Indigo dyeing and sizing machine - 14 boxes (dye and wash)
2 sizing boxes
25 to 35 m/min (82 to 115 ft/min)
2000 mm (78.7) width
Plate diameter: 1400 mm (55.1)
Cylinder diameter: 456 mm (17.95)
Frequency: 60 Hz
Voltage: 440 VAC
Control voltage: 24 V DC
Operating capacity: 2,000,000
Energy consumption: 48 kWh
Steam consumption: 4800 lb/h
Water consumption: 12 m³/h
Machine speed: 25-35 m/min
Machine Sections
Entry scray
Wash box 1, 2, 3
Oxidation zone
Dyeing boxes 1-7
Vaporizer
Wash box 1, 2, 3, sizing A & B
Drum dryer, exit
1 box for desizing
7 dyeing boxes
6 washing boxes
2 sizing boxes
Control System
Siemens S7300/S7200 English translation
Accumulator
Two independent sections, one can accumulate while the other is at rest
Each section consists of 20 grooved cylinders
Everything is operated by a hydraulic system with a 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
Box Descriptions
Desizing box: 880 L volume, foulard Ø 288 mm, 8 steel cylinders for material transport inside the box, submerged cylinders supported by bearings with seals
Washing box: 7 mL/kg consumption, foulard Ø 288 mm at the exit, 4 steel cylinders for material transport, submerged cylinders supported by bearings with seals, 4 extractor cylinders, 880 L volume
Dyeing box: 600 L volume, foulard Ø 288 mm at the exit, 9 steel cylinders for material transport, submerged cylinders supported by bearings with seals
Sizing box: 120 L volume, auxiliary foulard Ø 200 mm, main foulard Ø 225-200 mm, 5 immersion 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: 14 Teflon-coated drums, rotary joint and drainage system, chain and gear transmission system powered by a gear motor
Head
1 take-up cylinder Ø 240 mm nominal, width for 2200 mm, warp comb system
Hydraulic system with pump and control valves to regulate flow, cooling by water
Transmission via gears and chains, synchronized by a gear motor and control system
Indigo Dosage
50,000 L tank for storing pre-reduced indigo and feeding the dye boxes
Creels
2 creels, each with 16 warped cylinder positions
Extraction System
10 extractors along the machine, with the last three located in the pre-drying and drying zones
General Description
The process consists of indigo dyeing and sizing as preparation for the weaving process
The machine has 2 creels at the entry, where 16 warped cylinders are positioned in each
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 7 boxes
The process continues through the pre-drying zone before reaching two sizing boxes for warp sizing (roller width: 2000 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
