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Optimization of parameters to improve stenter efficiency

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 melliand
March 2020
1 D 45169 F

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
open-end rotors increased (ITMF)
24 Impact of draw frame process variables on
fiber orientation and sliver quality
P.B. Malakane, P.V. Kadole
26 Precision spinning machinery components
(A.T.E. Enterprises)
44 Easy to iron 100 % viscose woven fabric
A. Chakrabarti, S. Bhaumik, A. Darji
46 Augmented reality-based remote services for
the textile industry M. Plutz
47 New hot air welding machine
(Fischer Automation)
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
washing lines
• processes and working conditions accord-
ing to the most updated concepts of sus-
tainability and environment protection.
The machine is very flexible:
• it is possible to dye fabrics with very wide
range of weight
• it is suitable for fabric overdyeing and/or
color adjustments
• multiple-step dyeing is possible working
with low concentrations for intense and
• high concentration/high temperature dye-
ing processes are possible for exclusive re-
sults unmatchable with traditional ma-
chines.
Dyeing results
The process flexibility was one of the targets
pursued when designing Bingo.
Thanks to innovative technology and engi-
neering, all the dyeing parameters can be ad-
justed according to needs:
• color intensity
• color penetration
• dyeing bath volumes
• dipping time
• reaction/diffusion time.
All these possibilities have been tested dur-
ing several trials on the IndigoLab of Master.
Fig. 3 shows results of tests conducted with
Deinsol Pure Indugo and Diresul dyes by
Archroma and compared to Bingo with tradi-
tional dyeing technology. ■
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
Fig. 1 indicates that the difference between
efficiency before taking action and the effi-
ciency of the machine after taking action. In
this graph it is observed that the efficiency is
increased after taking action up to 3.12 %.
This is because of decreasing time required to
attend the problems mention above. In that
case, the time required to attend the prob-
lems is inversely proportional to the efficien-
cy of the stenter machine. That means if the
time required to attend the problems is de-
creased, the efficiency of the machine is in-
creased.
Fig. 2 indicates that the difference between
efficiency before taking action and efficiency
of the machine after taking action. In this
graph it can be observed that the efficiency is
increased after taking action up to 3.75 %.
This is because of the decreasing time re-
quired to attend the problems mentioned
above. In that case, the time required to at-
tend the problems is inversely proportional to
the efficiency of stenter machine, which
means if the time required to attend the
problems is decreased the efficiency of the
machine is increased.
Fig. 3 indicates that the difference between
efficiency before taking action and efficiency
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


graph it can be observed that the efficiency is
increased after taking action up to 5.00 %.
This is because of decreasing time required to
attend the problems mentioned above. In that
case the time required to attend the problems
is inversely proportional to the efficiency of
stenter machine. This means if the time re-
quired to attend the problems is decreased
the efficiency of machine is increased.
Fig. 4 indicates that the difference between
efficiency before taking action and efficiency
of machine after taking action. In this graph
it can be observed that the efficiency is in-
creased after taking action up to 6.00 %. This
is because of decreasing time required to at-
tend the problems. In that case the time re-
quired to attend the problems is inversely
proportional to the efficiency of stenter ma-
chine, which means if the time required to at-
tend the problems is decreased the efficiency
of machine is increased.
Conclusion
In this project it could be concluded that the
stenter machine has great influence on the
fabric quality. The stenter machine is the
heart of dyeing, so productivity or machine
Karl Mayer
Prodye-R rope dyeing unit
With its Prodye-S slasher dyeing unit, Karl
Mayer Textilmaschinenfabrik GmbH, Oberts-
hausen/Germany, is a leading provider in the
high-fashion denim sector. The Prodye-R for
the rope dyeing process is used in the gen-
uine/standard segment and is characterized
by a high speed during the opening of the
yarn ropes after dyeing – the so-called re-
beaming – and also with a reduced number
of the required dye boxes. The result is effi-
ciency and savings potential. This means that
significantly fewer chemicals, e.g. around
20 % less hydrogen sulfide, are required. The
re-beaming process is 15-20 % faster and the
machine requires a significantly shorter dye-
ing section.
The Prodye-R reaches color depths of up to
5.5 % with only 8-9 instead of 12 dye units.
Thanks to the fluted rollers in the sky oxida-
tion, the indigo dyestuff is extremely firmly
physically bonded, and the color shade is
bright. Due to the shorter dye section, it is
possible to reduce the total volume of the in-
digo dye bath by more than 25 % and also to
reduce the energy consumption. This is
based on targeted technical optimizations re-
garding the feeding of the dye liquor and the
rope guiding through the bath. Through the
View publication stats
utilization of the stenter needs to be im-
proved. By conducting a number of different
trials it could be concluded that:
- the stenter machine indicates the actual
production,
- the main causes of efficiency loss of the
stenter machine is program change, tem-
perature variation, maintenance, mangle
cleaning and others (e.g. shift changing,
power off, break-down),
- by using process control and standard pa-
rameter settings of the machine and the
machine condition by standard norms,
there could be control over the efficiency
loss of stenter machine,
- it was observed that the efficiency is in-
creased after taking action up to 6.00 %.
This is because of decreasing time required
to attend the problems mentioned. ■ [8]
References
[1] Santos, R.M.; Parra Llanos, J.W.; Quadri,
M.B.; da Rocha, I.C.C.: Study of Drying and
Consumption of Natural Gas in a Textile
Stenter of Direct Heating, Drying Technology
33 (2015) 37-54
[2] Laurie, K.S.: Stenter drying and heat treat-
ment of fabric, Journal of the Textile Insti-
tute Proceedings 51 (1960) 9, 562-565
special recirculation of the dye liquor, less
chemicals such as caustic soda are required
and by means of the special Eco wash box
design it is possible to reduce water con-
sumption by about 30 %.
The possible time saving of the re-beaming
process of the Prodye-R compared to similar
conventional plants is 15-20 %, which can be
used for reducing the required number of
Long Chain Beamers. Important prerequisites,
however, are technical solutions that ensure
a homogeneous buildup of the ropes during
their passage through the machine. Ropes
consisting of threads that considerably stick
together can only be separated slowly after
dyeing. Otherwise, yarn breakages occur
which have to be repaired by knotting, result-
ing in inferior quality and efficiency losses dur-
ing weaving. Special attention is already paid
to a uniform rope structure during the feeding
Ball Warper
(Karl Mayer)
Textile Finishing
[3] Sousa, L.H.C.D.; Motta Lima, O.C.; Pereira,
N.: Analysis of Drying Kinetics and Moisture
Distribution in Convective Textile Fabric Dry-
ing, Drying Technology 24 (2006) 485-497
[4] Dhobi, S.; Shinde, T.; Raichurkar, P.; Sidh-
puriya, R.: To Study the Effect of Alkali Con-
centrations on E-Control Dyeing, Colourage
(5/2018) 35-42
[5] Yang, H.; Yang, C.Q.: Durable flame retar-
dant finishing of the nylon/cotton blend fab-
ric using a hydroxyl-functional organophos-
phorus oligomer, Polymer Degradation and
Stability 88 (2005) 363-370
[6] Hasan, K.F., et al.: Dynamic Mechanical Be-
havior & Analysis of the Jute-Glass Fiber Re-
inforced Polyester Hybrid Composites, Amer-
ican Journal of Applied Physics (2016) 1-12
[7] Hasan, K.F.: Influence of Naturally Originated
Jute on the Fabrication & Mechanical Proper-
ties of Jute/Polyester Hybrid Composite,
American Journal of Polymer Science & Engi-
neering (2016) 82-90
Orhan, M.; Kut, D.; Gunesoglu, C.: Improv-
ing the antibacterial activity of cotton fabrics
finished with triclosan by the use of 1, 2, 3,
4-butanetetracarboxylic acid and citric acid,
Journal of Applied Polymer Science 111
(2009) 1344-1352
[9] Wang, C., et al.: Toxicity evaluation of reac-
tive dyestuffs, auxiliaries and selected efflu-
ents in textile finishing industry to lumines-
cent bacteria Vibrio fischeri, Chemosphere
46 (2002) 339-344
of the material into the machine. The Ball
Warper draws the yarns from the bobbins,
brings the threads together to form a rope,
and winds up the rope in crosslapping to a
ball. The computer-controlled system ensures
an operation that is gentle to the material,
with a constant, smooth run. Afterwards the
ropes are removed from the balls and guided
through the dye section. During this proce-
dure, an optimal tension control by load cells
facility that is adapted to the material ensures
that the compact, uniform structure of the
ropes is not adversely affected. In the dryer
section the conventional belts have been re-
placed by motors to ensure a perfect tension
control, keeping the correct elasticity of the
yarn. At the exit of the dryer, a coiler with cir-
cular motion ensures a uniform storage/stack-
ing of the ropes in cans. Coilers with linear
bars replace the commonly used mechanical
gear coilers, offering highest flexibility instead
of long reaction time. Within a very short pe-
riod, it is possible to adjust the rope twist to
different machine speeds and rope weights.
The result is yarn compound structures with-
out threads sticking together, which can be
separated at high speeds, and that can be
wound onto a warp beam. ■
melliand International 1/2020 41