Process consists of indigo dyeing and sizing as preparation for the weaving process
Box Configuration
1 box for desizing
8 dyeing boxes
5 washing boxes
2 sizing boxes
Box Descriptions
Desizing box: 1200 liter volume, foulard diameter 288 mm, 6 cylinders for material transport, submerged cylinders supported by bearings and bushings
Washing box: foulard diameter 288 mm at exit, 3 cylinders for material transport inside the box, 4 extractor cylinders, cylinders supported by bearings and bushings, cascade-type water feed flow
Dyeing box: 1000 liter volume, foulard diameter 288 mm at the exit, 6 cylinders for material transport, submerged cylinders supported by bearings and bushings, flow rate between 1 to 3 liters per minute
Sizing box: 150 liter volume, auxiliary foulard diameter 212 to 240 mm, main foulard diameter 211 to 240 mm, 6 cylinders for material transport inside the box
Pre-Drying and Drying
Pre-drying: 8 drums, rotary joint and drainage system, chain and gear transmission system powered by a gear motor
Dryer: 16 teflon-coated drums, rotary joint and drainage system, chain and gear transmission system powered by a gear motor
Head and Accumulator
Head: 1 take-up cylinder, diameter 253 mm nominal, width for 2200 mm, warp comb system
Accumulator: two independent sections, one can accumulate while the other is at rest; each section consists of 24 grooved cylinders; everything is operated by a hydraulic system with pump and control valves to regulate flow, with hydraulic system cooling through water; transmission is carried out via gears and chains, synchronized by a gear motor and control system
Indigo Dosage
50,000 liter tank for storing pre-reduced indigo and feeding the dye boxes
Creels
2 creels – one with 16 warped cylinder positions and another with 14 positions
Introduction System
Unwinding cylinder for feeding into the desizing box, 1 cylinder Ø 212 mm
Extraction System
5 extractors along the machine – 3 in the pre-drying section and 2 in the drying section
Hydraulic and Transmission
Hydraulic system with pump and control valves regulate flow, cooling by water
Transmission via gears and chains, synchronized by a gear motor and control system
Process Description
The machine has 2 creels at the entry, where 16 warped cylinders are positioned in one and 14 in the other
The material passes through a desizing box to remove impurities from the raw material and previous processes, improving dyeing quality
The process continues in the washing boxes to remove traces of the desizing process
After washing, the dyeing process begins in 8 boxes (which can be lifted mechanically for easier maintenance)
The material then goes through the pre-drying system before reaching two sizing boxes for warp sizing (roller width: 1800 mm, squeeze rollers covered with rubber)
Finally, the material passes through the dryer and the accumulation system before reaching the end of the process at the machine’s head, where the dyed and sized warp is wound onto cylinders, ready for weaving
Specifications
Year: 2003
Frequency: 60 Hz
Voltage: 440 VAC
Control voltage: 24 V DC
Operating capacity: 1,900,000
Energy consumption: 48 kWh
Steam consumption: 4800 lb/hour
Water consumption: 18 m³/hour
Machine speed: 25 to 35 meters per minute
Serial number: 12020048
Control system: Siemens S7400
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