher production (8% to 15% higher) are the main features Each three meter chambers have counter type heating and air circulation section arrangement as well as unique chamber insulation

Santex
They have introduced three novalties. First is a special drying chamber which act as an energy saving device, while the same time increasing productivity of new and exisiting Santex dryer. Secondly, a hot melt coating and laminating machine (Cavi-2-Coat) which featured four types of coating-full coating; Reverse coating; thru-coating and traditional Gravure (Dot) coating. Thirdly they offered continuous two stage compacting machine which combine virtues of the rubber belt with the superior handle of the felt shrinkage technique. This is a high speed compacter with the felt technology and give same residual shrinkage, lusture finish and excellent touch of the knit.

Monforts
Special emphasis was given to energy saving solutions and environmental protection. Integrated heat recovery system comprises a compact, air-to air heat exchanger (installed within the roof structure of stenter), is fitted as standard on all new Montex Stenters. The heat exchanger uses energy from the exhaust gas to preheat up to 60% of the incoming fresh air entering the stenter. It claimed to save 30% energy costs

Monforts
New eco applicator was also displayed to improve soft coating solution Significant energy saving with reduce drying time is expected with this applicator Also eliminate the need for a conventional wet-on-wet padder. Designed for three options: to apply a liquor/coating to one side of the fabric; to apply a liquid to both side of the fabric; or to apply a liquid to one side of the fabric and a different liquid to the other side.

HAS LTDS DIS TIC LTD, Turkey

Offered Raising machine (RCMD) single and double drum alternatively consist of 24, 28 and 36 working rollers Adjustable speed of the pile and counter pile rollers It is possible to zero the raising effect just by one button at the time of fabric transfer and to restore it by pushing the same button once again

Clariant International Ltd

All-in-one bleaching auxiliaries, ultra-low liquor ratio dyeing, brilliant acid dyes which bring a new color dimension in brightness, and efficient printing binders will be highlighted. Clariant s premium eco-care finishing which is setting a new benchmark when it comes to wrinkle-free finishes, will also feature at the booth. This is achieved with products improving fabric quality, cutting down production processes and generating benefits in water, energy and time savings.

Clariant International Ltd

Clariant launches a new durable eco flame retardant finishes, resin finishes, new elements for sustainable acid dyes , High wet fast disperse dyes

Washing technology MOTO : Water is for living, not for dyeing

Minimal fresh water consumption leads to saving in water, effluent and energy costs. Number of machine manufactures displayed various washing machines. A few of them are: MEMNUN MAKINA, Turkiye MOENUS, Germany MORRISON, USA Goller, Germany BENEKS, Turkiye BENNINGER, Switzerland MENZEL, Germany KUSTERS, Germany One thing was common that many Manufacturers have come out with advanced methods of washing.

BENEKS-Washing machine
Cab be used to wash the knitted and woven fabric. No crease formation Water consumption 16 to 30 litre/kg depending upon the shade. Speed up to 30 m/min

BENNINGER-Wash
Minimal fresh water consumption leads to saving in water, effluent and energy costs Available for knitted & woven fabrics Large guide roll diameters and adapted roll spacing that prevent the fabric from skewing and guarantee crease-free treatment from entry to exit of the range

Menzel-Scouring & Bleaching m/c

It has improved chemical add-on process in scouring and bleaching by removing the chemical pad-on trough and adding the chemicals directly on top of two squeeze rollers (nip). This allows for more precise add-on control as the pre-wet fabric is immediately exposed to the specific treatment without atmospheric exposure, as well as a higher liquor exchange rate.

Kusters Turbojet system of washing

This system utilizes a pressurized steam unit that operates at 100oC to increase water turbulence. This effectively washes both sides of the fabric without a spray bar unit in a short range of space. One unit contains two passes for high effective wash. It occupies less space.

Arioli-Plasma treatment
Arioli S.p.A displayed its new plasma equipment, considered still to be in the developmental stage. Very promising technology as a potential new step in preparation of fabrics (Man-made to natural) Benefits: Increased dye uptake and wettability Increased adhesion with certain finishing compounds.

BENEKS-Edge sewing machine

The special edge sewing machine is used to convert especially the open width prefixed lycra woven fabric into tube form by folding the ends and sewing the edge. Machine operates automatically until folding and the operator need not do any adjustment. Due to perfect sewing, the problems which might arise due to folds and wrinkles are eliminated.

Singeing machine
The features of singeing machines displayed are: Modified burners to produce high intensity uniform flame capable of using natural gas, butane, propane or LPG Improved washing efficiency

Menzel-Singeing m/c Morrison-Singeing m/c Osthoff-senge Parex Mather singeing machine

Machines are available for woven and tubular/Open width knitted fabrics

Menzel-Singeing m/c Independently controlled burners with separate gas combustion analyzer helps the efficiency of fuel usage. Improved washing process by adding another set of rollers on the top section of the wash box, forcing water through the fabric for second time to increase water penetration through the fabric, thus increasing the wash effectiveness.

Stenters/ Heat setting m/cs

Outstanding drying capacity Low energy consumption Reliability Flexibility of operations Operator friendly machine Numbers of machine manufacturers have displayed stenters.
Unitech Moenus Superba (Carpet yarn)

Unitech-single layer stenter

Machine is provided with insulating panel with high thickness, Independent heating of each chamber, insulated floor platform (On request) Heating system: gas burner, thermic oil or steam, combined heating system (Steam + electric) Easy extraction of filters while machine in operation, automatic filter cleaning (Optional) Many other features are available with the machine

SUPERBA-Advanced heat-setting line for carpet yarn

High productivity up to 12 Tones/day (99% efficiency) Quick lot/style change Low operation cost & environment friendly (Reduced energy consumption compared to other heat setting process, limited maintenance) Fully computer controlled

Single layer stenter for knitted and woven fabricsMoenus

Creates a special cushion effect that ensures absolutely uniform floating of the fabric. This permits relaxation of the fabric before the actual fixation process. The Star-Jet nozzle system guarantees optimal temperature distribution and even ventilation intensity. Air application is kept extremely uniform over the entire fabric This gentle drying makes for outstanding fixation and residual shrinkage values and a soft, bulky handle

Mercerizing machines
Mercerizing machines offered by various manufacturers claim to provide: Better control systems Suitability of machine for hot/cold mercerization Operator friendly machine A few manufacturers are: KUSTERS Menzel BENNINGER Morrison Lafer

Menzel-mini mercerizing m/c

Low cost and compact construction - ideal for finishing small and medium production outputs. The material goes to and fro several times through the machine during which it is mercerized and stabilized.

BENNINGER-Mercerizer
Can mercerize light weight, heavy weight, knitted and woven fabrics on same machine

Lafer-Liquid ammonia mercerising machine Liquid ammonia mercerization is an older concept (developed 1930 & abandoned due to complexities of processing & danger in handling liquid ammonia) Lafer offers safer, more feasible system of handling ammonia called Permafix

Lafer-Tubular compacters

It ensure flaw less results Used for tubular knitted fabric

TEKST-spray type hank dyeing machine

Consists of main tank and dye kitchen. Equipped with electrical and mechanical lid safety locking system. It works under 0,3 bar pressure with spray dyeing system. Machine works at low MLR. Capacity 5-300Kg After dyeing, the hanks enter fixing process at 98oC. Recycling of the dye solution is possible.

TEKST-Hank Drying machine

Minimum working temperature is 75oC and max. 95oC. Hank hangers are specially designed to make loading and unloading easy.

OBEM-Spray dyeing of yarn

Dye solution is sprayed from perforated spindle and penetrates in the yarn (M:L::1:5) The dyeing liquid then runs from the top of the hank to the bottom and goes to the circulation system The even distribution of the dye solution from the perforated spindles and the automatic movement of hanks in both clockwise and anticlockwise directions achieve an even colour shade of each hank. Benefits: It helps in reducing consumption of energy, water

OBEM-Multi purpose apparatus

API/V is the traditional vertical apparatus that can be used to dye different packages and materials, by changing the holding-material baskets It can be used to dye hank, tops, loose fibre and tow It is high pressure(4.5 bar) and high temperature (138oC) machine

Robotization of package dyeing (OBEM)

It is complete automatic dyeing plant for yarn( in package) to avoid error due to human Can dye all types of fibres with max. temperature 138oC with MLR 1:3.5

Robotization of Hank dyeing plant (OBEM)

Complete automatic hank yarn dyeing plant to avoid error due to human MLR 1:10 for mercerized cotton & 1:14 for acrylic, Max. temperature 100oC

Vari-Flex Padder for knitted & woven fabricsMoenus

Scope for side-centre-side corrections Reproducible electro pneumatic nip pressure setting Uniform liquor supply and mixing over entire fabric width Automatic padder cleaning for rapid colour changes Compact deign

tubes with an extremely efficient heat exchanger, and allows the cooling and rinse cycles to be combined, saving water, time and energy (up to 3360 Kg /batch) Eco-88D is designed for light to medium weight fabric made from manmade fibres and has two dyeing compartments in a single-tube machine. Spray nozzle inside the dyeing compartments reduces friction between fabric and metal and reduces fabric defects due to friction.

Jumboflow and Eco-88D piece dyeing machine Jumboflow can dye up to (Fong per dyeing tube-up to 12 280 kg s)

SCLAVOS-Soft flow dyeing machine

Athena 2 is the new development of Sclavos in the field of knitted & woven fabric dyeing Built with advanced automation Twin soft flow dyeing system Variable loading adjustment Integrated control of liquor ratio Heat exchanger

Dry salt dosing (DSL-SCLAVOS)

This specially developed device will ensure that dry salt will be dosed in the dyeing bath at any required linear rate without any pre-dilution in the addition tank Benefits: No involvement of machine s add tanks in salt dilution, so that faster process is obtained No need of fresh water for salt dilution, so that liquor ratio is not affected No involvement of machine s operator at all Very fast salt transfer when needed. This will lead to optimum use of salt and thus less TDS in effluent

HT Synchron Airjet fabric dyeing machine (DILMENLER)

Transportation of fabric by mixture of air & steam Dyeing process is carried out in a gas medium, where dyestuff, chemical and auxiliaries are directly injected in a air steam medium The exhaust rate of the bath is very high, so that the wastewater is clear and with a small residual amount of products.

Then-Aerodynamics fabric dyeing

THEN also provide airflow system for piece dyeing

Beam Jigger-Brazzoli
It is a combination of traditional jigger technology and autoclave dyeing technology Perfect penetration of the dye throughout the fibre High washing efficacy: washing times cut by 40-50% approx. & water saving 35-40% Bleaching & Scouring time is reduced 35-50% No centre-selvedge and head-tail problems

SERVO Jigger (Memnun Makina)

Fully automatic with PLC controlled dosing system Touch screen panel Addition tank with mixture and pneumatic panel

Thies- High Temperature Jiggers

Jigger for the processing of fabrics in open width for dyeing processes up to 143 C. Special features of the Thies Jiggers are steplessly adjustable fabric tension and speed as well as the economic dye trough for optimized short liquor dyeing under uniform process conditions.

MKB-2000 Fabric Indigo dyeing (Memnun Makina)

Speed 5-35 m/min Sulphur can also dye Automatic foam cleaner Automatic dosing

BENNINGER-Continuous dyeing system

For continuous dyeing machine fulfill the following requirements:
Uniformity of the dyeing High color fastness Short through time Cost efficient process High efficiency Flexible plant, suitable for many processes Crease-free fabric run High reproducibility

Kusters Continuous processing of knits

Tensionless continuous processing range Benefits: Use less water Dyes having high fixation are used with less salt. Leaves less colour in spent dye bath

Rousselet-Continuous Centrifugal hydroextractor

Feeding and discharging of fibres in a continuous way, allowing the greatest possibility throughput A compact unit requires small area By operating on thin layers of fibres, the centrifuge enables a uniform moisture content Limited maintenance Useful for natural and synthetic fibres after preparation & dyeing, Wool processing

Monti Antonio-Transfer Printing

It offers high level of quality and reliability An optional vacuum feature provides deep penetration of ink for fabrics requiring images on both side. Benefits: Reduction in consumption dyestuff, energy, effluent Short runs are easy to manufacture Limitation: Limited to volatile dyes & Not applicable for natural fibres

Zimmer Printing machine

It provides full range of printing machines-flatscreen, rotary-screen and inkjet. Inkjet printer can print 2.6-meter-wide fabric at speeds of 42 to 81 m2/hr. It also offered Quickfix preparation and heat-treatment machine for ink-jet printing.

DuPont Inkjet printer

Artistri 2020 & 3320 can print width of 1.8 and 3.3 metres respectively Speed 40 m2/hr for 760 dpi at two phases It also offered inks for other ink jet printer manufactureres.

Finishing
Theme: A major focus is Faster production Water, chemicals and energy saving Fabric handling

SWA-Yarn raising machine

-Electronic adjustment of the speed from 50-200 m/min -Adjustment of brushing ratio -Adjustment of angle of contact of the yarn -Device for rapid stop of the machine -Thread tension control device

Lafer-raising machines

Speed up to 50m/min Can be used for raising of Knitted fleece, Polar fleece

Lafer ultra soft brush-sueding m/cs

Lafer ultra soft brushsueding m/cs for woven & tubular knitted fabric

Garment Processing
Theme: A major focus is given on: Automation Creation of various effects Water, chemicals and energy saving Fabric handling