Development in Machinery World

Excerpt: Here are the news and developments in the Machinery World

Tecwin Series Soft Flow dyeing machine from Fong's: A boon to knit dyers

Fongs has introduced the latest model soft flow dyeing machine TECWIN for knitted fabrics. TECWIN combines some of the well-received design features of the latest model with a few novel elements designed to deliver superior performance and reliability

At a time when the knit dyeing industry is struggling with high MLR machines with high water and energy consumption, TECWIN ushers in path breaking innovation that would once and for all eliminate the challenges faced by the dyers.

Within a short span of time, TECWIN has steadily increased its foot print all over the world. In India as well, TECWIN machines have been successfully installed in Sacchi polyesters, Marvel Processors, Ludhina and in SPA Fabrics, Kolkata and a few more machines soon will soon be installed in Tirupur and Kolkata market.

Technical Data

  • Design temperature 140°C
  • Design pressure 3.0 bar
  • Heating gradient 25°C ~ 100°C approx. 5°C/min,100°C ~ 130°C approx. 2.5°C/min (Dry saturated steam pressure at 7.0 bar)
  • Cooling gradient 130°C ~ 100°C approx. 3°C/min, 100°C ~ 80°C approx. 2°C/min (Cooling water at 3.0 bar, 25°C)

TECWIN – Salient features

Material to liquor ratio is 1: 4.5

The new version of TECWIN has addition spray nozzle in the front which improves the degree of dye liquor exchange before the fabric enters in to the main nozzle. It ensures uniform dyeing results.

The main dye liquor exchange nozzle setting is adjusted automatically by means of a motor drive system, which ensures a smooth flow of fabric and the dye liquor. An additional pump is being used exclusively for spraying the liquor through the bottom nozzle in the front which ensures a better exchange of dye liquor during operation as well as enhances the washing efficiency while washing the goods Equipped with the adjustable loading chamber with optimized chamber design to resolve the separation difficulties occurred when running double rope fabrics. The variable chamber gives comfort to adjust the size of the chamber based on the load of the fabric to have a smooth fabric flow without any entanglement. An effective lint cleaning systems helps to remove the lint and other residues from the surface of the fabric Tecwin can be offered with various capacities from 1 to 8 tubes to meet out the requirements of the end users Unlike earlier version, the fabric is not submerged in to the liquor at the bottom of the vessel in the new Tecwin model by having a perforated Teflon sheet; it ensures no entanglement while processing body size fabrics Usage of high quality 316Ti/1.4571 stainless steel approved by international standards as the major material of construction for the TECWIN series enhances the machine metallurgy, hence leading to a longer machine life FC30EX is equipped with a 6.5-inch, 640x480-pixel, and TFT colour LCD display. Together with novel control functions, it is the most cost-effective control. FC30EX can also integrate with the central processing unit Viewtex and THEN-TDS central computer system, providing a comprehensive machine control management.

TECWIN - Schematic

Tecwin soft flow dyeing machine for knitted fabrics

With impressive features, TECWIN is indeed a boon for the knit dyers and it is all set to expand its footprint in India.

Further information from: A.T.E. Enterprises Private Limited A-19, CTS No 689,Veera Desai Road Andheri (West) Mumbai - 400053, India T (Board): +91-22-6676 6100 Ext: 198 T (Direct): +91-22-6676 6198 M : +91-9322120802 W : www.ategroup.com

Karl Mayer, Rabatex Industries and A.T.E. set up a joint venture

A new player starts in the market for warp preparation machines in India

On 29 March 2019 Karl Mayer, Rabatex Industries and A.T.E. signed a contract for setting up a joint venture. The legally independent company is called Karl Mayer Textile Machinery India Private Limited, has its registered office in Mumbai and production facility in Ahmedabad.

Karl Mayer is the majority shareholder and takes responsibility for the management of the new company.

Karl Mayer Textile Machinery India Private Limited will focus mainly on the manufacturing and sale of warp preparation machines and creels mainly for Indian market, as well as service and spare parts sale for warp preparation and warp knitting machines.

By means of the newly founded entity, the joint venture partners aim to enhance their position and distribution in the Indian market. Moreover, it is intended to make good use of the existing competencies and synergies, especially in terms of purchasing and customer service.

“With the further development of our international organization, and with our proven way to produce in our main markets, we want to continue to make a contribution to the long-term success of our customers. We are really proud of setting up this joint venture. By pooling our strengths, we will be able to even better support our customers, being close to them in the local market”, explains Arno Gärtner, CEO of Karl Mayer.

“The special contribution of Karl Mayer and Rabatex Industries to the joint venture will be production know-how and manufacturing capabilities in the sector of warp preparation machines. Both companies are important players in the warp preparation industry”, says Roland Kohn, President of the Business Unit Warp Preparation of the Karl Mayer Group. Karl Mayer is recognized as a leading and innovative machine manufacturer in the world market in all the areas it is active in.

A.T.E. enriches the group due to its proximity to the market and its strength in customer support. The company has already been Karl Mayer's distribution partner for many years. “We are honoured to deepen our relationship with Karl Mayer and start a new relationship with Rabatex Industries with this new joint venture. We thank our many customers that have encouraged us to take this step with their continuous support. We are confident we will be able to serve them better” says Anuj Bhagwati, Managing Director of A.T.E.

Dr. Pawan Kumar Singh, Managing Director of Karl Mayer Textile Machinery India Private Limited underlines this statement: “We are striving for market leadership in India and supporting the 'Make In India' initiative of the Government of India. By combining our know-how and our resources in the field of warp preparation machines, we can provide solutions to our customers with exactly those things which they require for their competitiveness, from production to customer service and support”.

Rabatex Industries also relies on the synergies of the new relationship. “Rabatex Industries is excited about this association with KARL MAYER, a technology leader in warp preparation machine industry and A.T.E., India's leading customer focused textile machinery marketer. Our respective strengths will help us in providing advanced technology machinery backed by professional aftersales service to the Indian textile industry”, said Haresh Panchal, Managing Partner of Rabatex Industries.

Karl Mayer is technology and market leader as well as driving force for innovations in textile machinery building. A.T.E.'s businesses encompass manufacturing, industrial sales, distribution and service in the areas of textile engineering, heating and cooling, wastewater treatment, flow technology, print and packaging equipment and IIoT etc. A.T.E. has developed several cutting-edge technology products and solutions and has several patents to its credit. Rabatex Industries is engaged in manufacturing warp preparation machinery, material handling, storage equipment and customized machinery for the textile & technical textile industry and also equipment for different engineering sectors.

A.T.E. launches Automation division for textile mills

Textile mills continuously seek to automate their processes and upgrade their machine and process controls so as to produce with better quality and lower costs. In some cases, they accomplish their goals through the purchase of new equipment, or through machinery overhauls with new parts. In other cases, the path to improvement requires a tailor-made approach – as the mills have machines that are in generally good mechanical condition, but need new kinds of control, or add-on systems for automation. Such customised projects in textile mills require to be executed by reliable partners with in-depth textile knowledge.

As a direct response to customers' requests that A.T.E. help them improve the performance of their installed machines, A.T.E. has launched an Automation division under its TEG (Textile Engineering Group) business unit.

A.T.E., endowed with deep domain knowledge in textile engineering and textile processes, has built-up a team of experts to undertake automation and upgrade projects. Machines are upgraded using modern retrofits and the latest software, resulting in significant improvement in the performance of these machines, both in terms of productivity and quality.

A.T.E. can undertake machine upgrade/automation of the following range of textile machines:

  • Weaving preparatory: Sizing and warping machines
  • Processing: Stenter/merceriser/dyeing ranges/pad dry/pad steam, etc.
  • Denim: Denim processing lines
  • Synthetics: POY/FDY winders, extruders, PSF lines, bale press, chip conveying and drying

Apart from custom machine upgrade/automation, the Automation division has also in its portfolio some productised solutions, such as a fancy yarn system – Fancy Spin – to add value to yarn, which would help mills realise higher value for their yarn.

Another such productised system is the pre-reduced indigo dosing systems for denim manufacturing (bulk as well as portable). These dosing systems help in maintaining consistent quality without any shade variation along millions of meters of denim produced and also help in reducing the load on the wastewater treatment plant.

“We have a team of experts with long experience in executing such projects smoothly. Customers can count on us for excellent support at all times of the project execution, and also post execution”, said Mr Vikas Banduke, Vice President – Automation, who is responsible for this new business at A.T.E.

Benninger incorporates traditional and modern at ITMA Barcelona 2019

In this 2019 ITMA year, Benninger(B205 in hall 2.) is celebrating its 160th anniversary. This anniversary stands primarily for 160 years of commitment to textiles, but also for 160 years of responsibility towards sustainable textile production. Thanks to consistent innovation and the continuous improvement and further development of our products, processes and services, for the past 160 years the name Benninger has stood for textile finishing plants that are particularly resource-efficient.

At this year's ITMA Barcelona Benninger will be presenting its latest developments:

  • The Benninger-Küsters CPB dyeing centre for knitwear and woven fabrics - the only salt-free cold dyeing process
  • The Tempacta washing steamer for knitted fabrics with freshwater supply that is controlled by the degree of contamination
  • The Trikoflex drum washing machine that is available up to a working width of 5400 mm. In addition, a specially developed expander roller for sensitive fabrics will be exhibited.
  • Benninger – Küsters Multipad - the new development for complex impregnation tasks on woven fabrics and knitwear with electronically monitored, automatic lubrication

Salt-free dyeing of woven fabrics and knitwear

Salt-free dyeing without the use of energy is only possible using the cold pad batch (CPB) dyeing process. This process is also becoming increasingly popular in tropical and subtropical regions, which is reason enough for Benninger-Küsters to adapt the CPB systems even more effectively to the climatic conditions. The heart of our CPB system is the Benninger Küsters Dypad, which we will also be presenting again this year at the ITMA Barcelona. Benninger is the only textile machine manufacturer with the know-how of the original S-roller technology, which is synonymous with an even dyeing result across the entire fabric width.

Contamination-dependent washing

The Tempacta washing steamer has been especially developed for all low-tension washing processes and is mainly used for diffusion washing (fastness washing). The unit has a consistent counterflow water supply. Online measurement of the degree of contamination regulates the necessary amount of fresh water in order to a.) guarantee the lowest possible water and energy consumption and b.) ensure a high reproducibility of the washing result.

Nothing is impossible: Tension-free and crease-free washing of textiles up to 5400mm

The Trikoflex drum washing compartment has the highest mechanical washing efficiency thanks to the double drum technology and the front and back washing technology. Crease-free fabric transport is guaranteed, even with sensitive fabric. In addition, Benninger has developed a cylindrical expanding roller for particularly sensitive textiles for wet and steam applications. The washing compartment is rounded off with the Hydrovac vacuum-water extraction system. Since each reaction process is followed by a washing process in wet finishing, 70% of the energy consumption is incurred during washing. For this reason, Benninger washing compartments are insulated so that up to 50% of the radiated energy can be saved here.

Benninger Küsters Mulitpad - there's nothing that can't be impregnated

The newly-developed Benninger Küsters Multipad is an absolute highlight with regard to flexible impregnation tasks. The unit is equipped with an optional double impregnation feature and is suitable both for heavy denim articles and for very light knitwear. One of the special applications is over-dyeing and mercerising of denim. The Multipad is also used for cold bleaching and pre-treatment of knitwear.

IoT - networked and informed at all times

The topic of the "internet of things" (IoT) is also becoming increasingly important in the textile machinery industry. True to the principle "trust is good, control is better", the important operating parameters of the Benninger systems are continuously monitored in a closed control circuit. Deviations are detected and corrected immediately.

Particularly quality-critical parameters are forwarded to those responsible by means of modern IoT technologies and an alarm is sounded in the event of limit value violations. A good example of this is the central bearing lubrication on the Benninger Küsters Dyepad: The critical lever bearings of the padder are permanently lubricated, malfunctions are reported and the lubricant is automatically replenished. Another example is online monitoring of the air-conditioned electrical circuit cabinets. A newly revised maintenance manager provides information about the maintenance status of the system at any time and generates a recommendation as well as a schedule for the next maintenance cycle. Another example of modern process monitoring is the newly-developed online measurement of the degree of contamination of the washing water and the resulting optimisation of water consumption. To give our customers an overview of their production facility at all times, we have further developed the established management information system BEN-iDATA. This allows the customer to query all important machine data, the maintenance status and the ecological footprint of the current production batch at any time and from any place. Last but not least, Benninger has developed an electronic ticket system for service assistance, which transmits diagnostic data at the time of the event to the Teleservice team in our main facility at the customer's request. This enables us to offer our customers efficient and timely support.

Further information from: Marion Rüesch, Corporate Marketing Benninger AG, 9240 Uzwil, Switzerland +41 +41, 71 8511; F +41 71 955 87 47 marion.rueesch@benningergroup.com www.benningergroup.com

Materials handling for Industry 4.0 concepts from Eton Systems

WITH over 5,000 tailored installations for a range of industries installed in over 60 countries, Eton Systems, headquartered in Gånghester, Sweden, has established a reputation as a clear leader in the field of complete material handling systems.

At ITMA 2019 in Barcelona from June 20-26th, the company will be demonstrating a complete installation based on a future production concept, with advanced software providing real-time information covering every aspect of the process.( A214, in Hall 2)

“Our systems are a natural fit with the major Industry 4.0 networked manufacturing plants that are now being constructed worldwide for sectors such as the garment and home textiles manufacturing and automotive industries,” says Eton's Sales and Commercial Director Roger Ryrlén. “We have had a very busy last 12 months, with more major projects in the pipeline. We understand, however, that one solution does not fit all situations, which is why we think in terms of custom-made solutions matched to specific customer needs. Buying a system from us, is buying a solution and a partnership. Each system includes support, service, training and knowledge built on more than 70 years of experience. When a customer invests in an Eton System the increased efficiency normally results in savings of between 40-60%.”

A typical system consists of overhead conveyors with individually-addressable product carriers which automatically steer their way through programmed operation sequences. They are monitored by a computer providing all the necessary data for optimally measuring and managing processes. The systems are also highly flexible and can be rapidly modified to changes in the production line or the need for expansion.

Options for smart factories

Eton's Flexible Productivity Concept (FPC) is based on two system platforms with a wide range of options, including:

  • Multiple rails for sorting at workstations.
  • Buffering
  • Automatic loading devices, pick-ups and work delivery robots.
  • Bridges and elevators that link systems and floors.
  • Historical links to products after completion.
  • Module-based software.

Via an addressable product carrier, an Eton system transports all the components of a complete product through the manufacturing process.

“The result is fully automated flow with complete control of every component for the end product – where they have been, where they are now and where they are going” Mr Ryrlén explains. “These are real Internet of Things installations and every component has its own unique identity due to the integrated transponder in each carrier.”

Eton is a member of TMAS – the textile machinery association of Sweden which will have a significant presence at ITMA 2019 in Barcelona.

For further information please contact: Therese Premler Andersson, TMAS Box 5510, 114 85 Stockholm, Sweden Phone: +46 8-782 08 50 E-mail: tmas@tebab.com; www.tmas.com

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