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Optimization of parameters to improve stenter efficiency

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 melliand
March 2020
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International
Worldwide Textile Journal

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Contents

melliand 1 March 2020

Volume 26

International
Worldwide Textile Journal

Leader 29 Quality wise sort analysis to optimize fabric

defect detection in terry weaving
V. Mali, R. Turukmane
1 DNA analytical testing of genetically
modified cotton L. Kruse 30 New yarn monitor for warp preparation
(Karl Mayer)

Industry News
Knitting
4 Lenzing: solid results 2019 in a historically
difficult market environment 31 Circular and flat knitting machinery
shipments (ITMF)
10-16 Management
32 Effect of tucked and missed stitches on
10 Dyntex: functional textiles made of physical properties of single jersey knitted
biosynthetic yarn and biodegradable fabric cotton fabric A. Assefa, N. Govindan
11 Myant: cooperation with Osmotex
15 Rieter: order intake +7 % in 2019
16 Karl Mayer: acquisition of Stoll Textile Finishing
17 Benninger: acquisition of Lab-Pro
34 Dyeing properties of recycled polyester DTY
Lu Tingting, Ji Feng, Zhang Ruiyun et al.
37 New regulations 2020 (Oeko-Tex)
Fibers/Yarns 38 Eco-friendly technology indigo
dyeing machines (Master)
19 Scented hollow fibers (Empa)
39 Optimization of parameters to
20 Comparative analysis of comfort properties improve stenter efficiency
of polyester yarn with different cross- T.A Shinde, L.N. Patil, A. Zingabhoi
sections J. Jadeja, A. Karande, V. Shivankar
41 Prodye-R rope dyeing unit (Karl Mayer)
22 World market trends for draw-texturing
machinery (ITMF) 42 Primer for digital pigment printing
K. Gewald, H. Haas, L.-M. Rudek

Spinning Textile Industry

23 Shipments of short-staple spindles and 44 Easy to iron 100 % viscose woven fabric
open-end rotors increased (ITMF) A. Chakrabarti, S. Bhaumik, A. Darji
24 Impact of draw frame process variables on 46 Augmented reality-based remote services for
fiber orientation and sliver quality the textile industry M. Plutz
P.B. Malakane, P.V. Kadole
47 New hot air welding machine
26 Precision spinning machinery components (Fischer Automation)
(A.T.E. Enterprises)
48 Visual inspection of fabrics – comparison of
alternatives (sentin)

Weaving 3 Calendar

28 Shuttle-less weaving machines show Inner back cover Advertisers Index

improvement of 39 % (ITMF) Inner back cover Company Index/Imprint

2 melliand International 1/2020

 Textile Finishing

effluents high fastness color • fixation degree

• easy integration with existing continuous • high concentration/high temperature dye- • color penetration
washing lines ing processes are possible for exclusive re- • dyeing bath volumes
• processes and working conditions accord- sults unmatchable with traditional ma- • dipping time
ing to the most updated concepts of sus- chines. • reaction/diffusion time.
tainability and environment protection. All these possibilities have been tested dur-
The machine is very flexible: Dyeing results ing several trials on the IndigoLab of Master.
• it is possible to dye fabrics with very wide The process flexibility was one of the targets Fig. 3 shows results of tests conducted with
range of weight pursued when designing Bingo. Deinsol Pure Indugo and Diresul dyes by
• it is suitable for fabric overdyeing and/or Thanks to innovative technology and engi- Archroma and compared to Bingo with tradi-
color adjustments neering, all the dyeing parameters can be ad- tional dyeing technology. ■
• multiple-step dyeing is possible working justed according to needs:
with low concentrations for intense and • color intensity Denisol, Diresul = registered trademarks

Optimization of parameters to improve

stenter efficiency
A study has been attempted to deal with efficiency losses of stenters used Material and Method
in the textile dyeing industry. Stenters are the heart of chemical processing
Material
and they indicate actual production of dyeing industry and stenters control 1. Polyester fabric
the fabric width, weight, spirality, shrinkage, curing and moisture content of 2. Elastane fabric
fabric. This is why the stenter machine plays very important role in the dye- 3. Viscose fabric
ing unit. It is therefore necessary to control the efficiency losses of stenters.
Method
In this project it was observed that there are many causes behind the effi- 1. Continuous process: pad-dry-cure method
ciency losses of stenters, such as program change, temperature variation, 2. Padding pressure: 2.5-3.5 kg
maintenance, mangle cleaning and others (e.g. shift changing, power off, 3. Polyester heat setting temperature: 170-
210 °C
break-down). It is a challenging activity for any textile technologist to gain
control over the causes by taking some decisions and applying them to in- Procedure
crease the efficiency of stenters. Here, a detailed study is made of the effi- 1. Firstly select the particular batch for trial
ciency losses and what kind of remedial action can be taken on the machine i.e. batch No. 306013.
2. The fabric weight up to 157 kg, length
to increase the productivity of the stenter machine when considering quality
1,958 m and width 122 cm.
of delivered material. 3. This fabric was loaded on the machine
then put in the washing chamber. This
Tushar A. Shinde, Leena N. Patil, stenter machines. The purpose of the stenter process continues up to 10 min at the
Ajay Zingabhoi machine is to bring the length and width to temperature of 110 °C.
SVKMS, NMIMS, Mukesh Patel School of pre-determined dimensions and also for heat 4. After washing, the fabric was removed
Technology, Shirpur/India
setting, and it is used for applying finishing from the machine for cooling purposes.
chemicals; shade variation is also adjusted. Thereafter, the washed fabric passed to
The stenter is the textile fabric finishing ma- The main function of the stenter is to stretch the next process which is chemical dos-
chine which dries, shrinks and adjusts the pa- the fabric widthwise and to recover the uni- ing.
rameters of open width fabric, and is also use form width. This process uses chemicals like 1) Nato-
for the chemical finishing of fabric. The sten- Stenters are widely used for stretching, dry- lube JD and 2) Seragal PLP.
ter is used to open form fabric; after passing ing, heat-setting and finishing of fabrics. The 5. Then the fabric went to the next process
the open compactor the fabric enters into stenter frame is usually 80-100 feet (approx. which was a dye dosing; in this process
the stenter. Stenter machines are power 24-30 m) long and 70-100 inches (approx. fabric is treated with a solution of Disp-
savers known for their reliability, efficiency 1.8-2.5 m) wide. The speed ranges from 10- EXH, Dianix Orange Plus and Coralene Yel-
and high level of output. Overfeed is digitally 45 m/min with a maximum setting time in low SR at the pH of 7. After dyeing the
controlled, and there is minimum heat loss to the setting zone 30 sec at temperature rang- fabric passes for the cooling process. In
the atmosphere. But some factors/problems ing from 175 to 250 °C depending upon the this way the samples for the trial taken in
are responsible for the loss of efficiency of thickness and type of the material. the stenter machine were prepared.

melliand International 1/2020 39

Textile Finishing

Result and discussion cy of the stenter machine. That means if the quired to attend the problems mentioned
Fig. 1 indicates that the difference between time required to attend the problems is de- above. In that case, the time required to at-
efficiency before taking action and the effi- creased, the efficiency of the machine is in- tend the problems is inversely proportional to
ciency of the machine after taking action. In creased. the efficiency of stenter machine, which
this graph it is observed that the efficiency is Fig. 2 indicates that the difference between means if the time required to attend the
increased after taking action up to 3.12 %. efficiency before taking action and efficiency problems is decreased the efficiency of the
This is because of decreasing time required to of the machine after taking action. In this machine is increased.
attend the problems mention above. In that graph it can be observed that the efficiency is Fig. 3 indicates that the difference between
case, the time required to attend the prob- increased after taking action up to 3.75 %. efficiency before taking action and efficiency
lems is inversely proportional to the efficien- This is because of the decreasing time re- of the machine after taking action. In this

Table 1 Fig. 1
Identifying problem and parameters Identifying problem, parameters and action taken

Sr. No. Problems Before [min.] After [min.] Difference

1 Program change 15 12 3
2 Temperature variation 10 8 2
3 Maintenance 10 7 3
4 Mangle cleaning 15 10 5
5 Other 5 3 2
6 Efficiency 11.4583 8.333 3.125

Table 2 Fig. 2
Corrective actions of problems Corrective actions of problems

Sr. No. Problems Before [min] After [min] Difference

1 Program Change 20 15 5
2 Temperature Variation 15 12 3
3 Trolley Change 13 8 5
4 Mangle Cleaning 12 9 3
5 Other 4 2 2
6 Efficiency 13.33 9.5833 3.75

Table 3 Fig. 3
Corrective actions of problems Corrective actions of problems

Sr. No. Problems Before After Difference

1 Program change 20 14 6
2 Temperature variation 18 13 5
3 Maintenance 10 5 5
4 Mangle cleaning 15 10 5
5 Other 6 3 3
6 Efficiency 14.375 9.375 5

Table 4 Fig. 4
Corrective actions of problems before and after Corrective actions of problems before and after

Sr. No. Problems Before After Difference

1 Program change 45 35 10
2 Temperature variation 50 38 12
3 Mangle cleaning 20 15 5
4 Mangle cleaning 20 15 5
5 Shift change 15 10 5
6 Other 15 9 6

40 melliand International 1/2020

 Textile Finishing

graph it can be observed that the efficiency is utilization of the stenter needs to be im- [3] Sousa, L.H.C.D.; Motta Lima, O.C.; Pereira,
increased after taking action up to 5.00 %. proved. By conducting a number of different N.: Analysis of Drying Kinetics and Moisture
Distribution in Convective Textile Fabric Dry-
This is because of decreasing time required to trials it could be concluded that: ing, Drying Technology 24 (2006) 485-497
attend the problems mentioned above. In that - the stenter machine indicates the actual [4] Dhobi, S.; Shinde, T.; Raichurkar, P.; Sidh-
case the time required to attend the problems production, puriya, R.: To Study the Effect of Alkali Con-
is inversely proportional to the efficiency of - the main causes of efficiency loss of the centrations on E-Control Dyeing, Colourage
(5/2018) 35-42
stenter machine. This means if the time re- stenter machine is program change, tem-
[5] Yang, H.; Yang, C.Q.: Durable flame retar-
quired to attend the problems is decreased perature variation, maintenance, mangle dant finishing of the nylon/cotton blend fab-
the efficiency of machine is increased. cleaning and others (e.g. shift changing, ric using a hydroxyl-functional organophos-
Fig. 4 indicates that the difference between power off, break-down), phorus oligomer, Polymer Degradation and
Stability 88 (2005) 363-370
efficiency before taking action and efficiency - by using process control and standard pa-
of machine after taking action. In this graph rameter settings of the machine and the [6] Hasan, K.F., et al.: Dynamic Mechanical Be-
havior & Analysis of the Jute-Glass Fiber Re-
it can be observed that the efficiency is in- machine condition by standard norms, inforced Polyester Hybrid Composites, Amer-
creased after taking action up to 6.00 %. This there could be control over the efficiency ican Journal of Applied Physics (2016) 1-12
is because of decreasing time required to at- loss of stenter machine, [7] Hasan, K.F.: Influence of Naturally Originated
tend the problems. In that case the time re- - it was observed that the efficiency is in- Jute on the Fabrication & Mechanical Proper-
ties of Jute/Polyester Hybrid Composite,
quired to attend the problems is inversely creased after taking action up to 6.00 %. American Journal of Polymer Science & Engi-
proportional to the efficiency of stenter ma- This is because of decreasing time required neering (2016) 82-90
chine, which means if the time required to at- to attend the problems mentioned. ■ [8] Orhan, M.; Kut, D.; Gunesoglu, C.: Improv-
tend the problems is decreased the efficiency ing the antibacterial activity of cotton fabrics
of machine is increased. References finished with triclosan by the use of 1, 2, 3,
[1] Santos, R.M.; Parra Llanos, J.W.; Quadri, 4-butanetetracarboxylic acid and citric acid,
M.B.; da Rocha, I.C.C.: Study of Drying and Journal of Applied Polymer Science 111
Conclusion Consumption of Natural Gas in a Textile (2009) 1344-1352
In this project it could be concluded that the Stenter of Direct Heating, Drying Technology [9] Wang, C., et al.: Toxicity evaluation of reac-
33 (2015) 37-54 tive dyestuffs, auxiliaries and selected efflu-
stenter machine has great influence on the
[2] Laurie, K.S.: Stenter drying and heat treat- ents in textile finishing industry to lumines-
fabric quality. The stenter machine is the ment of fabric, Journal of the Textile Insti- cent bacteria Vibrio fischeri, Chemosphere
heart of dyeing, so productivity or machine tute Proceedings 51 (1960) 9, 562-565 46 (2002) 339-344

Karl Mayer
Prodye-R rope dyeing unit
With its Prodye-S slasher dyeing unit, Karl special recirculation of the dye liquor, less of the material into the machine. The Ball
Mayer Textilmaschinenfabrik GmbH, Oberts- chemicals such as caustic soda are required Warper draws the yarns from the bobbins,
hausen/Germany, is a leading provider in the and by means of the special Eco wash box brings the threads together to form a rope,
high-fashion denim sector. The Prodye-R for design it is possible to reduce water con- and winds up the rope in crosslapping to a
the rope dyeing process is used in the gen- sumption by about 30 %. ball. The computer-controlled system ensures
uine/standard segment and is characterized The possible time saving of the re-beaming an operation that is gentle to the material,
by a high speed during the opening of the process of the Prodye-R compared to similar with a constant, smooth run. Afterwards the
yarn ropes after dyeing – the so-called re- conventional plants is 15-20 %, which can be ropes are removed from the balls and guided
beaming – and also with a reduced number used for reducing the required number of through the dye section. During this proce-
of the required dye boxes. The result is effi- Long Chain Beamers. Important prerequisites, dure, an optimal tension control by load cells
ciency and savings potential. This means that however, are technical solutions that ensure facility that is adapted to the material ensures
significantly fewer chemicals, e.g. around a homogeneous buildup of the ropes during that the compact, uniform structure of the
20 % less hydrogen sulfide, are required. The their passage through the machine. Ropes ropes is not adversely affected. In the dryer
re-beaming process is 15-20 % faster and the consisting of threads that considerably stick section the conventional belts have been re-
machine requires a significantly shorter dye- together can only be separated slowly after placed by motors to ensure a perfect tension
ing section. dyeing. Otherwise, yarn breakages occur control, keeping the correct elasticity of the
The Prodye-R reaches color depths of up to which have to be repaired by knotting, result- yarn. At the exit of the dryer, a coiler with cir-
5.5 % with only 8-9 instead of 12 dye units. ing in inferior quality and efficiency losses dur- cular motion ensures a uniform storage/stack-
Thanks to the fluted rollers in the sky oxida- ing weaving. Special attention is already paid ing of the ropes in cans. Coilers with linear
tion, the indigo dyestuff is extremely firmly to a uniform rope structure during the feeding bars replace the commonly used mechanical
physically bonded, and the color shade is gear coilers, offering highest flexibility instead
bright. Due to the shorter dye section, it is of long reaction time. Within a very short pe-
Ball Warper
possible to reduce the total volume of the in- (Karl Mayer) riod, it is possible to adjust the rope twist to
digo dye bath by more than 25 % and also to different machine speeds and rope weights.
reduce the energy consumption. This is The result is yarn compound structures with-
based on targeted technical optimizations re- out threads sticking together, which can be
garding the feeding of the dye liquor and the separated at high speeds, and that can be
rope guiding through the bath. Through the wound onto a warp beam. ■

melliand International 1/2020 41

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