ITMA 1979: Jet Dyeing Machinery A brief look at some of the machines available V. Simborowski The four- yearly cycle of the International Textile Machinery Exhibition provides a particularly striking insight into the advances made in the industry which explains the worldwide interest shown by textile specialists in each ITMA. The 8th Exhibition, held in Hanover, was a waited with eager anticipation since a number of innovations and continued developments mre presented for the first time. The exhibition confirmed the considerable amount of research and development effort that the textile machinery makers have invested in their products. There were numerous examples of the two main directions in which machinery designers were going: on the one hand towards higher machine capacities and automation associated with a shortening of the dyeing cycles and on the other towards reducing energy and water consumption and the creation of better working conditions through improved dust and noise control.

JET-DY ElNG MACHINES Over twenty manufacturers were exhibiting machines of this type, the main developments being directed towards the machines handling delicate fabrics and to reducing liquor ratios to as low as 4:l. Each manufacturer gave costing comparisons detailing the economics of their new machines. However, these economies appear to be due to the shorter liquor ratios which reduce the amounts of dyes, chemicals, heat and water required as well as shortening the processing times. In general economic terms, there seems to be very l i t t le difference between the various machines, al l things considered.

ATYC

Rapidsuau The horizontal 'soft flow' type machine (Rapidsuau), manufactured by ATYC, has proved to be extremely popular over the past few years. Their new unit, unveiled a t Hanover, was of similar outward design but, within the interior of the dyeing chamber, ATYC have developed an ingenious rotating spiral tube which, it i s claimed, ensures even packing of the fabric in the dye vessel and a controlled regular movement of the fabric.

BdnBflo w CBS Certainly different from other jet machines on display, the Bdndflow CBS employs an airhiquid system. Extensive trials have been carried out since 1976 in conjunction with Sandos and their Sancowad Process. The material i s passed through an air jet which untwists tubular fabric, causing it to balloon out, before being transported over a central, elevated, variable-speed winch. The fabric then comes into contact with the dye-liquor inside what Bdnd term an 'aqua exchanger' before being allowed to pass into the fabric storage chamber, where excess liquor is pumped back into the aqua exchanger via a heat exchanger.

The company claims that systematic trials have shown

that an elevated winch does not cause tension when the fabric i s correctly piled in the dyebath vessel. Further, due to the very short liquor ratios used, the running speed of the fabric is governed by the winch with the minimum of tension.

6. Control box 1. Fabric storage chamber 2. Exchanger for heating 7. Unloading winch

3. Variable-speed winch 9. Blower 4. Aqua exchanger 10. Dye addition tank 5. Gear drive

Bhnbflo w CBS machine

and cooling 8. Liquor circulation Pump

The advantages claimed in terms of economy include (a) Water (4-10 times less than conventional machines) (b) Steam (30-50% less) (c) Dye (up to 15% less) (d) Auxiliary Products (15-20% less)

and those in terms of quality include (a) A reduction in the number of poor quality dyeings

produced. (b) Good levelness, due to frequent contact between

dye-liquor and fabric. (c) Perfect repeatability between lots.

Gaston County Aqualuft piecedyeing machine

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(d) Improved physical appearance of the fabric com- pared with conventional machines - reduction and even elimination of breaks.

(e) Improved handle. (f) The Sancowad process can be used with foam, a t

present only under atmospheric conditions. Bdnd state that light and heavyweight jersey materials are

untwisted by the air jet and present no problems for plain colour dyeing. Cotton can be dyed with direct, cold and hot reactive, sulphur and vat dyes; nylon with acid or metal-complex dyes; mixtures of cotton and nylon by double dyeing cycles.

Gaston County

Aqualuft I I The largest manufacturer of textile wet-processing machinery in the USA and maker of the world's first jet-dyeing machine, Gaston County displayed the latest model of the'ir Aqualuft piece-dyeing machine. The Aqualuft I I is a high-pressure, second-generation, jet-type machine which, the company claims, dyes a wider range of fabrics using less water, less steam, and less chemicals per unit weight of fabric than any other piece-dyeing machine available anywhere in the world.

Gaston County reports that i s has put into operation over 200 Aqualufts in 60 dyehouses, and the machines are being used to dye every type of rope-dyeable fabric, from the lightest, sheer filament knits to heavy upholstery fabrics. Five fabrics dyed in quantity on the Aqualuft were displayed with the machine to show i t s versatility.

Dyehouse managers, the company claims, report that the Aqualuft provides the highest production and the lowest unit processing cost of any piece-dyeing machine now available. It can do this because it is able to dye large loads of cloth in short cycles at low liquor-to-cloth ratios and can provide efficient wash cycles with precise control of water volume.

The Aqualuft II is available in single- and multi-tube units. With an average cloth capacity of 180 kg per tube, the large 6-tube unit dyes 1080 kilograms of cloth per batch.

Vald Henriksen

VH- Ultimat Vald Henriksen were offering a recently-developed machine, the VH-Ultimat, which has been tested under production conditions for a t least 12 months. It i s an atmospheric, non-flooded, two-nozzle machine using a short liquor ratio for the dyeing and bleaching of piecegoods. It was designed to replace atmospheric winches, and specifically for use with reactive dyes where in washing-off it has a particular advantage over many of the unpressurized jet-dyeing machines, because of i t s cloth drainage method. It operates a t liquor ratios between 4 and 8: 1, depending on the type of fabric and fibres to be dyed. After passing through the nozzle and funnel section, the only point a t which liquor is circulated through the material, it i s laid onto a freely rotating grate in a 20-35-cm deep layer. The subsequent draining of dye-liquor (which is returned to the pump) from the fabric minimizes pressure on the bottom layers. After rotating through about 270' the fabric passes over a guide roller and returns to the nozzle and funnel section, Since the cloth i s lifted no more than 35 cm, the makers claim there is very l i t t le chance of tangling unless the machine is grossly over loaded.

1. 2. 3. 4. 5. 6. 7. 8. 9.

10. 11.

Cylindrical vessel Reservoir Circulating pump Heating and cooling coils Filter plates Guide roller Nozzle Layout funnel Transport grate Liquor guide plate Brake band

12. Central circulating pipe 13. Nozzle delivery branch 14. Fabric front 15. Addition tank 16. Ball valve 17. Ball valve 18. Throttle valve 19. Hoist 20. inspection hatch 21. Cover 22. Overflow pipe

Flow diagram of the VH-Utimat machine

The machine is designed as a two-unit system, each unit having a capacity of 150 kg. It offers the possibility of dyeing with both nozzles simultaneously (full capacity) or only one nozzle (half capacity). Two VH-Ultimats can, if required, be coupled together giving an increased capacity of 600 kg.

1 12 J SDC Volume 96 March 1980

I 2 3 4 5 6 7 8 9 1 0 Jagri

1. Loading porthole 6. Forcing jet 2. Guide roller 7. Heat exchanger 3. Control panel 8. Dye addition tank 4. Overflow function 9. Liquor circulation pump 5. Dye injection pump 10. Filter

Univerjet piecedyeing machine

ILMA

Univerjet ILMA claim that their machine meets the required frequency of contact between dye-liquor and fabric to enable the user to obtain level dyeings in a short time. This frequency of contact is achieved by running the fabric a t high speeds (up to 400 m/min) and by using a 14.7 kW pump that can deliver liquor a t up to 3 cycles/min. The fabric tension is monitored by a control device and is minimized by altering the speed of the winch so that it coincides with the fabric speed as indicated by a seam counter timer. Considering that the fabric i s fully submerged, the average liquor ratio claimed (8: 1 ) is very low.

The fabric feeding system is very flexible. A combination of the overflow and forced jet function can be used in various proportions or each independently. Using this facility, it is claimed that the operator can dye particularly delicate fabrics a t high running speeds.

Simplex jet Developed a t the same time as the Univerjet (19771, ILMA state that the Simplexjet is complementary to the Univerjet. It i s a high-temperature machine used for dyeing piecegoods in rope form. Considerable loadings of light- and medium-weight materials, that are not too delicate, can be run a t up to 450 m/min, and hence more economically than the Univerjet. It is claimed that there is no tension when taking up the rope, since the fabric is fed (injected) by the jet and the grid and wheels are not driven. The standard machine consists of 4 jets in parallel, each feeding the material into long horizontal trays.

F The Simplexjet high-temperature machine

Orbit-flow Dyeing Machine The fabric to be dyed i s carried orbitally in a horizontally rotating perforated cage in a similar manner to fabric in the Henriksen 'VH-Ultimat'. However, the fabric i s driven by a winch which lifts it about 160 cm (as opposed to 20-35 cm by a non-driven guide roller in the VH-Ultimat). The fabric is then passed through a nozzle where the liquor flow can be adjusted from gentle overflow to full jet action, the speed of the rotating cage being adjusted accordingly so that the fabric l ies there in a completely relaxed state, thereby avoiding stress or tension on the material.

The machine is sold as a single unit with capacity up to 200 kg.

Krantr

K-jet Dyeing Machine This is a low pressure (0.5 Atmos), low liquor ratio (5 to 1O:l) dyeing machine. Krantz claim cost savings of energy, water, dyes and chemicals are achieved and that it i s most

b

A Dyeing tank 6 Preparation tank Q Heat exchanger T Rapid closure

1. Circulation pump 2. Addition pump 3. Pressure throttle 4. Water valve 5. Drain valve 6. Heating valve 7. Steam trap

8. Cooling valve 9. Air outlet

10. Air inlet 1 1. Suction valve 12. Liquor level 13. Reversing valve 14. Drive for rotating cage 15. Guide roller 16. Unloading roller 17. Return valve 18. Instrument panel

Jagri Orbit- flow dyeing machine

Krantz K-jet dyeing machine

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suited for dyeing the lighter weight or narrower width fabrics, especially tubular-knitted cotton, woven polyester- wool blends, knitted terry goods and nylon tubular materials. It i s available in two, three or four unit sizes, each chamber having a capacity of 100 kg. The savings claimed include 5-15% on dyes, 35-40% on water, 25-30% on steam consumption.

Mezzera

Circular Rapid Jet HT (Model Cut-R) This 'tube-type' machine has been manufactured by Mezzera (under licence) since 1978. The makers claim that i t s development, from the Hisaka Circular Jet Dyeing Machines, arose from the need to check the parameters affecting the cost of dyeing. It i s available in 1-, 2-, or 3-tube models. Essentially the machine is designed for the rapid dyeing of polyester fabrics. Recent modifications include

(a) Reduction in diameter of the transfer tube from the jet to the dyeing tube, giving a higher liquid velocity in the tube, reduced pressure in the je t and less friction in transferring the fabric from one end of the machine to the other. The longer horizontal

1. 2. 3. 4. 5. 6. 7. 8. 9.

10.

Fabric loading door Fabric driving reel Dyeing tube Adjustable valve Adjusting flow control valve Adjustable valve Heat exchanger Main liquor circulating pump Dye-injection pump - motor-d riven Dyes and auxiliaries preparation tank

Circular Rapid Jet HT

construction of the dyeing tube reduces compression and crushing of the fabric.

(b) A fully immersed jet, which reduces fabric tension and production of foam.

(c) A short distance between the fabric-driving reel and the liquor level to minimize tension on the fabric leaving the liquor.

(d) Lower liquor volume. (e) Increased liquor flow rate and higher fabric speed to

increase the frequency of contact between fabric and liquor.

( f ) A means of synchronizing the speed of the fabric-driving reel with that of the fabric, thereby reducing the risk of tangle and minimizing tension and friction on the fabric.

MCS

This large Italian producer has been highly successful in selling a wide range of jets. Their well-known teflon-coated dye chambers have now been replaced by a new base, which

acts similarly to a 'roller bed' thus ensuring that delicate, surface-interest fabrics are not damaged.

Obermaier

Soft Beck Obermaier's Soft Beck fabric dyeing machine i s a further development of their Jet Beck. The company claims that it retains the advantages of short-liquor dyeing machines and that the new design has widened the range of application, in particular to fabrics with delicate surfaces. Two types are manufactured: model A - their atmospheric machine - and model HT - a high-pressure machine for temperatures up to 140°C. The fabric is transported by means of a winch with an infinitely variable gear. The soft-flow nozzle device allows penetration of the fabric and i t s gentle displacement into the container. By adjusting the flow of liquor and the winch speed, smooth running of heavy (100 g/m a t 40 mlmin) and lightweight fabrics (40 g/m a t 400 m/min) can be achieved. The liquor ratio can be varied between 4 and 12:1, and up to six units, each with a capacity of 100-120 kg, can be linked together.

The Soft Beck was developed to fill the gap between the conventional winch dyeing machines and Obermaier's Jet Beck.

1. 2. 3. 4. 5. 6. 7. a. 9.

10.

15 16 75 lh ;9 2b

Beck Loading and unloading door Rope guide or seam detector Guide roller Transport winch Unloading roller Emergency stop Soft flow nozzle Flow control butterfly valve Heat exchanger

11. Rope oscillator 12. Overflow rinse 13. Direct heating 14. Addition tank 15. Fluff collector 16. Circulation pump 17. Main drain 18. Water inlet 19. Fabric container 20. Operation platform

Obermaier Atmospheric Soft Beck fabric dyeing machine

Samuel Pegg

Universal H T The 'Pegg Universal HT Fabric Dyeing Machine' i s a pressurized development of their 'Fablo Fabric Dyeing Machine'. It i s a machine of the compact type, and is built in six standard sizes - comprising 1, 2,3,4, 5, 6 sections - each upto 150 kg capacity. It incorporates Pegg's highly polished, specially designed, anti-friction surface featured in their 'Fablo' machine. The pump has been modified to give continuous circulation from the vat to each independent accelerator. The vessel i s self-pressurized by means of an air cushion above the liquor, thus enabling dyeings to take place at a l l temperatures up to 140°C. Fabric is transported by a variable-speed, motor-driven winch, which can function a t

114 JSDC Volume 96 March 1980

speeds up to 400 m/min, and has forward and reverse control. The machine will stop and an alarm will sound should the fabric tangle or stop. These machines are fitted with a control panel incorporating rate of temperature rise and cooling facilities.

Scholl

Rapid Piecedyeing 'Subtilo' Jet Machine This machine has been designed for the gentle processing of fabrics having very delicate surfaces, such as terry cloth,

A AUtocldVe B Preparation vessel

1. Main pump 2. Mixer 3. Heating element 4. Cooling element 5. Filter in pipe 6. Throttle valve 7. Throttle valve 8. Drain valve autoclave

(sewerage) 9. Drain valve, overflow vessel

(sewerage) 10. Overflow valve

preparation vessel

11. Additions valve 12. Water feed valve on unit 13. Modulating valve heating 14, Modulating valve cooling 15. Valve to spray ring

overflow vessel 16. Loading and unloading

winch 17, Main winch 18. Fabric running control 19. Seam tracing device 20. Dye liquor acceleration

21. Fabric storing chamber 22.Tontact roller

device

Scholl Subtilo rapid piecedyeing iet machine

plush, track-suit fabric, interlock and stretch cord of cotton and i t s blends, a t temperatures up to the boil. It is claimed to be suitable for dyeing a wide range of fabric weights - 100 to 1200 ghunning metre - in rope form. The unit is available in one-, two-, three- or four-chamber sizes, the capacity of each chamber being 150-200 kg. The average liquor ratio claimed is between 6 and 8:1, although this can be reduced to 4: 1 for certain articles and for small batches. The units are supplied equipped with a temperature programme regulator or semi- or fully-automatic process control, according to the customer's requirements. The most important advance is the mechanical plaiting of the rope after it leaves the transporta- tion tube. This ensures even packing of fabric in the dye chamber.

Serracant

Carrousel Jet Serracant were offering a recently developed machine, the Carrousel Jet. It is an atmospheric, non-flooded, soft-nozzle machine that uses a short liquor ratio for the dyeing of piecegoods in rope form. It operates in a similar manner to the VH-Ultimat and the Orbit Flow machines of Henriksen and Jagri in that it too uses the principle of a horizontally rotating perforated cage. Ropes are transported positively by a winch, specially designed to prevent slippage and hence tension on the fabric. Impregnation of the fabric by dye-liquor occurs a t the soft-flow nozzle which is situated a t

Folding zone

Filter

Addition tank -

Serracant Carrousel jet machine

the entrance of a 'flared' dye tube, where the fabric folds before resting on the rotating perforated cage. Here, excess dye-liquor is allowed to drain into the dyebath and is recirculated. The rotating cage has a positive and independent drive. The machine is designed as a 3-unit system, each unit having a capacity of 120 kg.

Serracant claim short dyeing times, economies of water, steam, dyes and chemicals, very gentle treatment of the fabric, and versatility.

Textile Processing

Texpro CF 2000 Dyeing Machine The manufacturers claim that their machine combines the advantages of the je t and overflow principles, stating that the new design with combined overflow and venturi je t and 'soft glider' cloth-storage chamber means true versatility in rope- dyeing technology.

The advantages claimed include (a) Extremely sensitive fabrics can be processed without

problems, since the combined overflow and venturi jet treat the fabric very gently, even a t high rope speed.

(b) Processing times are reduced to a minimum, since the running conditions can be adjusted by means of

JSDC Volume 96 March 1980 115

Texpro CF 2OOO dyeing machine

the winch, overflow and jet. Running costs are reduced owing to the machine's high capacity, low energy consumption, and to the low liquor ratios used. The cloth i s conveyed by i t s own weight a t constant speed and without tangling on a sliding surface made of a low-friction material.

The makers state that their new design offers trouble-free dyeing of fabrics sensitive to mechanical action, e.g. terry towelling, as well as delicate lightweight fabrics. The jet pressure that is required is claimed to be very low even a t high rope speeds, owing to the low-friction lining. They recommend liquor ratios of 4 to 8:l for the best running efficiency.

The machine i s available in HT and atmospheric versions with 1 to 6 units, and is designed for automatic control.

Soft Glider Mini Jet Using the same working principles as the Soft Glider Jet, the Mini Jet has Wen designed to cater for small dyelots (5-50 kg) under atmospheric conditions. Programmes developed on this machine can be directly employed on the Soft Glider Jet giving, it is claimed, complete reproducibility.

Thies

Roto-Stream Thies have a product range wider than that of most other manufacturers and have developed and sold large numbers of 'fully-flooded', 'soft-flow' and 'compact' type jet machines. The manufacturers feel that their Roto-Stream is suitable for most synthetic fabrics and their blends, and have developed it to replace their R-jet 140. Cloth is transported by passing the material into a cylindrical drum in which the peripheral wall is perforated. The drum is free-wheeling and rotates axially about a horizontal axis as a result of the weight of material being fed in. Thies claim that the machine is

The machine is available in HT and atmospheric versions with 1 to 6 chambers,and is designed for fully automatic control.

Texpro Soft Glider Jet Textile Processing have redesigned the fabric storage chamber. The dye-liquor and fabric are effectively separated, the fabric being conveyed by i t s own weight on a low-friction I i ni ng.

Thies Eco-Soft machine

tangle-free, and even delicate, lightweight woven and knitted fabrics are ensured perfect running.

Texpru Soft Glider jet machine

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Eco-soft In the special cases, where a 'soft flow' type machine i s required, Thies have redesigned their R-jet 95 to give improved performance a t a lower price per kg of cloth.

The Eco-Soft machine is suitable for dyeing a t temperatures up to 105°C. It is a short-liquor-ratio machine (4:l to 15:1, depending on the delicacy of the fabric) for processing knitted and woven fabrics made from natural and synthetic fibres as well as their blends. The manufacturers claim that, with i t s soft jet of special design, this machine dyes the most delicate ropes of fabric a t short liquor ratios.