Fabric Science

AIR INSTEAD OF WATER

• Airflow was the key element of the technology, as air is an ideal transport medium. The
replacement of dye liquor with air as a method of transporting piece goods in jet-dyeing machines
was a big step toward reducing water and chemicals consumption. Compared to the jet system in which
the nozzles are filled with liquor, nozzle pressure is negligible, thus offering optimum protection
of sensitive textile surfaces. At the same time, the use of the mass flow principle provides a
major improvement in fabric hank laying, thus preventing creasing.
• The moisture-saturated airflow ensures the uniform distribution of temperature on the fabric
and in the machine, constituting a prerequisite for even and reproducible dyeing. Moreover, the low
level of liquor in the dyeing boiler means the fabric is lighter than in conventional machinery and
can therefore be accelerated quickly to high speeds. Thus, the risk of draft or strain is minimal,
which is particularly advantageous with regard to the finishing of items containing elastane
fibers.
• The high transportation speeds of the fabric result in very short fabric turn time. High
heating-up gradients are possible because a very low liquor ratio is maintained. The unique ability
to use a hot drain system and rinsing with fresh water in a running wash system considerably
reduces the time required for the dyeing process.
The Airflow technology represents the combined result of the entire
range of possibilities provided by the technology. Through the
interplay of all technical possibilities and functions, economic and
ecological advantages over the traditional dyeing technology are
achieved. The main advantages are as follows:

• unlimited flexibility with regard to all fiber – except pure wool – and
fabric weight classes
between 30 and 800 grams per square meter, as well as all standard
market dyestuffs;
• the lowest liquor ratio on the market: approximately 1:2 for man-
made fibers and 1:3 to 1:4 for
natural fibers, depending on the article and structure;
• energy savings of up to 40 percent, thanks to a frequency converter,
and the use of air as a
transport medium, while all other systems need water;
• a reduction in the overall process time of approximately 25 percent;
and
• lowest water/wastewater levels.
LOTUS 200 DYEING MACHINE
The long tube design, superior fabric displacement and gentle
polytetrafluoroethylene rods
contribute to the success of smooth treatment meeting high quality
demand for Then Maschinen’s
newly developed Airflow® Lotus 200 dyeing machine.
 The New L-shape Airflow
• However, the Airflow dyeing machine had one disadvantage: dyeing
of extremely delicate fabrics didn’t give a perfect result. Current
and future trends pointing toward more and more lightweight
fabrics with high contents of elastane in finest yarn counts and
gauges prompted the
next stage of Airflow machinery design.
• To meet the required voluminous hand as well as top-grade quality
standards, the world’s first long-tube Airflow machine, the Airflow
Lotus 200, was developed. The new dyeing machine incorporates
the latest advances in Airflow technology and operates according to
the original aerodynamic principle. The dye liquor passes the self-
cleaning filter and is then evenly applied and finely distributed as a
mist with the aid of the blower, assuring outstanding penetration,
according to Then.
 Handling Delicate Fabrics
• The Airflow Lotus 200 is said to be especially suitable for the wet finishing of delicate
cellulose- and man-made-fiber knitwear and woven fabrics with a high percentage of
elastane. Such fabrics are used in the automotive, lingerie, sports-, leisure- and swimwear
segments. Close attention has also been paid to the achievement of significant savings of
precious water and energy resources — similar to the Airflow Synergy dyeing machine.
• Extremely safe and gentle product running and outstanding displacement comprise Airflow
Lotus 200’s characteristics. With its concept in machine design, unmatched results in process
technology and unparalleled achievements regarding economy and ecology, the new
machine will substantially extend the field for aerodynamic applications, Then reports.
• The newly designed dome blower ensures that the fabric is transported just by air. This
means the liquor actually is used to do what it is meant to do: dyeing only. The liquor ratio is
reduced to between 1:2 and 1:5 and provides savings in terms of water and water treatment,
chemical, and energy costs. This will bring up to 80-percent savings of liquor compared with
costs associated with outdated hydraulic machines, as well as significant savings of time.
Shortest cycle times and loadings of up to 1,200 meters for lightweight fabrics and up to 200
kilograms for average articles allow high daily production rates.
SCHEMATIC DIAGRAM OF AIRFLOW TECHNOLOGY
Air is the key element, and is said to be the
ideal medium to transport piece goods in dyeing machines.
 Polyamide Dyeing
• Most of the fabrics for lingerie, swimwear and automotive
applications are made of polyamide.
• That’s why the new L-shape dyeing machine handles fabrics made
of 100-percent polyamide with the same results as previously
mentioned fabrics.
• Roland Adrion, senior sales manager, says that
“current and future trends point towards more and more
lightweight fabrics with high contents of elastane in finest yarn
counts and gauges.
• Meeting the [voluminous hand specifications] as well as
top-grade quality standards were there when we developed the
world’s first long tube Airflow machine, the Airflow Lotus.” Perhaps
a more appropriate name for the new machine would have been
“Longflow.”
ADVANCEMENT IN PRINTING
 Direct to garment digital printing
(DTG)
• This is process in which a special inkjet printer with special ink is
used to print directly on fabric from the computer directly.The
artwork and the dye is heat set with a heat press or tunnel dryer.
• The advantage of direct to garment digital printing is that you can
make any number of prints, even small lots at low cost and you get
realistic looking pictures printed on to the fabric .
• The disadvantage is that the effect may wear off with repeated
washes. It is also best when used on lighter colored fabric with
darker ink colors. There are also some fabrics which are not suited
for this printing. Another disadvantage is that as quantity increases
cost increases exponentially
• But the fast and easy application and versatility make this a
favourite method of printing especially for making samples
DTG MACHINE
The industrial class DTG M2 is the culmination of 10 years of R&D and garment
printer development, it delivers the industries most advanced, user friendly
and precise print platform specifically designed for textile applications
 Sublimation transfer printing
• This method involves a sublimation dye which is transferred to the
fabric with heat.You need inkjet or colour laser printer, sublimation
ink and a heat press machine for this printing technique
• This method is definitely costlier than the thermal transfer method
as the ink is very costly. But the resultant prints are very vivid and
attractive
• A major disadvantage of this method is that it is not possible to
print onto cotton fabrics ( the best fabrics are synthetic or
100% polyester) and if you want to use this method for printing
onto cotton fabric you will have to apply an appropriate coating on
cotton fabric surface .
• Though sublimation printing is supposed to be very durable and
lasts a long long time it may wear off with exposure to direct
sunlight.
SUBLIMATION PRINTING MACHINE

1.8M Epson DX5 Head Sublimation Printing Machine For Fabric

/ Textile Printing