Veredlung Von Frottee E

8/8/2019 Veredlung Von Frottee E

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Dyeing and Finishing of Textile

Materials

-

Feasibilities and problems


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Global situation of dyeing factories

Dyeing factories must tackle following problems:

Reduction of the water consumption

Compensation of the price increase for energy,

raw materials and dyes/auxiliaries

More stringent quality control by the customers Short delivery times (=> faster finishing times)

The above parameters can be divided into two groups:

Environmental impact

Commercial factors


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Global situation of dyeing factories

Environmental impact:

Water availability quality

Effluent treatment costs for waste water treatment

Energy power and steam costs

Commercial factors: Reduction of delivery times - reproduction - Right-First-Time dyeing

Shorter production times

Lower profit margins

Higher quality standard

- reproducibility from batch to batch

- appearance of the textile surface

-preservation of the physical properties of the material


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Finishing of


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What is the marketdemand?

or

What is the marketachievement?

M&S - Standard

50 ltr/kg material

4-5 batches per day

Easy operation

These are the basic prerequisites toThese are the basic prerequisites to

make profit.make profit.


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Important parameters for dyeing and finishing of terry:

- Quality

- Energy consuption

- Process times


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- Quality

Features:

- Valves all drain valves come as ball valves to avoid blockade of the

pipelines

- Nozzles large nozzles to ensure positive and smooth fabric flow (between

150 and 300 mm, dependent on the linear metre of the terry fabric)

- Transport pipe large transport pipes to guarantee positive fabric plaiting and

smooth fabric transport

- Fabric plaiter improved fabric plaiting

- MCD Multi Contact Dyeing - faster treatment times due to improved

liquor interchange (fabric/liquor)- Autom. filter avoiding blockade of the pipelines - increase of productivity


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- Quality

Features (2):

- HT-bleach faster and state-of-the-art process control, improved

fabric quality, reduced consumption of chemicals

- proVAT function to support vat dyeing

- Autom. dosing faster and state-of-the-art process control, improved levelnessof towels


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- Energy consumption

Features:

- Liquor ratio shortest liquor ratio min. 1:5, resulting in lower

costs for steam, water, effluent and electrical power

- Temperature manager low steam consumption

- RINSEtronic optimisation of the reactive post washing, resulting in lowerwater and steam consumption as well as time savings

- Power drain/-fill reduction of drain and fill times

- CCR Combined Cooling/Rinsing - re-use of the cooling water as

rinse water - reduction of water consumption

- 100% Stock tank preparation of the next baths - significant savings of time andensuing electricity and steam costs


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- Process times

Features:

- Liquor ratio shortest liquor ratio min. 1:5, resulting in lower

costs for steam, water, effluent and electrical power

- 100% Stock tank preparation of the next baths - significant savings of

time and ensuing electricity and steam costs

- Autom. filter no filter cleaning required - time saving

- HT-drain drainage of the of the bath at HT-conditiones - shorter

processes

- HT-bleach faster and state-of-the-art treatment

- Batch parameters reduction of the numerous programs resulting in quicker andeasier handling of the machine


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- Process times

Features (2):

- T 737 / T 858 Windows based control technology, quick and easy to learn

- OrgaTEX overhead control system for simplification of the planning, for

recording consumption data and operation of the dyeing machines

- Look-ahead software function in the OrgaTEX overhead system, fasterpreparation of the next batch


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- Process times

Features (3):

- Chamber loading 250-400 kg per chamber, dependent on the weight per linear

metre of the terry fabric

- Dry loading time saving

- Modern processes short production times2 dyeing processes (reactive) are sufficient

- VS + bifunctional: dark shades in All-In- process

treatment time approx. 5 to 5,5 hours

- VS + bifunctional: light and middle shades in

migration method - salt added in advance

treatment time approx. 5,5 to 6 hoursprecondition is a high rate of Right-First-Time


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These days there are different options for dyeing and finishing terryproducts

1. Half-continuous dyeing followed by continuous finishing

2. Continuous dyeing followed by continuous finishing

3. Discontinuous dyeing (exhaust dyeing) followed by discontinuous and continuous

finishing


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2. Continuous dyeing followed by continuous finishing

- desizing on a continuous washing machine

- intermediate drying on a stenter

- continuous bleaching and washing machine


- Pad-Steam (dyeing)- wash-off on a continuous washing machine


- softening - padding

- drying on a stenter

- continuous tumbling (e.g. Thies T 310)

- cutting - sewing - packing

At least 7 different machines


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3. Discontinuous dyeing (exhaust dyeing) followed by discontinuous orcontinuous finishing

- desizing on a jet

- bleaching on the same jet

- dyeing (exhaust dyeing: reactive or vat dyeing) on the same jet

- softening on the same jet or padding- hydro extraction (centrifuge)

- rope opening

- drying on a stenter or immediate tumbling and drying in T 310

- continuous tumbling (e.g. Thies T 310)

- cutting - sewing - packing

At least 4 different machines


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Advantages:

- pre-treatment and aftertreatment can be executed on the same machine (lower

acquisition costs)

- different fabric widths and -weights can be processed at the same time (In the

continuous field only possible to some extend because otherwise creases or

off-shade dyeing will result)

- reduced effluent contamination as less dyestuff is used to achieve the same

depth of shade

- higher flexibility


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Advantages (2):

- the same production costs, irrespective of 1-chamber or 6-chamber machine

- higher reproducibility (continuous dyeing involving significantly more sources oferror)

- less logistics required, in case of continuous processing always several machines

must be scheduled

- faster process times as everything is executed on one machine

- in case of problems only 1 supplier must be addressed, with continuous dyeingmost times 2 or 3 suppliers


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- Production costs

Cost breakdown of a major producer of terry towels in India - however, dyestuffcosts are not included:

Desizing Washing ProcessCost of Desize range/hour 5109 5109 5109 5109 5109 5109 5109 5109

Capital, Housing & other Fix Costs/ me tre 1,54 1,12 0,91 0,80 0,76 0,74 0,73 0,72

Labour Cost / metre 0,16 0,11 0,09 0,08 0,08 0,07 0,07 0,07

Water & Energy Costs/ metre 2,05 1,49 1,21 1,07 1,01 0,99 0,97 0,96

Labority/ metre 0,44 0,33 0,28 0,25 0,24 0,24 0,23 0,23

Auxiliary and Chemicals Costs / metre 1,49 1,49 1,48 1,48 1,48 1,48 1,48 1,48

Total Costs per metre 5,68 4,55 3,98 3,69 3,57 3,52 3,49 3,47

Mega Bleach Wash rocessCost o

dyeing range/hour 82 82 82 82 82 82 82 82

Capital, ousing & other ix Costs/ metre 2,93 2,13 1,73 1,53 1,45 1,41 1,39 1,37



Labority cost/ meter 0,77 0,60 0,52 0,48 0,46 0,46 0,45 0,45


Total Costs per metre

, 4 9,36 8,48 8, 3 7,84 7,76 7,7 7,68

Basic Parameters for Continuous ProcessingLength (m) 25 5 2 35 5 75

Weight (kg) 375 75 5 3 525 75 25 5

Running speed (m/min) 50 50 50 50 50 50 50 50

Reprocess (%) 5 5 5 5 5 5 5 5

abric weight (g/running metre) 5 5 5 5 5 5 5 5

ick-Up (%) 100 100 100 100 100 100 100 100


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- Production costs


Dryi rocess os tof ye i

range / our 2120 2120 2120 2120 2120 2120 2120 2120

Capital, ousing other i

Costs/ etre 0, 0, 0,09 0,08 0,08 0,07 0,07 0,07

LabourCost / etre 0,04 0,03 0,02 0,02 0,02 0,02 0,02 0,02

EnergyCosts/ etre 1,36 0,99 0,80 0,71 0,67 0,66 0,64 0,64

Leadercloth / etre 0,01 0,00 0,00 0,00 0,00 0,00 0,00 0,00

AuxiliaryandChemicalsCosts / metre 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00

otal Costspermetre 1,

1,13 0,!

2 0, " 1 0,# #

0,#

0, #$

0, # 3

Basic Parameters for Continuous ProcessingLength (m) 250 500 1000 2000 3500 5000 7500 10000

Weight (kg) 375 750 1500 3000 5250 7500 11250 15000

Runningspeed (m/min) 50 50 50 50 50 50 50 50

Reprocess (%) 5 5 5 5 5 5 5 5

Fabric weight (g/runningmetre) 1500 1500 1500 1500 1500 1500 1500 1500

Pick-Up (%) 100 100 100 100 100 100 100 100


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- Production costs


Pad- Steam- WashDyeingCost of dye ing range/hour 7980 7980 7980 7980 7980 7980 7980 7980




Labority, Leader cloth & Reprocess Costs / metre 9,47 4,91 2,63 1,50 1,01 0,81 0,66 0,58


Total Costs per metre 47,61 26,57 16,05 10,79 8,53 7,63 6,93 6,58

ad Batch Wash DyeingCost ofdyeing range/hour 5109 5109 5109 5109 5109 5109 5109 5109Capital, % ousing & other & ix Costs/ metre 9,09 4,89 2,80 1,75 1,30 1,12 0,98 0,91



Labority, Leader cloth & Reprocess Costs / metre 8,22 4,24 2,25 1,26 0,83 0,66 0,53 0,46


T ota l Costs per metre 33,69 19,00 11,66 7,98 6,41 5,78 5,29 5,05


Weight (kg) 375 750 1500 3000 5250 7500 11250 15000


Reprocess (%) 5 5 5 5 5 5 5 5

abric weight (g/running metre) 1500 1500 1500 1500 1500 1500 1500 1500

ick Up (%)100 100 100 100 100 100 100 100


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- Production costs

Cost breakdown of a major producer of terry towels inIndia - however, dyestuff

costs are not included:

Exhaust Dyeing (Pretreatment+ Dyeing)Cost of dyeing range/ hour 314 314 314 314 314 314 314 314



Dyestuff cost p.kg : 0 0 0 0 0 0 0 0

Chemical cost p.kg Pretreatment: 4,37 4,37 4,37 4,37 4,37 4,37 4,37 4,37

Chemical cost p.kg Dyeing: 4,58 4,58 4,58 4,58 4,58 4,58 4,58 4,58

Water cost p.kg : 3,06 3,06 3,06 3,06 3,06 3,06 3,06 3,06

Steam cost p.kg : 4,15 4,15 4,15 4,15 4,15 4,15 4,15 4,15

Electr.cost p.kg : 2,61 2,61 2,61 2,61 2,61 2,61 2,61 2,61

Water consumption in Litres p.kg: 65,50 65,50 65,50 65,50 65,50 65,50 65,50 65,50

T ota l Costs per metre 26,10 26,10 26,10 26,10 26,10 26,10 26,10 26,10

achine considered is 1000 kg machine for 15 mio INR


Weight (kg) 375 750 1500 3000 5250 7500 11250 15000


Reprocess (%) 5 5 5 5 5 5 5 5

Fabric weight (g/running metre) 1500 1500 1500 1500 1500 1500 1500 1500

Pick-Up (%)100 100 100 100 100 100 100 100


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- Production costs

Cost breakdown of a major producer of terry towels inIndia - however, dyestuff

costs are not included:

SummaryTotal Cost by Continuous Pretreatment and Cold-Pad- ' atch Dyeing 52,07 34,05 25,03 20,52 18,59 17,82 17,22 16,92

Total Cost by Continuous Pretreatment and Pad-Steam Dyeing 65,99 41,61 29,42 23,33 20,71 19,67 18,86 18,45

Total Cost by Exhaust Pre Treatment and Exhaust Dyeing 26,10 26,10 26,10 26,10 26,10 26,10 26,10 26,10


Weight (kg) 375 750 1500 3000 5250 7500 11250 15000


Reprocess (%) 5 5 5 5 5 5 5 5

Fabric weight (g/running metre) 1500 1500 1500 1500 1500 1500 1500 1500

Pick-Up (%) 100 100 100 100 100 100 100 100

From 3000 kg batch size and moreFrom 3000 kg batch size and more

per shade the continuous processingper shade the continuous processing

is less expensive.is less expensive.


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Have you always got

a 3000 kg batch size

for ONE shade ???

If you dont, we offer you ...


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One machine for desizing, bleaching, dyeing, wash-off and, if

requested, softening:

ecoMaster

F


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We are yourexperienced partner!


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