Traditional dyeing processes always need heat to fix colour into the fabric. With Cold Pad Batch (CPB) techniques, the dyeing liquor and fabrics are rolled at room temperature, therefore saving energy significantly. CPB was introduced for reactive dyes in 1957 with very simple technology: padding. Read more about List of Dyeing Machine for Fabric dye in Textile
Most new driers come with
built-in control equipment. Therefore this measure is especially attractive in
case existing drying equipment is replaced. The cost of instruments for measuring
the remaining moisture in dried fabrics ranges from USD
6 000 to 12 000. Savings are achieved through
the reduced energy consumption (up to 30%), less risk of excess drying (10 to
15% productivity increase) and an improvement of the quality of the final
product. Besides, in case the sales price of the fabric is based on the weight,
a higher moisture level will raise the sales value of the product (2 to 3%
increase).
Cold pad batch dyeing is a widespread technology for the semi-continuous dyeing of cellulose (mainly cotton and viscose) woven and knit fabric with reactive dyestuffs. The dyeing liquor and necessary auxiliary chemicals, like alkali for fixation, are fed to a dyeing trough for pad batch dyeing for impregnating the textile. The reactive dye, together with necessary alkali (Na2CO3 or NaSiO3) for fixation, is padded to cellulose fibres (cotton, viscose, lyocell, linen…) from a padder for impregnating. The impregnating fabric is maintained for 6-24 hours at room temperature (25-30oC) for meeting wet colourfastness. Then the fabric is rinsed out to clean the dyestuff on its surface.
This is one of the simplest methods and applied widely in Europe. This method is recommended due to : • Low energy consumption • Low investment in equipment and labour • Good quality in colour, its fastness and reproducibility • Reduction of pollution load As the liquor ratio is 1:6, there is a significant reduction in the amount of water and chemicals. Besides, this method does not require salts, as in other exhaust or pad-steam dyeing methods. It is estimated that 80% of BOD, COD can be reduced. CPB dyeing is a widespread technology for the semi-continuous dyeing of cellulose (mainly cotton or viscose) woven and knit fabric with reactive dyes.
Installation of soft starters and variable speed /frequency drives for higher capacity motors.The possibility of implementing this measure depends on the specifications of the final product and has to be analysed on a case by case basis. In general, thermal dewatering is expensive in comparison with other dewatering techniques, such as mechanical squeezing or vacuum extraction. In case a replacement of dewatering equipment between two baths is contemplated, it is therefore recommendable to consider switching techniques. In case thermal dewatering is selected, the air flow can be reduced to a point where a minimum airflow is guaranteed at all times in order to prevent condensation and contamination. It is very similar like Laboratory Jigger Dyeing Machine
Variable frequency drives (VFDs also termed as inverters) may also be useful in Jet / Soft flow dyeing machines, where most of the pumps are of higher capacity (than actual requirements) and water flow is throttled (around 50%). Hence it would be worthwhile to use VFDs (inverters) for the main pump and remove pressure control valve. (The savings could be around 30%.)
For the large size hydraulic jiggers the main pump motor consumes about 15 HP throughout the operation. The machine usually runs at 80 – 120 m/min against the designed speed of 150 m/min and in these cases it would be worthwhile to use an inverter by replacing flow control valve (savings in the range of 30%).
VFDs are also worthwhile to use for blowers in the stenters / dryers for efficient moisture removal. Increased power factor and reduced energy consumption and reduced GHG emission. Applicable for all motors of higher capacity and having variable speed applications (e.g. ID and FD fans of boilers, motors of drum washers etc.) This option is beneficial for only higher capacity motors. Savings: apart from the monetary savings, the reduction in the greenhouse gas emission is considerably high, which is a motivating factor for the implementation of this option. The payback of Jigger Machine for such a measure would be less than 20 months.
What is Terry Towel Weaving Machine? Fabric Dyeing Process
Terry Towel laving width: 500 mm
Suitable Yarn: Cotton Spun
Shedding type: Electronic Jacquard with minimum 1400 Hooks
Harness mode: one hook /one thread
Weft Insertion: Rigid Rapier
Weft cutter: Mechanical or Pneumatic
Number of Colors: minimum 08
Take-up: Electronic – Independent Stepper Motor Drive
Let-off: Electronic – Independent Stepper Motor Drive
Warp and Weft Stop Motion: Automatic
Controller/Software: PLC based dedicated with pattern editor and diagnostic option , Separate Drawing-In Station: Automatic with 8 Colors and 20 Heald frames
In a textile manufacturing company, cooling water is used in many places such as: Engine and burner cooling; Fabric cooling with cooling drums filled with water; Cooling dye baths; and Cooling of the air between different drying stages in a pressure dryer.
The spent cooling water can be circulated back to the process water storage tank or it can be transported to a separate storage tank for warm process water. The only disadvantage can be the increased risk of contaminants in the process water. However, a monitoring system can be installed to detect this (measuring, e.g., pH, conductivity, turbidity) and filters can be installed to purify the water. Recycling of cooling water can reduce total water consumption by about 50% and energy consumption by about 20%. The applicability is company specific and depends, among other factors, on the demand and supply of water in the company. The investment costs depend on the specific company situation and recycling possibilities. The recycling of cooling water can lead to water savings of up to 50%.
In a counterflow washing process, fresh water is introduced only at the exit wash unit and counterflows back toward the dirtier units. This process increases water consumption at each separate washing stage, but the overall water consumption is reduced considerably. In textile dyeing and printing, counterflow washing is applied because most of the water consumption is related to the washing of the materials. Besides, counterflow washing provides a more efficient cleaner wash. Since 1985, the use of counterflow washing machines has resulted in a decrease of water consumption and a corresponding reduction in the volume of the wastewater. Many textile companies have adopted the counterflow washing process. The further development of these washing machines has resulted in the optimisation of the washing process leading to a further reduction of the water consumption. With the implementation of the counterflow washing process, a water savings of 75% can be achieved.
Conclusion
Portable spectrometer – Counterflow washing can be applied to all washing processes in the textile industry, with the exception of washing processes that take place in yarns painting equipment, flake painting equipment and reel barrels. Converting a conventional washing process to a counterflow washing process has a payback period of several years.
Multi-Component Melt Spinning Equipment along with Melt Blender
Melt Blender Specifications – Capable to handle variety of polymer typesPossibility of making different yarn types, e.g., POY, FOY; multifilament, Monofilament Capable to produce Mono, Bi and Tri-component filaments (at least bi components) Temperature range up to 450°C Throughput 0.1— 6.0 kg/hr (speed around 1000 m/min)
Boiler pressure can be set at the lowest acceptable level by:
Tuning the boiler pressure to the energy demand. The lower the pressure, the lower the energy losses are. Check the lowest steam pressure at which the connected equipment functions properly.
Reducing the margins between maximum and minimum steam pressure at which the boiler reacts (often it switches between half power and full power) This reduces temperature variations. Based on professional experience it is possible to adjust the margins. By doing so, the boiler and the steam circuit last longer and require less maintenance.
Making sure that the settings are such that the boiler never switches off. Switching off and restarting the boiler cost extra energy since the boiler requires air rinsing for safety reasons. In cases when boiler is used 24 hours a day, the steam demand is often less during the night. Reduce the pressure in the steam circuit during these periods to the required minimum level. Programmable switches allow automatic switching.
For example, a jet dyeing machine may need steam at 6 kg/cm2 for achieving 3 kg/cm2 pressure in machine. The steam generation may be at 8 kg/cm2 (saturated) considering steam transmission losses. However if boiler operates at 15 kg/cm2, the pressure would need to be reduced through pressure reducing valve to again 6 kg/cm2, at the machine. Thus incurring energy loss corresponding to heat at 15 kg and heat at 8 kg. In case of leaks etc. the loss would be much more in case of 15 kg line compared to 8 kg line. Reducing steam pressure reduces energy losses. Every company that has a steam installation. Cost of changing the settings of a steam pressure is negligible. Purchase of a programmable switch can be considered. Reduced energy losses leads to reduced energy costs.
