New development in winch dyeing-Dyeing high efficiency & low energy consumption high temperature dyeing machine

Compiled by M. Rezaul Karim Tutul

New development in winch dyeing-Dyeing high efficiency &
low energy consumption high temperature dyeing machine

In view of tight & heavy single jersey fabric is easily to occur crease mark during process of
dyeing & finishing, this article explore its reason & introduce solution with aids of some new
dyeing machines which not only solve such problem &, at same time, versatile application can increase
success rate of dyeing sensitive fabric which is highly recommended by customers.

Introduction
In this moment, demand for increasingly stringent environmental protection Five-Year
Guideline had also pointed out that energy saving & emission reduction would be as one of
assessments at all Five-Year Guideline. Textiles manufacturers & machinery suppliers have
been fully aware of this, & have taken action to achieve this norm. At same time, standard
of textiles manufacturing technology & demand for improvement of machinery
quality/performance & processing technology to produce higher quality of products had
been put to a higher level. Therefore, developments of new series of dyeing & finishing
machinery are major target for textile machinery manufacturers in coming years.

Designed & built to achieve higher loading capacity, lower LR, higher quality & more eco-
friendly high temperature dyeing machines. This dyeing machine has an excellence
performance in dyeing tight & heavy single jersey cotton fabric such as knitted by 40S/2,
26S/1, 20S/1 etc; it can eliminate crease mark problem of these kind fabrics as usually seen
in other dyeing machines when dyeing these kind of fabrics.

Crease mark formation
What is a crease mark?
There are some other common names for crease mark, such as machine line mark, water-
mark line, straight line mark etc. formation of this crease mark is due to fabric being folded
into rope form, during process, rope shape (folding part) had not been transposed
frequently. At such, colour in this folding part will be darker with darker line along. This is
special obviously in case of dyeing heavy single jersey. In recent years, development of
knitting machines rapidly, now there are more & finer gauge knitting machines are available in
market, & therefore knitted fabrics are more tightly, & also in other hand, thanks to advancement of
spinning technology, now low quality cotton can also be spun into usable yarn for making
fabrics. This complicated & extra yarn formation process increases internal stress (tension)
of fabric being made is released during dyeing & finishing process, such internal stress
causes uneven fabric shrinkage, & makes folding section cannot be easily transposed, then
there creates a permanent folding mark (crease mark).

How to solve the crease mark problem?
As in past, when customers encountered crease mark problem, customers usually would
consider to change their machines. As a thumb rule, there is a tendency of crease mark
formation in dyeing machines, but degree of formation is different from machine to
machine in round-shape dyeing machine, formation of crease mark is less in L-shape
dyeing machines. But there are drawbacks in L-shape dyeing machines, such as higher LR &
higher power consumption when compared with same loading capacity of round-shape
dyeing effluent treatment process. It increases cost of effluent treatment process & running cost.


New development in winch dyeing-Dyeing high efficiency & low energy consumption high temperature dyeing machine
Compiled by M. Rezaul Karim Tutul
Many textile auxiliary manufacturers are also producing new type of lubricants & softeners
to help elimination of crease marks, these chemicals help up to certain level but still effect
is not so prominent. Adding such chemicals will increase cost of production and enhance
difficulty of effluent treatment process.

So many customers try to eliminate crease mark problem by using heat setting device
stenter either in open width or tubular form rather than to change machine immediately.
They try to heat set fabric in tubular form under water or in wet state by steam so that
internal stress can be released to reduce formation of crease mark. But this method again
has a drawback which is symmetric mark and this operation also increase production cost.
Or other way, they use stenter to have pre-heat setting/stretching so as to release internal
stress. This operation helps a lot in elimination of crease mark but it also increases
production cost and after slitting fabric & before dyeing they need to stitch back again, so
this process again increases labour force & cost.
Line with customers & actively cooperates with customers, combines with help of staffs
from R&D & hydraulic dyeing machines into its latest JUMBOTEC series. special design in
nozzle & body structure combining with suitable dyeing processes enhance elimination of
crease mark & increase quality of fabric without increasing cost.

Specification
Assurance of high quality and high efficiency
In recent years, cotton prices fluctuates constantly, especially in 2010, cotton price rose sky
high, textile manufacturers tried hard to reduce cost, making the most basic single jersey
fabric specially for yarn count 20S/1. 26S/1 & 40S/2 becomes a difficult product for them.
Although they spend a lot of effort to conjunction with its various departments as
mentioned, from design to dyeing process, developed new high efficiency JUMBOTEC series.

Assurance of high quality
Integration of good features from L-shape and round-shape dyeing machines into this new
series, we design a new nozzle which provides sufficient flow but at same time it can
provide enough power to expand fabric. It ensures fabric running in a high speed manner
with sufficient transposition of folding part to release internal stress; as a result, it
minimizes formation of crease mark and enhances even dyeing process.

Assurance of high efficiency
Textile manufacturers pursuit high quality products, & at same they also pursuit machines
with high efficiency, high efficiency machines mean that it can increase productivity &
speed up delivery, as a result they will have a higher market share. G assures that our high
temperature TEC series are high quality products & at same time we assure that TEC series
are high efficiency machines in production.

High loading capacity per chamber
JUMBOTEC high temperature dyeing machine can be loaded up to 300kg per chamber, no
other machine can load up to this capacity.

New Salt Addition tank
In cotton dyeing process, addition of salt depends on depth of shade & sensitivity of colour.
Usually, there are two ways of salt addition (1) salt at start (before addition of dyes) or (2)

New development in winch dyeing-Dyeing high efficiency & low energy consumption high temperature dyeing machine
Compiled by M. Rezaul Karim Tutul
addition of Salt by Portion after addition of dyes. Salt at start method usually is suitable for
dark colour or dyes not sensitive to salt; in method (1) salt can be rapidly injected in dye
bath. Addition of salt by portion is suitable for light & medium shade & sensitive colours, &
it is done by dosing. In old machines, addition of salt was done by solving salt separately &
then injects salt solution slowly in dye-bath; it consumed al ot of time & affected efficiency.
Our TEC series has been integrated with overflow function in addition of salt (in addition
tank), combination with dosing function, flow return function & circulation mixing
function, direct steam (or indirect) heating & high temperature injection function (105
o
C)
to achieve excellent dyeing result & cost effective & economic efficiency.

Patented lint collector
In course of dyeing cotton fabric, there are a lot of adverse effects in dyeing process by
presence of lose fibre & dirty substrates, such as uneven dyeing or dirty/lint staying on
fabric surface. So machinery makers are aware of this to provide lint collector & remove of
lint/dirties, traditional cage filter has following drawbacks:
(1) It is difficult to remove the lint from the filter
(2) The lint blocks the filter frequently
(3) Once filter is being blocked, the nozzle pressure drops & affects dyeing result
(4) Once stop machine for cleaning, the production will be affected also.

In view of above problem, we had developed a new automatic lint collector; no more
traditional cage filter will be used in this new TEC series. It will collect & accumulate lint in
v-shape bottom section & then drain it automatically during drain function.
1) It will not cause blockage of filter during dyeing process, so the nozzle pressure will
not be unstable, so it will not affect the dyeing quality.
2) Two machines for cleaning, so the productivity increases.
3) No need for cleaning, it saves a lot of labor.

Unloading device
By using X-Y unloading & plaiting device, it enhances fully automatic unloading of fabric.
We can unload many chambers at same time; fabric will be nice plaited onto cloth trolley.
Pneumatic operated horizontal plaiting device can be adjusted to fit cloth trolley width, so
that it can reduce labour & reduce time of unloading.

Multi-function Stock Tank
As usual, new TEC series also can be equipped with MST. It has following functions:
Quantity fill, heating, mixing
Preparation of hot water, to save time in filling and heating
Preparation of chemicals to save time in addition and mixing time
Transferring of dyeing solution between MST & addition tank to enhance
preparation/addition of chemicals
Rapid addition to the main kier.

Washing function
This TEC series equipped with Multi-Intelligent Rinsing function, by using modulation
valve & water flow-meter, quantity of water can be controlled precisely, it is a continuous
low level rinsing to save time in filling and draining, we can set rinsing level & rinsing

New development in winch dyeing-Dyeing high efficiency & low energy consumption high temperature dyeing machine
Compiled by M. Rezaul Karim Tutul
temperature to increase rinsing efficiency & saving time. By using Rinsing Index, we can
achieve uniformity rinsing for each batch and further enhance automation in rinsing step.

FC30 controller
This new FC30 controller was developed based on original FC28 controller by upgrading
hardware & functions, such as colour display, pre-installed dyeing programs to save labour
& reduce human error. At same, controller can record up to 8 processing parameters. Users
can define up to 4 processing parameters in same display. Its auto-navigation function can
provide plenty of pre-defined programs & running parameters for different kind of
materials, customers can put machine in production quickly. And of course customers can
create their own running parameters in different programs such as main pump speed,
winch speed, cycle time & product information such as fabric structure, fabric width, fabric
weight and setting of VL etc.

Assurance of energy saving
Development of JUMBOTEC series was based on original JUMBOFLOW technology &
integrated with advantages of L-shape dyeing machines to ensure low LR and further
optimize performance of the machine.

Vertical main pump
We change horizontal main pump to vertical type, so that suction point can further lower
down. Main pump is special designed to enable self-cooling without using external cooling water.

Vertical heat exchanger
This high efficiency vertical heat exchanger provides maximum heating/cooling gradient &
enhances drainage of dyeing liquor & condensate & cooling water. This can avoid formation of scale,
so as to reduce heat loss & wastage & to prolong longevity of heat exchanger. As it is part of piping, it
will not store water; its optimized position further reduces LR.

FC30 controller
In this new FC30 controller, we had added a special function Consumption Report
consumption can be actual one or estimated one according actual device installed, such as
water, electricity & steam & cost of production per kg. It has automatic calculate batch
parameters fabric weight, water content in fabric, addition in service tank. These LR filling
functions can be set in different state of processing, such as before loading (dry fabric), wet
fabric state, LR for after treatment etc.

Conclusion
With increasingly high demand for energy saving & environment protection, textile
manufacturing will continue to put its effects on environment protection, energy saving &
emission reduction as its mission, to provide customers a one-stop solution for their need
of high productivity high efficiency & eco-friendly innovative dyeing & finishing machines.
The latest TEC series high temperature dyeing machines with its excellent performance,
not only enable customers to produce high quality products as expected but also to
enhance productivity. It is consistent with current China 12th Five-Year Guideline Energy
saving and emission reduction. It try Group.