Airflow Dyeing Machine

Prepared By : Mazadul Hasan sheshirID: 201000040000813th Batch (session 2009-2013) Department :Wet Processing Technology Email/Facebook: mazadulhasan@yahoo.comBlog : www. Textilelab.blogspot.com (visit)

Southeast University Department Of Textile

EngineeringI/A 251,252 Tejgaon Dhaka Bangladesh

Prepared By :

Aerodynamic technologyThe fact that the limits of the aerodynamic Airflow system first presented by Wil- helm Christ in 1984 are far from being reached and that great potential remains is indicated by the High-Speed Leveling (HSL) process (patent registered). System- atic further development aimed at the ex- ploitation of the innumerable advantages of the aerodynamic system has led to shorter dyeing processes and massive resource savings. However, a mastery of aerodynamic technology is a prerequisite for the safe use of this process.The basic principle underlying the aero- dynamic system is that the fabric passes through an air-steam mixture emitted from a blower. This means that contrary to a hydraulic dyeing machine, neither a dye bath nor an aqueous medium is needed

for fabric transport. In other words, the fabric passage is possible without liquor. The material is in constant motion from feeding to the end of the process, as well as during drainage and filling procedures. Fig. 1 shows the air suction pipe, which has been designed as a filter, in the center of the dyestuff vessel. The blower and the airline, which leads to the transport nozzle, can be seen in the background. The fabric skein is drawn off from the dyestuff vessel by the winder, fed to the nozzle line and then returned to the storage chamber via the cuttler. The storage chamber is fitted with PTFE rods (Fig. 2). PTFE, which is familiar under the brand name Teflon, offers very good non-adher- ence characteristics with the result that the surface of the fabric is well protected. There is no dyeing liquor in the dyestuff

This is another development of the very popular jet dyeing machines. The

main difference between the Air Flow Machine and Jet Dyeing machine is

that the airflow machine utilizes an air jet instead of the water jet for

keeping the fabric in circulation. Typically the fabric is allowed to pass into

the storage area that has a very small amount of free liquor. This results in

a reduction in consumption of water, energy and chemicals. The figure

below shows how in an Airflow Machine the bath level is always under the

level of the processed textile. Here the fabric does not remain in touch

with the liquor (the bath used is below the basket that holds the fabric in

circulation). This invariably means that the bath conditions can be altered

without having any impact on the process phase of the substrate.

Airflow Dyeing Machine

Discontinuous processing of textile substrates require more water and energy compared to continuous processes. However, for a long time efforts are undertaken to optimise discontinuous processes with respect to productivity, efficiency and also to minimise energy and water consumption respectively. This lead to dyeing jets. Thereby liquor ratios have been reduced step by step. The latest developments have LR of 1:3 (for woven PES fabric) and 1:4.5 (for woven CO fabric). To achieve such low LR, within the machine (jet), the fabric is moved by moisturised air or a mixture of steam and air only (no liquid) along with a winch. The prepared solutions of dyestuffs, auxiliaries and basic chemicals are injected into the gas stream. The bath level is always below the level of processed textiles in order to maintain low LR. The principle of such an airflow dyeing machine is illustrated. Rinsing is carried in a continuous manner. During the whole rinsing process, the bottom valve is open and rinsing water is discharged without additional contact with the fabric (which is the case in conventional machines) This also allows the discharge of hot bath liquors, also after high-temperature dyeing at 130°C. Thus, in addition to time saving, optimum heat recovery can be performed. The fabric itself is processed with low tension and crease formation is minimised.

Description

1. Completely Separated circuit for liquor circulation without getting in touch with the textile

2. Bath less Dyeing operation3. Rinsing process offers all the added benefits of continuous processing as it

is no longer a batch operation4. Extremely low liquor ratio5. Virtually nonstop process6. Comparatively lesser energy requirement due to faster heating/cooling and

optimum heat recovery from the hot exhausted dye liquors7. Reduction in consumption of the chemicals (e.g. salt) dosage of which is

based on the amount of dye bath8. Lesser water consumption savings up to 50% from the conventional Jet

dyeing machines 9. Sensitivity towards ecology10. Economical operation 11. More safety while dyeing.

Advantages of Airflow Machine

XDWG 225, 450, 675, 900, 1350

For cotton: (XDWG 450)

Liquor ratio: 1: 4

No of fabric container: 2

Load capacity: 400-450 kg

Fan Power: 45 kw

Main pump: 7.5 kw

Cloth lift: 4.4 m

Total power: 56.9 kw

Operating power: 18.8 kw

Capacity of preparation tank (L): 2000 L

Transmission speed: 100-700 m/min

Rate of temperature rise (Average): Steam pressure more than 5 kg/ m2

Rate of temperature drop (Average): Steam pressure more than 2 kg/ m2

Main technical data:

Shorter processing time and higher efficiency

Extreme low total water consumption

Obvious reduction of dyestuffs and additives

Flexible load and stable liquor ratio( bath ratio )

Dyeing stability

Applicable for high quality and high demand fabrics

Full automatic control or reduce personal error

Machine Obvious Features :

Specification s(Numbers of tubes )

1 2 3 4 6 Remarks

Load

Capacity (kg )

225 450 675 900 1350

Liquor ratio Cotton 1:4 1:4 1:4 1:4 1:4 Putdry cloth

in the water

Polyester 1:5 1:5 1:5 1:5 1:5

Power Fan 25 45 75 90 120 Equipped

Main Pump 5． 5 7． 5 11 11 15

Cloth lift 2． 2 4． 4 6． 6 8． 8 13． 2

Total Power(kw ) 32． 7 56.9 92.6 109.8 148.2

Operating Power(kw) 10.8 18.8 30.6 36.2 51.9 Measured

Capacity of preparation tank(L) 1000 2000 3000 4000 6000 Optional

Delivery Speed 100-700 m/min

Rate of temperature rise (Average ) 6 ℃/MIN Steam Pressure ＞ 5kg/m2

Rate of temperature drop(Average ) 6 ℃/MIN Steam Pressure ＞ 2kg/m2

Main Technical Data Of Airflow Dyeing Machine

It adopts air dynamic theory ,making high speed airflow generated from high

pressure fan ( blower ) enter into nozzle from air entrance . And at the same time,

injecting atomized dyeing liquor to nozzle from water entrance . Atomized dyeing

liquor merges with high speed airflow in the nozzle and after further atomizing

process it will make the fabric move accordingly .

Airflow making fabric circulate to lower bath ratio to minimum

Dye liquor after being atomized is fed to provide better even dyeing effect .

The atomized airflow blow to the fabric to make it change the rope status

constantly .So that it can make the change to crease for sensitive textile be the

lowest .

The nozzle adopts special design , supplying more comfortable handling

environmental for fabrics , which can make the fabric more smoothness .

Nozzle system of airflow dyeing machine:

Figure : Schematic diagram of Then Airflow technology; the air suction pipe, which is designed as a filter, is located in the middle of the dyestuff vessel (Then)

Figure : Storage chamber of the Airflow dyeing machine is fitted with PTFE rods; the PTFE rods have non-adherence characteristics, which protect the surface of the textile

THEN Air Flow dyeing Machine

THEN Airflow Made by Fongs – China

THEN-AIRFLOW® SYNERGY G2

THEN-AIRFLOW® SYNERGY G2Ongoing further development forms a major element in our corporate philosophy. Therefore, we are proud to be able to present the SYNERGY G2 dyeing machine which apart from a high load per strand also provides further sizeable reductions in water and energy consumption. In other words, the SYNERGY G2 is a top product from both a cost-efficiency and ecological point of view. “Our SYNERGY G2 is based on the tried and tested technology of the successful THEN-AIRFLOW® system. Accordingly, the use of proven advantages and the creation of additional innovative features has resulted in our best ever piece dyeing machine.”

THEN-AIRFLOW® SYNERGY G2

Increased loads —A number of decisive changes to the design of the fabric storage chamber have led to an increase in load to a maximum of 300 kg per chamber.

Process time reduction —The G2 slashes the process time, which is seen as a cost-efficiency benchmark to record-breaking low values.Lower energy and water costs —The G2 further reduces water consumption by 20% and at the same time provides corresponding energy savings.

Shorter liquor ratio —In tandem with an unaltered basic design, the increased payload of the SYNERGY G2 results in another marked reduction in the nominal liquor ratio.

Exact reproducibility —The SYNERGY G2 furnishes unsurpassed reproducibility and “right first time” dyeing rates of up to 98%.Immense fabric range—No other piece dyeing machine on the market can successfully and economically dye such a wide range of fabrics.

1. Main tank made of supreme stainless steel SUS . ( SS 316L )2. The bottom of main tank is covered with fine Teflon Pipes .3. Special stainless steel fan with inverter control .4. Cloth lift and laying up synchronous adjustment with inverter control.5. Air dust filter of fabric cuttings and fluffs .6. Filter of fabric cuttings and fluffs before pump .7. Full automatic program , computer control .8. Proportional temperature control .9. Feed pump of dosing tank .10.Liquor atomizing and jetting device .11.Proportional dozing device .12.High efficient steam heat exchanger .13.Analog water level control system .14.High temperature discharge system .15.Delivery device .16.Double-inlet drain-select system .17.Cloth end detection device .

Standard Equipment For Dyeing Machine :

Blower

Blower Pipe

Heat Exchanger

Main Pump

Nozzle

Unloading Motor

Spray dye Liquor Air Blowing

Steam valve

Flow Diagram

Dyeing Flow Chart :

Dinmenler Jumbo Type Air flow dyeing Machine - 6 Nozzle

Blower

Nozzle

Air Blowing

Dinmenler Air flow dyeing Machine - 3 Nozzle

DMS 03 DIL-AIR1

Operational dataThe airflow dyeing machine offer combination of high productivity and reproducibility and reduction of water, chemicals and energy consumption.

EconomicsInvestment cost for airflow dyeing machines, compared to conventional dyeing jets are around one third higher but due to high savings a short payment period can be achieved.

Driving force for implementationHigh productivity and reproducibility and minimisation of water, chemicals and energy consumption have been and still are the main driving forces for the application of this technique.

Main achieved environmental performance

Textile processing at low LR and practically continuous rinsing, water

saving of about 50% are achieved compared to machines having a

hydraulic system (the fabric is moved by injection of process liquor and a

winch) at LR of 1:8 up to 1:12. The same is for heating energy. There are

also savings of auxiliaries and basic chemicals of about 40%. The savings

are compiled in Table 4.16 for exhaust dyeing with reactive dyestuffs

The application of this technique needs investment in new dyeing machines Existing machines can not be retrofitted. The machines can be used both for knit and woven fabric and for nearly kinds of textile substrates. Fabrics consisting of wool or wool blends with a percentage of wool of more than 50% can not be dyed because of felting. It can not be recommended to dye linen fabric with the described system because of scaling of the machines with linen fluffs. For silk, the system has been approved but is still rarely applied for it.

Concerning dyeing with vat and sulphur dyestuffs, a process has been developed to minimise the oxidation of dyestuffs by oxygen from injected air (minimisation of oxidation by heating up to steam atmosphere).Elastic fabrics containing polyurethan fibres (lycra) are always difficult to dye with respect to dimension stability but they can be dyed in the airflow system. Also other substrates, such as PES or PES/WO blends are difficult or impossible to process in case of low dimension stability of the fabric.

Applicability

The New L-shape Airflow

However, the Airflow dyeing machine had one disadvantage: dyeing of

extremely delicate fabrics didn't give a perfect result. Current and future

trends pointing toward more and more lightweight fabrics with high

contents of elastane in finest yarn counts and gauges prompted the next

stage of Airflow machinery design.

To meet the required voluminous hand as well as top-grade quality

standards, the world's first long-tube Airflow machine, the Airflow Lotus

200, was developed. The new dyeing machine incorporates the latest

advances in Then's Airflow technology and operates according to the

original aerodynamic principle. The dye liquor passes the self-cleaning filter

and is then evenly applied and finely distributed as a mist with the aid of the

blower, assuring outstanding penetration, according to Then.

The New L-shape Airflow

Schematic drawing of the Airflow® technology: Air is the key element, and is said to be the ideal medium to transport piece goods in dyeing

machines.

High temperature high pressure airflow dyeing machine

M7202 High temperature high pressure airflow dyeing machine

Technical parameters :Tube number : 1, 2, 3, 4, 6 tubes.Fabric volume: for one tube machine, 225 kg, for six -tube machine,1350 kg (for 170～ 300g/m 2 medium thick fabrics)Bath ratio: Chemical Fiber Fabrics ≤1:2 , Cotton and wool fabrics ≤ 1:4.Max Operating Temperature: 140℃.Max Operating pressure: 0.4Mpa

Normal temperature normal pressure airflow dyeing

SME2701 Normal temperature normal pressure airflow dyeing machine

Technical parameters:Tube number : 1, 2, 3, 4, 6 tubes.Fabric volume: for one tube machine 225 kg, for six-tube machine,1350 kg (for 170～ 300g/m2 medium thick fabrics)Bath ratio:1 : 4.Max Operating Temperature: 98 .℃

Fig. 3: THEN-AIRFLOW® SYNERGY G2.

THEN-AIRFLOW® Dyeing Machine

The researchers at THEN had already predicted the situation of increasing scarcity of usable water as far back as the 1970s, when they began developing a jet dyeing system that would dramatically save water. The basic idea was to use dye liquor for the sole purpose of dyeing the fabric, and not to waste copious amounts of it, to simply move the fabric through the kier. They achieved this by harnessing the air inside the dyeing vessel and use it as a jet stream to propel the fabric through the dyeing nozzle. Thus, the chemicals and, in reactive dyeing, particularly of Glauber’s salt. Dyeing of most synthetic fabrics can be effected without the use of anti-foaming agents. Over and above this, the lower liquor ratio also offers a higher efficiency of dyestuffs. In THEN- AIRFLOW® technology, the dyeing point is in the nozzle. By injecting the dyeing liquor into the airstream trans- porting the fabric through the nozzle, an aerosol mist is created that offers dyestuff penetration far beyond the reach of any dye bath. In reactive dyeing, customers achieve annual savings of around 5% on their dyestuffs bill. The low liquor ratio and low overall water consumption also mean that total cycle times are greatly reduced. For a 100% cotton fabric in a dark red (maroon) shade, the total process time including loading, pre- bleaching, reactive dyeing, washing-off, rinsing and unloading is 278 min. This means a theoretical batch rate of 5.2 per day and thus a massive improvement in productivity over old technology. The overall water consumption for this fabric from loading to unloading is 39 l per kg. In pure bleaching operations, THEN-

Water consumption figures of 8 litre per kg for RFD (ready-for-dyeing) and 9 litre per kg for optical white. THEN-AIRFLOW® machines are available as high-temperature models or as atmospheric machines. There are presently more than 2,500 units of late design in operation worldwide, offering their respective owners economic and ecological superiority on both woven as well as knitted fabrics across all natural and man-made fibre contents. AIRFLOW® machines achieve water con- THEN-AIRFLOW® concept was born, and it became an immediate success initially in Europe and America in the 80s and 90s of the last century. Today, the global success story of the THEN-AIR- FLOW® continues, and it has become the most popular brand of exhaust dyeing machines even in China. As air is used to move the fabric through the machine, the liquor ratio required in THEN-AIRFLOW® machines (Fig) is typically 30% to 50% lower than in hydraulic round vessel dyeing machines.

For 100% cotton fabrics, it is typically 1:3.75 at full loading, and even at half loading, 1:4.6 is achievable, as the THEN-AIRFLOW machine works without a liquor bath in the bottom of the kier. The significantly lower amount of water in circulation also means consider- ably lower requirements of auxiliary

THEN-AIRFLOW technology is unrivaled as the most economical exhaust dyeing technology and the most ecologically sound solution in the industry: it offers the smallest water footprint of any exhaust technology available today.

The recent new factory is for one of our subsidiary company- KC Print. The new factory has installed THEN Airflow dyeing machine.

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