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!