HIMANSHU.A.SINGHD.K.T.E’S

12DSTXCH28FINAL YEAR(TC)

STENTER MACHINE:

• A machine or apparatus for stretching or stentering fabrics.

• The purpose of the stenter machine is to bringing the length and the width to predetermine dimension and also for heat setting and it is used for applying finishing chemicals and also shade variation is adjusted.

Functions of Stenter Machines:

• Heat setting is done by the stenter for lycra fabric ,synthetic and blended fabric.

• Width of the fabric is controlled by the stenter.

• Finishing chemical apply on fabric by the stenter.

• Loop of the knit fabric is controlled

• Moisture of the fabric is controlled by the stenter

• Spirility controlled by the stenter

• GSM of the fabric is controlled by the stenter.

• Fabric is dried by the stentering process

• Shrinkage property of the fabric is controlled.

• Curing treatment for resin,water repellent fabric is done by the stenter.

• Why choose BRÜCKNER?• Good reasons to invest in a BRÜCKNER• POWER-FRAME stenter• –– Highest drying performance due to the well-engineered and patented• SPLIT-FLOW® air circulation system• –– Up to 35 % energy saving thanks to economical heat recovery and• energy saving concepts• –– Absolutely homogeneous distribution of air flow and temperature due to• the alternating air flow in the thermo zones (every 1.5 m)• –– The flexible SPLIT-FLOW® air circulation system allows a process control• which is fine-tuned to the particular finishing requirements of all kinds of• fabric• –– Optimum straightening results due to an innovative, integrated• straightener with shortest possible fabric path to the pin-on point• –– Extremely robust and low-maintenance chains, chain rails as well as pin• bar carriers and clips• –– Exactly reproducible finishing results thanks to full automation and the• recipe administration of the line

Components of Stenter Machine:

• Paders• Weft straightner(Mahlo)• Burners• Heat recovery• Attraction rollers• Circulating fans• Exhaust fans• Winder• Clips• Pins• I.R• Cooling drums

8

Stenter Frame

Mazadul Hasan Shishir , Southeast University

STENTER FRAME RANGE• Infeed Combination• Stenter Frame-Twin Air with horizontally reversed pin and clip chain• Outlet CombinationFor Treatment of : Woven and Knit FabricsNominal width : 200 cmWorking Width Maximum tension width : 180 cm Minimum tension width : 60 cmMechanical speed range : 5 – 100 m / min.Heating : Circulating oilSpecification : Pin and Clip (Combi)

STENTER FRAME-HORIZONTALLY REVERSED PIN AND CLIP CHAINStenter Inlet complete with : Overfeed device, Fabric inlet frame with operating platform, Control box, Upper traction roller, Overfeed device electronically controlled with Digital Indicator for maximum overfeed + 60% ascompared with the stenter chain speed, Bottom traction roller electronically controlled with Digital Indicator Speed variable + 10%, Drive for the traction rollers, One driven expander roller (fine pitch) profile surface made of stainless steel with motor, One manually adjustable weft correction roller.

Fabric Infeed device complete with : Two needling in-apparatus selvedge tensioning device right and left separately adjustable Selvedge Uncurlers with 2 fixed screws Spindles Overfeed device, edge spreader LS 3001 (E+L make)Fabric Feed device complete with : Infeed track control KR 43 with FR 15 sensor, Inlet field tracks 3000 mm long, + extension track of 1440 mm After-pin brushes for the inlet tracks, Pneumatic chain tensioner, Chain tracks in the treatment chamber, Longer delivery tracks 2820 mm long, After-pin brushes for outlet field tracks, Frequency controlled individual Chain drive, Horizontal reversed pin and clip chain (ball bearing type) with low maintenance, Swivel type De-pinning rods, Fabric outlet frame Lower spreading and positioning roller , nozzle with crimp shoe

Fabric Infeed device complete with : Two needling in-apparatus selvedge tensioning device right and left separately adjustable Selvedge Uncurlers with 2 fixed screws Spindles Overfeed device, edge spreader LS 3001 (E+L make)

Width adjustment of the Stenter chain via lube-free with adjusting spindles with individual drivescomplete with :- 6 Spindles for the chain tracks in the treatment chamber each driven, One Spindle for the outlet field tracks driven width indication in front and in the rear Digital width indication at inlet and outlet of stenter frame

Treatment Chamber `TWIN-AIR' with separate directed top and bottom air, each with 2 aircirculation fans complete with Isotherm zone at entry and exit 5 treatment fields with 150 mm thick insulation cladding for especially high thermal insulation, 5 x 2 drives for the air circulation fans, with invertor control upto 1500rpm Drawable CAD stream KLD-nozzles, Single lint filters which can be pulled out and cleaned during productionCompact front walls of the chamber - Cold air barriers at the fabric inlet and outlet openings

Floor insulation Special insulation panels made of mineral fibre 100 mm thick for machine installation directly on theground floor of the factory hallExhaust Air – 2 Suction fansCirculating oil Heating 5 Air heaters for treatment chambers

OUTLET COMBINATIONDel ivery Suppor t wi th traction rol ler Delivery support with traction roller Separate drive for take off roller. This drive will also run plaiter and batcher Selvedge shifting deviceSurface – driven winder, winding diameter upto 1800 mm Fabric guiding arms, pneumatically actuated with mechanically driven traction roller Bowed spreading barFolder Plaiter disconnectable during batching process Lap length – 1000 mmAntistatic device for plaiter & batcher:Meter Counter• Complete power supply

Working.

• The fabric is collected from the batcher to the scray and then it is passed through the padders where the finishes are applied and some times shade variation is corrected.

• The fabric is entered into the mahlo (weft straightener)the function of the mahlo is to set the bow and also weave of the fabric is griped by the clips and pins are also provided but the pins has the disadvantage that they pins makes holes at the selvedge but the stretching of the pins are greater then the clips.

• These pins and clips are joined to endless chain.

• There are 8 to 10 chambers provided on the machine each chamber contains a burner and filters are provided to separate dust from air.

• The circulating fans blow air from the base to the upper side and exhaust fans sucks all the hot air within the chambers.

• Attraction rollers are provided to stretch the warp yarn.

• After stentering we can increase the width of the fabric up to 1.5-2 inch .

• The speed of the machine is about 7-150m/min.

• 3 meters fabric can run in each chamber.

• Temperature is adjusted that according to the fabric as for.

• P/C-210°c

• Cotton-110-130°c

Fabric take-up, scrays, fabric accumulators

J-box fabric scray with fabric guiding elements

More productivity with the new POWER-PAD padder

FINISHING PADDERTwo Bowl Pad Mangle with inclined pad bowl arrangement complete with :- Machine frame with traverses and claddings discharge sheets made of stainless, largedimensioned pneumatic cylinders for achievement of high contact pressures Squeeze rollers - One Top counter pressure roller hard rubber 100 shore A and one bottomcrowned roller, soft rubber 85 Shore A Drive for counter pressure rollerLiquor Trough made of stainless steel - Pneumatically lifted and lowered Single trough Longer immersion path in troughExpander unit for Knits goods -- Driven Scroll Roller before the nip

Benefits of the new straightening process–– Possibility to straighten bow and S-shaped distortions by differentspeeds of the right, left and central rope–– Gentle fabric transport into the dryer due to the fabric support by theropes and additional conveyor belt–– Significant increase of the evaporation capacity by integration of a newsuction drying device in the first dryer zone. Suction drying processsupportedby conveyor belt leading into the dryer–– No distortion of the fabric at the selvedge as the fabric is supported bythe conveyor belt over the entire width

Newly developed weftstraightening process with ropes in the entry zone

Straightening in the entry zone

New integrated weft straightenerThe new integrated weft straightener allows achieving perfectresults due to the optimum roller configuration. As the fabricis being straightened immediately before pinning-on, thestraightening effect is maintained and the formation of newfabric distortions will be avoided.

Integrated weft-straightener in the entry stand

Benefits of the indirect gas heating–– Higher temperature homogeneity–– No mixing of exhaust gas with the air circulation in the dryer–– High efficiency with lowest emission values–– Minimum risk of yellowing effects on the fabric–– No chemical reaction of the exhaust gas with the fabric

Heat exchangercirculatingair/exhaust gas(indirect gas heating)

Benefits of the direct gas heating–– Maximum efficiency with low rates of emission–– Extremely short heating-up time–– Minimum maintenance–– Maximum temperature uniformity of the air circulating in the dryerby the nozzle system and the counter-type arrangement with twoburners and two precision temperature controllers per one 3 metrecompartment–– Continuous control range of 1:40

Stenter versions with conveyor belt

Benefits and field of application of the horizontal stenter withconveyor belt–– Particularly recommended for fabric which is susceptible to distortion–– Fabric transport with very low tension–– No sagging of the fabric–– No fabric distortion across the complete width and at the edges–– Different speed of belt and chain allow to straighten bow distortions–– Without chain, the machine can be used as relaxation dryer and allowsachieving optimum residual shrinkage values–– Possibility to install a suction zone in front of the first drying zone toincrease the evaporation capacity

Available as an option:Automatic lint screen cleaning

Double lint screens

Available as an option: Montaña nozzles

for higher evaporation

capacity and more turbulent fabric

movements

BRÜCKNER chain and chain rail systems

It is a unique feature of all BRÜCKNER transport chains, that theglidingelements are directly fixed on the clips (horizontal chain).All gliding elements are easily accessible from outside of the dryer formaintenance.No disassembly of the chain rail required.The gliding elements are made of a compound material whichneeds no lubrication and is thus almost maintenance-free.

Pin plate holder for horizontal chain

Clip for horizontal chain

Vertical chain with maintenance free chainrail

The vertical chain STAR-DURThe vertical chain rail is completely maintenance free as all glidingelementsare directly mounted onto the chain.

The horizontal transport chain STAR-FORCE is a very solid system

that is designed for extremely high transverse force. Due to the closed

grease-deposit lubrication, this needle-ball-

bearing chain needs onlyminimum

maintenance.

The horizontal chain STAR-FORCE

The horizontal transport chain STAR-FORCE is a very solid systemthat is designed for extremely high transverse force. Due to the closedgrease-deposit lubrication, this needle-ball-bearing chain needs onlyminimummaintenance

Due to the oil-lubricated steel bushing and the ball bearingcombination, the horizontal chain STAR-ROLL is a very solid systemthat is designed for extremely high transverse forces.

The horizontal chain

Operation of drive settings

Features of MULTI-CONTROL Plus

Available as an option:cleaning hatches for optimummaintenance

Specification of a stenter Machine:Brand Name Bruckener

Serial no 72276-0463

origin Germany

Year of manufacture 1995

Speed range 15-30m/min

Temperature range 50-250°c

Used utilities Electricity,gas,compress air, steam

Production capacities 8ton/day

No.of chamber 3

Maximum fabric width 102”

Minimum fabric width 30”

Steam pressure 2 bar

Air pressure 10bar

Applied for Open tube fabric

No. of ratamatic burner 6

Extra attachment Mahlo weft straightener

M/C parts Burner ,Nozzle, Exhaust air fan ,over feed roller, suction fan, chain arrangement

Technical Data of stenter machine

Roller Width - 1500mm to 3800mm.Fabric width - 1200mm to 3600

mm.Mangle - Two Bowl or Three Bowl.Fabric feeding draw nip - 1.1kW/1.5kW.Mangle Motor - 5.6/7.6/11kWTop Roller - 305mm diameterDriven Roller - 295mm diameterBottom Roller - 305mm diameter

Trough –single trough with 2 or 3 guide rollers or double trough.

Guide roll diameter-114mm/141mm/152mm/177mm(wider width).

Weft correction-fully automatic electronic or motorised manual.

Stenter-from 3 chamber to 10 chamber

Pin-clip chain, clip chain, pin chain vertical return pin chain execution.

Heating media-Thermic oil/direct gas/steam.

Selvedge tension motor-1.5kW/2.2kW AC

Over-feed Motor-1.5kW AC

Pinning Motor-0.75kW AC

Blower Motor-5.6kW/7.6kW/11kW

Thermic Fluid Heater-60,000-1,30,000Kcal –Multipass-2 per chamber)

Natural Gas/LPG Burner-60,000Kcal to 1,50,000 Kcal(2per chamber)Approx.65-150kW.

Drive –Variable frequency AC Drive

Exhaust-with/without moisture controller.

Bruckner 200 cm .mp4.mp4