EQUIPMENT
Monforts' new "Thermex 6500" hotflue reduces dyeing process time for knitted fabrics from hours to minutes providing previously unknown levels of productivity and reproducibility.
A. Monforts Textilmaschinen GmbH & Co. KG has launched a completely new, modular design "Thermex" hotflue system for knitted fabric producers to reduce dyeing process time from hours to minutes. The "Thermex 6500" is an all-new loop dryer with a fabric capacity of up to 51 m. Offering previously unknown levels of productivity for knitted fabric dyeing, the machine has a number of new features, including the control system, drive system and indirect gas heating.
In Control
A key feature of the "Thermex 6500" is the economically designed control desk. This provides easy access to all the main control and operating functions via a touchscreen monitor located at eye level. A simple menu system guides operators through the set-up procedure. The system is now uniform across the Monforts range, making it even simpler for operators to move between different types of machine.
The "Thermex 6500" is available with a choice of two control systems. The standard "Qualitex 540" allows important operating parameters, including temperature set points and fan speeds to be set and monitored using the touchscreen.
The optional "Qualitex 740" is a full-scale, programmable logic process controller that incorporates the "Monformatic" system. Additional functions offered by "Qualitex 740" include the storage of set-up data, batch management and network interfacing.
Both "Qualitex 540" and "Qualitex 740" have a two-loop system for emergency run and can be connected to Monforts' remote diagnostics system.
"Econtrol Knit"
Developed for use with the new "Thermex 6500" hotflue, "Econtrol Knit" delivers previously unheard levels of productivity. A batch that would require between 12 and 24 hours to produce using a discontinuous process, takes just two minutes with "Econtrol Knit". Moreover, "Econtrol Knit" can reproduce the results time after time, even with large batches. Precise control of the dwell time ensures there is no variation in color. Unintentional Moir_ (rippling) effect is also avoided because the process puts no mechanical strain on the fabric surface.
Unlike other processes, "Econtrol Knit" dyes cotton/elastane blends without the fabric having to be sewn into a tubular form.
Another benefit is that the fabric is dry after the dyeing process so it does not have to be immediately washed out.
"Econtrol Knit" is suitable for all types of reactive dyestuffs. Although the process requires no salt or urea, it achieves up to 5-8% higher yields from dyestuffs than with other processes. Production costs can be up to 45% lower than for discontinuous methods of dyeing.
"Econtrol" is a trademark from DyStar Textilfaurben GmbH & Co. Deutschland KG.
Individual Drives of Hotflue Rollers
Standard roller diameter on the "Thermex 6500" is 140 mm, a 180-mm diameter version is available as an option. Manufactured from stainless steel, the rollers in the drying section are "Teflon"-coated, while those in the thermosoling section have a highly polished surface finish.
An AC motor powers each pair of upper rollers. This allows for higher speeds compared to the single chain drive used on previous "Thermex" models. The motors can be controlled by either a common or individual frequency converter.
ST Stabilization Rollers
For fabrics that are prone to waving or creasing during hotflue drying, Monforts has developed the ST stabilization roller. Featuring a dual density rubber coating, the ST rollers feed fabric through the hotflue without leaving marks.
Indirect Gas Heating
The "Thermex 6500" is the first Monforts hotflue available with the "Exxotherm" indirect gas heating. This Mon forts-developed system keeps combustion gases separate from the circulation air to prevent yellowing of elastomer fabrics. It can be used in modern reactive and naphthol dyeing processes with no neutralization of the alkali.
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