Tuesday, June 3, 2014

All about THEN-AIRFLOW® dyeing machine|| Air flow dyeing process

1:07 PM

For hundreds of years, water, which is a precious human resource, has been the most important element in textile finishing. Water has been used in large quantities for fabric dyeing.
A step in the opposite direction was taking place in 1979. The THEN Research and Development department asked itself the question how the enormous volumes of water required for piece dyeing could be reduced along with the related energy costs.

This rethink commenced with the development of the THEN-AIRFLOW ® technology, which already faced the fact that even though water had served as a transport medium in the past; it was and is still today not available everywhere in sufficient quantities. 
However, water is today an even more expensive medium. The answer to this is the new THEN-AIRFLOW® SYNERGY. This model offers previously unattainable economic and ecological advantages.
Simple Mechanism:
The patented aerodynamic system is based on the principle that the fabric transport is effected by air only, which means that as opposed to a hydraulic dyeing machine, no dye liquor or aqueous medium is required to transport the fabric. The fabric is constantly in motion from loading to the batch end, even during the discharge and filling processes. 
The THEN aerodynamic system
Let the Air Flow
The patented aerodynamic system is  based on the principle that the fabric transport is effected by air only, which means that as opposed to a hydraulic dyeing machine, no dye liquor or aqueous medium is required to transport the
fabric. The fabric is constantly in motion from loading to the batch end, even during the discharge and filling processes.
No Limits
 Knits and woven fabrics from light up to heavy weight and virtually any fibre or fibre blend can be bleached and dyed without machine modifications or changes. The modular system of the THENAIRFLOW ® SYNERGY allows taylor made machine configurations, which guarantees maximum efficiency.

Proven Success
Several hundred plants in successful operation around the world document the reliability and economy of this dyeing system, which is based on aerodynamic principles.



The aerodynamic original








1. Aerodynamic transport. Economical, frequency controlled blower.

2.Safe fabric transport. Optimum displacement and minimum crease formation are
ensured by the aerodynamic drive.

3. Active fabric running control. This facilitates slip regulation, the exact monitoring of the fabric speed and protective fabric handling.

4. Unique rinsing method. Short processing times with excellent rinsing through
spraying with fresh water.

5. Maximum dyeing safety. Aerodynamic fabric transport enables dyeing processes
in a saturated steam atmosphere.

6. Optimised fabric storage. Smooth plaiting guarantees excellent fabric displacement.

7. Dye liquor and fabric separation. PTFE slide bottom ensures maximum gliding
and protection of the fabric surface.

8. Liquor sump. The “Self Cleaner” filter system ensures a lint-free surface and
reduces the setting times between batches.

The outstanding advantages are:
  • Unlimited flexibility with regard to all fibres (except pure wool) and fabrics weight classes between 50–800 g/m.
  • The lowest liquor ratio on the market: man-made fibres approx. 1:2, natural fibres 1:3 to 1:4, depending on the article and structure.
  • Energy savings of approx. 40% compared to hydraulic jet-dyeing machines.
  • A reduction in the overall process time of around 25%.
  • The most advanced piece-dyeing machine available today. Providing a competitive edge through the lowest available processing costs.
  • Lowest water consumption and ­effluent represent an ecologically sound solution.
Components
THEN-One step leveller ®
The dyeing liquor consisting of dyestuff and the dyeing chemicals will be prepared
in the enlarged 1st addition tank, and the dry salt in the salt dissolving tank. By the
help of the circulation between the addition tank and the salt dissolving tank, the
salt will be dissolved and mixed with the dyestuff.   
 In a single “all in” process phase, the premixed liquor containing dyestuff,  chemicals
and salt is applied evenly and fully automatically to the fabric in only one cycle,
followed by a migration time of 10–15 minutes.
Alkali, which is prepared in the 2nd addition tank, will be metered, depending on the dyestuff and the dyestuff combination between 30–45 minutes, followed by a fixation time of approx. 20 minutes.
This fully automatically guided and controlled sequence at the highest process
technology level, results in a considerable shortening of the dyeing process and
excellent reproducibility.
THEN-Time saver ®
The “THEN-Time saver ®” has an effect on all the process phases downstream of
dyeing: Massive timesavings being achieved through the effective use of the unique
THEN-AIRFLOW ® “Direct Rinse” method in combination with the “Power Rinse” process. Precisely matching components are increasing these time savings even further.

The most important ones are:
The volume of pre-heated rinsing water (60 °C) per time unit can be programmed
and is matched to the need for the rapid washing off of chemicals and hydrolysed
dyestuff. Observation takes place via a through fl ow measurement device, which
ensures that optimum rinsing is achieved. An optional hot water tank ensures that
sufficient rinsing water is available at the right temperature.
“Volmedos” facilitates extremely, exact dyestuff and chemical dosing via a control circuit with through flow measurement device and control valve.

THEN-DYNET ®
The intelligent THEN-DYNET ® control unit consists of a Windows ® PC with touch
screen and a main control unit (MCU).
On the one hand, in network operation, the control system can access the control
station data and, on the other hand, the complete control system can also be

operated from the control station.
Batch processing is shown in real time. Apart from the set and actual values of the
machine, defects and manual interventions by the operator are also registered.
Self cleaning filter
The self cleaning fi lter system ensures a lint-free surface and greatly reduces the
setting times between batches. As opposed to conventional fi lters, which can only
be cleaned manually, the self cleaning fi lter system continually keeps itself clean.
The lint is washed away automatically at the end of the process.


THEN-Hot drainer
The THEN-AIRFLOW ® SYNERGY allows a drain at temperatures of over 95 °C while the fabric is in motion. This is possible after pre-bleaching and dyeing and results
In time savings of 15–30 minutes. In the case of polyester fabrics, oligomers contamination can be removed efficiently.




THEN-Flexport ®
The dyeing of narrow fabrics is no problem. The “THEN-Flexport ®” is a separate
chamber with variable loading for cuffs and collars. The “THEN-Flexport ®” is controlled entirely autonomously. Both the speed via the winch and transport nozzles, as well as the quantity of injected liquor, are independently regulated on the basis of differing rope lengths and the chamber load. Consequently, these articles can also be dyed with identical shades in the same machine


Spectra dyeing
A simple modification of the THEN-AIRFLOW ® SYNERGY machine using the
SPECTRA module allows the creation of a wealth of effects, e.g. multicolour, rainbow
and batik shading. During the SPECTRA process, liquor circulation is interrupted
once the fi xing conditions have been reached. Dye application takes place rapidly
via the special SPECTRA nozzles. The designs appear to be original.








Models and technical specifications











AIRFLOW ®             50         250      500    750     1000    1500


Dimension A [mm] 4000      4300    4300   4300   4300    4300


Dimension B [mm] 3370      3580    3580   3580   3580    3580


Dimension C [mm] 4320       4800   6400   8100   9650    12500


Dimension D [mm] 4000       4550   4620    4750   4900    5250


Dimension E [mm] 4000        5150  5500   5650    6150    6350


Dimension F [mm]  5500       5700   6000   6200   6500    7300


Recent development and new model: THEN-AIRFLOW® SYNERGY G2
Ongoing further development forms a major
element in Companies corporate philosophy. Therefore, they are 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 standpoint.

INCREASE OF LOADING
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 which is equivalent to an increase of 20%.



REDUCTION OF PROCESS TIME
The SYNERGY G2 slashes the process time, which is seen as a cost-efficiency benchmark, by a record-breaking low values.
- Cotton reactive medium shade 225 min - 3¾ h
- CO/PES medium shade 327 min ~ 5½ h

SAVES ENERGY AND WATER COSTS
The SYNERGY 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: CO 1:3.3 ; PES 1:1.5

EXACTLY REPRODUCIBLE
The SYNERGY G2 furnishes unsurpassed reproducibility and “right first time” dyeing rates of up to 98%.

IMMENSE RANGE OF FABRICS
No other piece dyeing machine on the market can successfully and economically dye such a wide range of fabrics.

SYNERGY G2 represents the 2nd generation
   • with significant increase in loading
   • resulting in the highest productivity and
   • the ability to process the widest range of fabrics
   • with lowest water and energy consumption.

SYNERGY G2 - an ecological sound solution!












Writer and editor

I am Nur Mohammed From comilla,Bangladesh.I studied in Textile Engineering and very much fond of blogging; so try to write about Textile

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