Dyeing and Finishing Machinery

Itaru Abe* and Masayoshi Kubo** *Consulting Engineers (Fiber)

**Toray Industries , Inc.

1. Preface

With respect to dyeing and finishing, the 3rd OTEMAS made

us surely astonished in their distinguished development. Though

the main theme of the format 2nd OTEMAS were energy-saving,

this time it was altered to the automation, and there were so many

technical points to be learned. On the other hand, absolute new

machines were really difficult to find.

Generally speaking, marvellous development to the automa-

tion is considered desirable and necessary. However, we are

afraid that only limited use or area is to be remained worthwhile

because of the recessed and difficult situation on dyeing and

finishing industries.

In order to secure the automation efficient, certain develop-

ment to the basic technology on the respected processes and

machines should have been accomplished previously.

Interesting machines or engineering systems observed at the

3rd OTEMAS are presented hereinafter, although we regret it

will not cover all of the items displayed.

2. Yarn Dyeing Machines

In spite of significant progress in every phase observed pack-age dyeing, numbers of machines displayed were very limited.

Suzuki Mfg. Co.'s full automatic cheese dyeing machine, Model "CLM-SP" , was arranged to pack cheese along the shaft

inclined at 30 degrees. Owing to this inclination, it will be ex-

pected to minimize the shock during packaging of cheeses. Pack-ing capacity was 800 cheeses/hr without spacers and 600 cheeses/ hr with spacers.

Hisaka Works showed a full automatic cheese dyeing system through a video displayer and panels (Fig. 1). It can pack at the speed of 3 sec/cheese, that is 200 cheeses/hr. Due to the re-

volving-turret carrier, idle time can be saved. It is supposed to be

the largest capacity of automatic package dyeing machines in the

world. "Lolymac model LLC" of Hisaka Works was equipped with

highly efficient heat exchangers and pumps, and the conventional

by-pass was taken away. It should be appreciated for suggesting

us the non-use of by-pass in many cases in future.

Nippon Dyeing Machine displayed "5-OUP-EC" model, 5

sequential package dyeing baths system, which had 5 vessels for

7 kg each capacity and 3 pumps to meet every possible produc-

tion. That is to say, from one to three colors of 7 kg dyeing unit

can be dyed simultaneously (Fig. 2).

As the dehydration of the yarn package gives us plenty of prob-

lems, several interesting ideas were presented to us. '' Multi -Cheese-Ace" of Ueno Industrial Machineries Co. has

mounted ingenious carriers which can be dehydrated as they are. To meet this contrivance for the dehydration, the spindle for the cheese carrier has been shortened and thickened to get sufficient

strength against centrifugal force (Fig. 3).

Fig. 1 Full automatic cheese dyeing system (Hisaka Works)

Fig. 2"5 -OUP-EC" , 5 squential package dyeing machine

(Nippon Dyeing Machinery)

Fig. 3 Multi-cheese-ace UMC (Ueno Ind. Machineries Co.)

Fig. 4 Model RR-II-16 Dehydrater for cheese (Suzuki Mfg. Co.)

Journal of the Textile Machinery Society of Japan76

Full automatic centrifugal dehydrator, model "RE-H-16" of

Suzuki Manufacturing Co. had an advantage of revolving on its

axis during centrifugal dehydration (Fig. 4). Usually the yam

package is pressed against the casing panel due to the centrifugal

force. The casing on this machine has a rotating speed differ-

ent from the revolution of the yarn package, and the friction be-

tween the casing and the yarn package makes the package rotate

on its axis. This rotation prevents the yarn package from deforma-

tion and secures the evenness during dehydration.

Nippon Dyeing Machine Co. illustrated on a panel an equip-

ment which can make packages dehydrated and dried in a carrier

simultaneously. Rather longer spindles were mounted on the

carrier, and drying operation was performed during centrifugal

dehydration. We have never seen before such a machine as cen-

trifugal dehydration and drying are performed at the same time.

As a dryer for the package, only Thees GmbH's high pressure

air circulating dryer with direct cooling performance was ob-

served. It is instructive that none of the micro-wave dryers were

seen in this 3rd OTEMAS.

Spray dyeing machine model RARE-SR of Shinko Mfg. Co.

had specially designed spraying cylinders, and dye solution was

sprayed continuously. This machine is considered the most ex-

perienced machine for yarn dyeing. Also, spray dyeing machine

Model FS displayed by Daiwa Tokusyu Kizai Co. had the same

continuous spraying way as the above RARE-SR.

These model were specialized to realize lower liquir ratio and

higher perormance for spray dyeing usage.

3. Washing and Other Preparation Machines for

Fabrics

the

3.1 Mercerizing machines

Dornier displayed its reputed mercerizing machine for cir-

cular knitting fabrics which was equipped with an inner frame

with a round section named ciggar to prevent edge marks on cir-

cular knitted fabrics.

In addition to the above, Benninger exhibited a famous chain-

less Mercerizing machine of Model "MGA".

3.2 Scouring and relaxing machines

Union Giken Co. showed a continuous reciprocating rope-form scouring machine Model ''RSC'', which was able to adjust

loop length automatically. By this worldwide spread machine, stabilized and highly efficient production might be attained.

3.3 Caustic soda treatment unit for softening

Fukusin Industries have found that caustic soda will be con-sumed in proportion to the dissolved amount of polyester. In

accordance with this principle, Fukushin Industries have devel-oped an interesting control system for caustic soda treatment

(Fig. 5). In this system, decreasing of the concentration of caustic

soda is measured by automatic titration, and when the concentra-tion decreased till the target, the process is terminated. Every-

body knows the caustic soda treatment process is rather danger-ous, and sometimes there comes too soft or too harsh hands. This system will assure the process safe and efficient.

Ichikin 'Industries successed to make 'APOLLOTEX'' con-tinuous (Fig. 6). Of course, "APOLLOTEX" is not only for the

caustic soda treatment process, but Ichikin Industries suggests it first. Generally speaking, to ensure unform heating with micro-

waves is not easy. However, it seems that the continuous system

was attained by the coexistence of steam and micro-waves for heating. No doubt this machine is applied an innovated system,

and further effect or much improved usage should be attained. In addition to this, Ichikin Industries displayed also a laborato-

ry machine named ' APOLLOPET'' for test use of "APOLLO-

TEX" .

3.4 Washing machines A wide open width washing machine of Arioli was shown,

which is the most reputed machine for washing process after

printing. Uenoyama Kiko's ' Jet-Stream-Soaper'' was improved by

introducing waste steam into the vaper phase of the enclosed vessel for soaping.

Incidentally, several years ago, people were interested in the horizontal open width washing range, and there was keen com-

petition to its improvement. However, none of horizontal open width washing ranges can be found this time at all. Concerning with this point, Benninger enforced the advantages of their ` ̀ Ex-

tracta-LE and added that the conventional horizontal way merely takes the space to install.

3.5 Rotary washing and milling machines Tokyo Sensen Mfg. Co.'s micro-computer controlled washing machine Model '' MOX-90MT'' had an advantage for getting ex-

cellent finish hands on the angola-rabbit blends.

3.6 Other machines for preparation Santo Iron Works displayed a panel of famous continuous

high pressure steamers. According to Santo's finished samples through the steamer, excellent appearance and finished hands

were confirmed on cotton and polyester/cotton blended fabrics.

4. Dyeing Machines for Fabrics

As far as continuous dyeing machines are concerned, a couple of demonstrating panels were seen somewhere. But there was nothing to be worthwhile to explain except batch dyeing.

4.1 Jigger Jex-21 Jigger (Fig. 7) provided by Hanayama Industries wasFig . 5 FACTS (Fukusin Industries Co.)

Fig. 6 APOLLOTEXModel R (Ichikin Industries Co.)

Vol. 32, No. 3 (1986) 77

equipped with a very precise program controller which can manage 16 program with 96 steps. This jigger could be our great hope for the beck dyeing, because every program required for beck dyeing was memorized throughly and each operation in the dyeing plant was performed completely.

4.2 Jet dyeing machines "Dash Line SE" of Oshima Kikai Co. was a well designed jet for normal pressure dyeing which attained 1:4 minimum liquor ratio.

` ̀Foamy Flow" jet for normal pressure dyeing from Techsam Giken (Fig. 8) was explained to perform dyeing process in the

foamed solution with 1:5 liquor ratio of excellent hands. Foam-ing may cause serious trouble, but "Foamy Flow" utilizes this foam in effect. Incidentally, "Foamy Flow" can be changed the

machine inclination.

Suzuki Mfg. Co.'s ''Epock Flow' Model HEF-NL is con-sidered suitable to thinner fabrics, and somewhat resembles Hisa-ka Works' Circular Model CUT-R.

Hisaka Works' Circular Model CUT-NJ-4 was developed to meet the requirement for long thicker fabrics. It can contain up to

1,400 kg of dyeing goods. Nippon Dyeing Machine's ' Rapid UNIACE 600'', Model

VPH-FP seems to have found their definite use to thinner fabrics

of synthetic fibers. Thies GmbH exhibited a new miniature model of ' Silk

Stream'', which might be the succeeding model of "Soft Stream" . Nippon Dyeing Co. demonstrated by VTR an auto-

matic doffing system for dyed goods from dyeing machines. Hi-saka Works presented a similar way of demonstration at ATME-I'85, but this time it was not seen anymore.

4.3 Beam dyeing machines

Hisaka Works introduced their lower liquor ratio beam dyeing machine, Model ''LLB'', in which the principle of their lower

liquor level dyeing for the package was applied. This model can reduce liquor volume to 1/2 and dyeing cost in proportion, com-

paring to the conventional type.

4.4 Rotary dyeing machines

Thies GmbH showed a rotary dyeing machine, Model ''TKF-

stocking, is able to process from scouring drying in sequence.

It should be very convenient in the actual dyeing plant for stock-

ings and hosieries.

Strictly speaking, not much technical progress has been con-

firmed with respect to the batch-wise dyeing machines displayed

since last OTEMAS. Every interest in the batch-wise dyeing has

been concentrated to controllers for machines or processing

flows.

5. Auxiliary Machines for Dyeing

Through dyeing and finishing processes are concerned, dyeing

must be more critical than others. Furthermore, due to small qual-

ity production with many sorts, dyeing is a typical process which

requires flexible manufacturing systems. Therefore it should be

very important to make this process ensured from fail or re-dyed

lots. Every expectation or desire in this line should be concentrat-

ed how to manage and control troublesome processes. In order

to reply on the above, there were so many kinds of controllers

displayed in this OTEMAS.

5.1 Weighing and measuring systems

Since electronically controlled balances were introduced, they

have been provided by many manufacturers. Modernized electro-

nic balances are able to issue electronic signals of digital or ana-

logue as requested, and automatic zero returning or data printing

system is now very popular.

Toyobo Engineering Co.'s computer controlled weighing

system seemed well made and fool proofed, where every dyestuff

container was marked with bar-code identification numbers to

prevent miss selection of dyestuffs, and the allowable tolerance

was noticed by aural signals. Furthermore, each information to

be memorized was recorded on a floppy disk and printed out as re-

quired. We are little afraid of standings of bar-code with dyestuffs

quired. We are a little afraid of standings of bar-code with dye-stuffs, however, this system is the most effective way to avoid

miss weighing or failed selection of dyestuffs.

5.2 Laboratory dyeing systems ''Kayalibra'' of Nippon Kayaku Co

. (Fig. 10) can prepare

100" . Quite seldom Thies GmbH has made rotary dyeing ma-

chines. This model might represent the increasing tendency for

garment or made-up goods dyeing. To meet this requirement, TKF- l00 was equipped with injection nozzle to have dyeing solution circulated as much as possible for getting evenness. Takatori Machineries' ' TKD-50'', a full automatic rotary

drum dyeing dehydrating machine (Fig. 9) for hosieries and

Fig. 7 Full automatic Jigger Model JEX-21 (Hanayama Ind. inc.)

Fig. 8 ''Formy Flow' (Techsam Giken Co.)

Fig. 9 TKD-50, Full automatic drum dyeing machine

(Takatori Machinery)

78 Journal of the Textile Machinery Society of Japan

standard dyestuff solution automatically and distribute it to the weighing unit pneumatically for obtaining rapid response.

' Toyobo-CCK'' of Toyobo Co. also applied a pneumatic devices for injecting standard dyestuff solution. ''SACTOS" of Sakata Trading Co. utilized an automatic pi-

pette named Auto-Pipetter to inject standard dye solution. When-ever there comes shortage of standard solution having been stocked, an automatic preparation system will be employed accordingly. Only the problem will be it rather takes time for the preparation of standard dye solution.

5.3 Computer color matching system (CCM) Excellent computerized Color Matching equipment also is now available everywhere.

However, Macbeth's MS-2020 devices are widely used for measuring colors. Xenon flush is adopted on "MS-2020" as a light source which is adjusted to D65 by means of a filter. Each light beam is measured at the light sensor unit with 20 pieces of silicone elements. That the completion of immediate and precise color analysis, should become worthwhile to spread to use. Emori Trading Co.'s "Color-Agent" can show the color chart during color matching calculation is going on. ''KOSMEK -III' of Nippon Kayaku Co. has an advantage of rapid calculation and various amendment performances for dye-ing. Especially, the combined system with ''KOSMEK-III' and "Kayalibra" called ''KOSMEK -IV' (where only one computer

unit is necessary) is quite effective to eliminate every possible input error. Toyobo Color Matching system (Fig. 11) of Toyobo Co.

can perform various calculation on color matching from recipies ever had. Also it manages to adjust color recipies in accordance with blended rate of fibers.

Incidentally, this system will be connected to the dyestuff solu-tion preparation unit described above. Anyway, tremendous benefit will be obtained by refering to experienced recipies ever had and adding precise amendment.

''NM7000 Computer Match Prediction System'" of Instrumen-

tal Color Systems Co. can be jointed with various sub-systems and contribute many controlling functions for the storage or dye-stuff weighing station.

5.4 Dyeing program controller

(1) Dyeing Program Oshima Machineries' "FAD" system was developed to apply

their ' Dash-Line'' . It will be able to supply water precisely to the dyeing vessel as free from water content of the goods, if the weight of raw fabric and bath ratio is introduced to the com-

putering unit. This system should be appreciated to the variation of bath ratio which often may give shade fluctuation on the dyed material. Besides, when exact time and period are pre-noticed, requested chemical supplying can be attained, accordingly. Of course, each condition programmed and the passage carried out can be con-firmed on the CRT displayer, or printed out as requested. "DDC -8" system of Daiwa Tokusyu Kizai Co. will control 8 dyeing machines with a central controlling instrumental panel. Actual plant-site model was available. At the CRT displayer of . 'DDC -8'' , detailed processing conditions for 8 dyeing machines can be shown individually or simultaneously upon request. In addition, sequential data in a day or during certain period de-fined can be displayed or printed out. Total memorized capacity for the programmed patterns is estimated to 500 or more. Daiwa Tokushu Kizai Co. is also manufacturing "SUP-8" which is an automatic dyestuff solution injecting system to support the above "DDC-8" . Nippon Dyeing Machine Co.'s "NIC-16" will manage 2 dyeing machines as a rule and memorize 99 patterns pro-

grammed. "NIC-16" has 4 types for clients selection to meet the variety of use. This system also can provide dyestuff injection and measuring performances. Consequently, if the programme required, divided injection for the dyestuff solution will be available.

Suzuki Mfg. Co. installed "FADIC-10" of Fuji Electric Co. at the machine side, and if required a host computer shall be con-nected. "FADIC -10" was made compact and displayed with LED. It memorizes 99 patterns programmed with each 99 segments, and has 10 points of time signals and time correcting performance during temperature elevation. We feel sure these performances will be quite useful for the actual production control. Relating to the above, "FASDI-100" and "FASDI-300" are available for the group control.

Hisaka Works employed a little modofied programme con-trollers of Fuji Electric Co. for their own use. In this connection, Hisaka Works Co. has accomplished large production controlling systems already, where every plan or schedule for the production is memorized and sequential commands required for the opera-tion are to be issued. Besides, Hisaka has completed full automatic production systems without operators for package dyeing. Through this system, full sequential processes such as packing, dyeing, washing, drying and doffing, should be performed (Fig. 1).

Schermuly Electronik Co. introduced the following control-lers.

Model "DC 150" manages 9 programms with 9 steps for one dyeing machine. Each step can be stopped and call operators if requested. Also, their model "PC 1000" is able to set 99 steps with 2 each

Fig. 10 'Kayalibra"(Nippon Kayaku Co.)

Fig . I 1 Toyobo color matching system (Toyobo Engineering Co.)

Vol. 32, No. 3 (1986) 79

switching functions for the operating programme. Model "PC3000" provides 25 programms with 30 steps or 8

programms with 99 steps, which has 15 switching functions and 3 analog out-put lines for the instrumentation.

Model "PC4000'' is equipped with a new controller with liquid crystal displayers. ''PC4000'' can supply dyestuff solution if the central coloring kitchen is connected. When it is jointed to "DS -100" (explained after), each auxiliary chemical will be

added in accordance with the programme. If it is connected to

the host computer, central controlling system will be accom-

plished. Model ' PC5000'' is also available as a host computer in this

respect. Moreover, Shermuly Electronik Co. introduced ` ̀Colorlex"

which can control the dyeing temperature through the time-temperature curve pre-settled. A drum dyeing machine Model "TKD-50" of Takatori Ma-

chineries for stockings (Fig. 9) can memorize 8 kinds of pro-

gramms to be controlled sequenctially through special control-lers. Hanayama Industry's "JEX-21'' (Fig. 7) was also mounted an excellent controller.

As far as the above mentioned various controllers are con-cerned, each had its own specaility. That means every client has individual conditions for the process and requires different way

of controlling systems. Due to mass production of controllers by few manufacturers

like Schermuly Electronik Co. or Fuji Electric Co., the manu-facturing cost of controllers will be reduced to offer to the clients

with reasonable prices.

(2) Chemical Supplying Programme The above mentioned "DS 100" was provided for this pur-

pose. It seems "DS 100" was developed under the colaboration with Thies GmbH, because Thies GmbH has applied "PC-120"

controller to the machine which have quite similar peformance to "DS 100" of Schermuly Electronik Co .

Using "PC-120", Thies GmbH is now manufacturing "MFD" for fluid chemicals supplying system (Fig . 12) and

.'MSD'' for solid chemicals supplying system . Both have been

developed for the reactive dyeing, and have aroused the interest

in this line recently.

6.1 Image processers Dainippon Screen Co. displayed ` ̀ PASTEC-4000" . It wasn't

changed in principle from the former model "DS PASTEC-4000" which was shown last OTEMAS. Also, their hard copy

production system by ink jet method was already disclosed last OTEMAS. However, this time it has been improved to perform

larger,170 x 120 cm film size, than before.

6.2 Screen

Stork Screen Co. presented "Hexa 105 Mesh" and their

various photo-sensitive chemicals for making emulsion. ' ̀ Hexa 105 Mesh" was called ' Almost Penta'', because of the re-

semblance to famous ''Penta'' in its performance and with cheap-er price similar to conventional standard screens. In any case,

these might have distinguished progress on weaving technology. We hope much finer mesh screen shall be provided in very near future.

6.3 Printing machines Although there were many types of printing machines dis-

played, no entire printing machine ranges were seen at all ex-cluding special machines.

Respecting to flat screens, ''Hydromag 5-V" of Buser and "Ichinose -7000" of Toshin Industry were displayed. Both have

advantage and reliability of their own. "Ichinose-7000" has been improved to set operating conditions much easier than before.

With respect to rotary screen printing machines, "Rotomac 3"

of Buser, "Renoir" of Reggiani and "Ichinose MR-600" of Toshin Industry were displayed. Both "Renoir" and "MR-600"

can apply magnetic roller squeegees. These machines are ex-

perienced enough for the actual production. Uenoyama Kiko Co. showed a panel of ' ̀ Planet" Rotary

Screen Printing Machine. In this case, rotary screen rollers are mounted on the drum as large as the conventional roller printing

machine. This kind of design has never seen before, where blanket is not required and fabrics can be printed without contact on the drum. The advantage of "Planet" is in saving the space

for installation.

6.4 Automatic printing thickner preparing systems

Automatic Color Thickner Preparation Systems of CIR Co.

(Fig. 13) have already been delivered 217 units to the clients. Consequently, plenty of practical and detailed considerations have been employed everywhere. The accuracy of weighing was

refined to 1 g/100 kg or 0.1 g/ 10 kg. Toshin Industry disclosed "Ichinose Colorway" (Fig. 14).

Fig. 12 'MFD'', Multi product injection system (Thies GmbH)

Fig. 13 "CIR", Automatic color thickner preparation system

(CIR Co.)

80 Journal of the Textile Machinery Society of Japan

This system is equipped also similar weighing mechanism

which provides 60 kg maximum capacity and 0.1 g minimum

capacity. Due to the system developed by the most experienced

and reputed company on printing, its worldwide spread might be

expected. ' Liquid Master Model CCK'' of Daika Japan Ltd

. was in-

troduced with a weighing mechanism by volume. As we have

accustomed to the weight measuring system, the volume measur-

ing is not familier to us. There may be some problems of density

difference of each thicker. But the volume measuring has an

advantage for quick response. So, we feel sure that the volume

measuring will be familier with us very soon. The accuracy of "Liquid Master" was said less than 2/1000

, which is related to

the concentration of components in the thickner. Therefore

smaller part of the components will gain much accuracy than

others. Although higher weighing accuracy would be better,

much attention must be paid to the dyestuff concentration.

7. Padders, Applicators and Coaters

7.1 Padders

Odaka Rubber Industry and Kinyosha displayed various man-

gling rollers, though it was very hard to find innovated padders

there.

However, "UP Padder" from Kyoto Machinery and "Para-

flex Padder" from Wakayama Iron Works were much improved

by installation of cleaning and supply devices to chemical

solutions, where chemical supplying could be achieved auto-

matically.

In the case of Kyoto Machinery, full automatic pressure set-

ting device can be equipped if required.

There improvements for automation should be quite effective

to save labour and operating time for the lot conversion.

7.2 Applicators

In spite of the expectation, only few applicators without new

improvement and none of dehydraters could be seen. Triatex Co.'s "MA-E2B" was a kind of kiss-roll type applica-

tor which makes the applied quantity even by -ray absorption rate (Mahlo's "Gravimat"). "WEKO Rota-Damping Machine" of Weitmann & Konrad Co. was a well designed compact equi-ment which has disks rotating at high speed for spraying chemi-

cals (Fig. 15). In this case, 400 ml/m/min in the maximum

spraying out-put will be expanded as a standard. If 2 stages of rotors are applied, the maximum out-put will be increased to 800 ml/m/min. The out-put amount seems rather so small that the

application at higher speed will be in quetsion. However, it will be suitable for slight amount of application.

Reggiani Co.'s "REX" could be employed as a printing head for a single rotary screen, and might be use as an applicator or a coater. Uenoyama Kiko's "Rotary Screen Printer" had similar func-tion and usage, too.

Hirano Kinzoku Co. has connected "Shrink Surfer" and "ADC System" which is foam applicator with slit nozzles .

Chemical amount applicated on the fabric is controlled in accord-ance with the absorption rate of j3 -ray ("/3-Micro"). Washing and chemical feeding for the machine are performed automatical-ly.

No other foam applicator except the above has been observed. That might be caused by the difficulty how to handle foam itself.

7.3 Coaters Only limited number of coating machines were displayed. Hirano Kinzoku Co. showed "Coating-Laminating Machine"

(Fig. 16). Its coating head is called "Muliti-Coaters" which has 3 functions for knife, comma and graving coating. "Comma Coater" has a function to control and adjust the bent

curve of the roll by itself. In addition to this, its coating head is equipped with "Gap Controller L-101" to adjust the clearance with accuracy in + 1 µ and an automatic sewed line passing-by function for saving chemical solution or resin consumed at the

joint places. The dryer connected to this coater is called "Quick Jet" which was modified from their mechanical concept of

"Simplex".

In order to control the complete range on the above, ' `CCC"

system shall be employed, which memorizes several classified

operating conditions.

Fig . 14 "Ichinose Colorway (Toshin Industry)

Fig. 15 "WEKO Rota-damping machine' (Weitmann & Konrad Co.)

Vol. 32, No. 3 (1986) 81

In accordance with defining the processing condition, each set-ting for the range will be performed and assured immediately. Of course, some of the conditions shall be calculated for get-

ting optimum figures and then transfered to the automatic control lines.

7.4 Pick-up and application quantity controllers

Besides the above mentioned "ADC System" and "MA-

E2B 'Gravimat FMI'' of Mahlo Co. controlled by a 9-ray sensor and ''Aqualot HMF-7' measured by micro-wave were displayed.

8. Heat Setting Machines and Dryers

8.1 Heat setting machines and controllers

(1) Heat setting machines Kyoto Machinery and Wakayama Iron Works displayed their

repured heat setting machines (Fig. 17, Fig. 18). Both are much

improved in the mechanical structure.

Kyoto Machinery is accustomed to make compact and air-tight models. On the other hand, Wakayama Iron Works is used to make the structure accessible and smart.

These heat setting machines were displayed as full ranges with

padding mangles, and distinguished improvement to the operat-

ing condition setting was observed.

Both are prepared to accept wider range of automation, and in

accordance with the required levels, every stage of adjustment for

the automation can be set. Toyo Machinery showed "DMD-100" for the selvage chasing

guider which was driven by a DC servo-motor system. This system has had definite reputation, and further improve-ment has been introduced recently.

(2) Controllers Toyo Machinery presented ' ̀ Permaset VMTR-8" of Mahlo

Co. and various controllers with regard to heat setting. Each has been experienced in the actual production and improved year by

year.

''Permaset VMTR -8' is an automatic controller to settle the

optimum holding time right after the fabric temperature reached

to the heat setting temperature anticipated. Similar controlling system was also presented by Mate Science

Co. as "Model R80-2B" for optimum speed controlling to the stenter (Fig. 19).

Generally speaking, radiation thermometers are used as tem-

perature detecting sensors to fabrics. However, Mahlo Co. adopted ' OMT'' type fabric temperature measuring device , and Mate Science Co. applied "Cloth Temprader" . A plenty of thermo radiation detective sensors were displayed from various

manufacturers, though all of them might not be suitable for the requirement on heat setting machines.

(3) Pollution measuring units for exhaust air Mate Science Co. presented model "DK-1100" as a pollution mesuring unit for exhaust air from the heat setting range , which can be installed at the outlet of dampers. It is based on the absorp-

tion phenomenon of infrared beam with wave length 3.4 µ to the saturated hydrocarbon liquid.

This unit is considered useful for energy-saving and environ-mental improvement.

(4) Other Devices for Heat Setting Respecting to heat setting, a wide range of important displays

have been observed as listed below:

Weft Straighteners, Centering Units, Fabric Width Measuring Units and Lubrication Units.

8.2 Dryers

(1) Dryers for woven and knitted fabrics Only the machine exhibited for fabric drying was ` ̀ Shrink Surfer" of Hirano Kinzoku Co. which achieves over-feeding

during passing through horizontal zig-zag channels composed with 2 layers of screen conveyors . In the mean time the hot air is blown intermittently by revolving dampers mounted in each air

duct nozzle. So, the fabric is smashed against screen conveyers and vibrated or trembled. This performance was improved so

complete from the conventional "Shrink Surfer" that this new model is called "Air Shock Model" to discriminate from the old model.

Tokyo Sensen Machinery has been manufacturing Tamble Dryers with colaboration of Passat Co . In this OTEMAS, a couple of improvements described below was induced.

(a) To increase the volume of hot air for circulation. (b) To allow wider range of revolution to the drum by an inverter.

Fig. 17 Super tenter' (Kyoto Machinery)

Fig. 18 "Hi-Echo tenter (Wakayama Iron Works)

Fig. 19. R80 -2B" Optimum speed controllin

machine (Mate Science Co.)

g unit for heat setting

82 Journal of the Textile Machinery Society of Japan

This model was named

WHT" (Fig. 20).

"Tosen Passat Tambler POT -354T-

(2) Controller for dryer Various temperature measuring sensors and controlling units explained at the heat setting machine , are also able to be applied to dryers.

Mate Science Co.'s drying condition measuring monitor will let us know the drying state by indication lamps. Their "MSF-25 digital continuous moisture content measuring device is per-formed by means of electro conductivity, and it can be connected to "CR 1 1 OM" controller for automatic controlling of the drying range.

' Deltamoist'' of Heals Co. which was introduced by Yoshida Shokai Co., was also understood as a similar unit for measuring moisture control. Its measuring head shall be changed to another type for loose fibers or package, if required. Strandberg Engineering Co.'s ''M601 Moisture Monitor' has also the same function which can be jointed to a drying speed controller.

' M602'' is a measuring unit to control the pressure for steam

dryers. 'Textometer RMS'' of Mahlo Co. has also the same perform-

ance to measure the humidity of drying chambers and control the speed to be passed over. This unit should be of great use to

prevent pulling undried fabric out from the drying chambers. "Dry Stop Model M-702" of Strandberg Engineering Co. is

able to detect the exhaustion air temperature from batchwise dryers, such as tumble dryers, and presumes the drying level and the terminating time for the dryer.

9. Other Machines and Systems

In addition to the above, there were so many important ma-

chines such as finishing machines, selvage guiders, inspecting

machines, energy-saving facilities and other laboratory ma-

chines. Particularly, the followings were the most notable ma-

chines among them.

9,1 Calender roll material "Elaglass" of Kinyosha Co.

Polyamide resine has been applied widely for elastic calender

rolls. However, "Elaglass" displayed by Kinyosha Co., was

made of polyurethane elastmer. Frankly speaking, it hasn't been

experienced enough yet in the actual production. Attributed to its

elasticity, much progress in future should be anticipated.

9.2 "Under Blade H4 Quality" of Severin Heusch Co. Severin Heusch Co. is a specialized company for cutters and blades on shearing machines. They have quite a high reputation on rotary cutters and under blades. Among their various things

exhibited, an under blade named "H4 Quality" was really dis-tinguished from others. It might perform excellent shearing effect

against nylon and polyester, we hope.

9.3 "i-PACS" of Emori Trading Co.

Development of full automatic inspecting machines has to be expected, but nothing can be seen this time.

Of course, computers are widely used to calculating and print-ing the inspected data through key boards. ''i-PACS' was much improved to utilize widely each datum obtained from the inspec-

tion lines to production control lines. We feels sure that the auto-ation for production management should be expected to progress in the very near future.

10. Conclusion

G. R. Turner, consulting Editor of Textile Chemist and Color-

ist has commented after inspecting ATME-I '85 spring, as fol-lows: (1) "In the past

, almost all control equipment was available only from specially companies, but today many machinery manufac-

turers supply their own computerized systems. Much more dye delivery automation was seem this year than in previous shows, both for production and laboratory use. The theme of the ex-

hibition seemed to be that of decreasing labor costs and at the same time building in more reliability. A highly automated pack-

age loading and unloading arrangement was shown by Itoman. " The opinion above is quite applicable for this OTEMAS, too.

No doubt, how to secure the reliable automation should be the worldwide tendency. Furthermore, G. R. Turner refered to ' ̀ OTDY System" of

Osaka Bobbin Group and an automated arrangement by Hisaka Works for unloading piece goods from a jet dyeing machine, and

said with grief, "Again, a Japanese innovation. It would appear that in spite of all the efforts being made to "buy American",

American manufacturers continue to defer innovation to foreign suppliers.'' ~'

We don't hope the same disappointment may return tows some

days after. However, it was with great regret that the above two innovated systems for automation were not displayed this

OTEMAS. All the machines explained in this report should be only a part

of the worldwide developing movement for automation. Fortu-nately the distinguished automation on dyeing and finishing

processes is moving mainly in Japan. It should be appreciated by dyers, finisheres and the people along this line. In such circum-

stance, these automatic machines and useful devices should be applied effectively. At least, the most important thing to know is "Do not produce defectives in the automated way and don't

continue undesirable production automatically."

Reference

[1] G. R. Turner; Textile Chem. Col. , 17, 169 (1985).

Fig. 20"Tosen passat tambler POT -354-WHF"

(Tokyo Sensen Machinery)

Vol. 32, No. 3 (1986) 83