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Benninger, Indigo Dyeing and Sizing Machine, 2007, 2000mm Width, 7 Dyeing Boxes, 2 Sizing Boxes

Benninger, Indigo Dyeing and Sizing Machine, 2007, 2000mm Width, 7 Dyeing Boxes, 2 Sizing Boxes

Description

  1. Overview
    1. Indigo dyeing machine
    2. Width 2000 mm
    3. Year 2007
    4. The process consists of indigo dyeing and sizing as preparation for the weaving process.
    5. The machine has 2 creels at the entry, where 16 warped cylinders are positioned in each.
    6. The material passes through a desizing box to remove impurities from the raw material and previous processes, improving dyeing quality.
    7. The process continues in the washing boxes to remove traces of the desizing process.
    8. After washing, the dyeing process begins in 7 boxes.
    9. 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).
    10. 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.
  2. Specifications
    1. Year: 2007
    2. Frequency: 60 Hz
    3. Voltage: 440 VAC
    4. Control voltage: 24 V DC
    5. Operating capacity: 2,000,000
    6. Energy consumption: 48 kWh
    7. Steam consumption: 4800 lb/h
    8. Water consumption: 12 m³/h
    9. Machine speed: 25-35 m/min
    10. Serial number: 2501850
  3. Entry And Exit Cylinders
    1. Entry and exit rollers are 2000 mm wide
    2. 1 box for desizing
    3. 7 dyeing boxes
    4. 6 washing boxes
    5. 2 sizing boxes
    6. Control system: Siemens S7300/S7200
    7. English translation
    8. Accumulator: two independent sections, one can accumulate while the other is at rest. Each section consists of 20 grooved cylinders.
    9. Everything is operated by a hydraulic system with a pump and control valves to regulate flow, with hydraulic system cooling through water.
    10. Transmission is carried out via gears and chains, synchronized by a gear motor and control system.
  4. Box Descriptions
    1. 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.
    2. 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.
    3. 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.
    4. 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.
  5. Pre-Drying And Drying
    1. Pre-drying: 8 drums, rotary joint and drainage system, chain and gear transmission system powered by a gear motor.
    2. Dryer: 14 Teflon-coated drums, rotary joint and drainage system, chain and gear transmission system powered by a gear motor.
  6. Head
    1. 1 take-up cylinder Ø 240 mm nominal, width for 2200 mm, warp comb system.
    2. Hydraulic system with pump and control valves to regulate flow, cooling by water.
    3. Transmission via gears and chains, synchronized by a gear motor and control system.
    4. Indigo dosage: 50,000 L tank for storing pre-reduced indigo and feeding the dye boxes.
    5. Creels: 2 creels, each with 16 warped cylinder positions.
    6. Extraction system: 10 extractors along the machine, with the last three located in the pre-drying and drying zones.
  7. Cylinders
    1. Infeed squeezer: nominal hardness 85, nominal diameter 200 mm, current diameter left 198.8 mm, center 198.8 mm, right 198.8 mm, current hardness left 80, center 80, right 80.
    2. Padder 1 scouring box D100 squeezer: nominal hardness 85, nominal diameter 288 mm, current diameter left 284 mm, center 284.2 mm, right 284 mm, current hardness left 82, center 82, right 82.
    3. Padder 1 scouring box D100 metallic drive: nominal hardness 100, nominal diameter 258 mm, current diameter left 258 mm, center 258 mm, right 258 mm, current hardness metallic.
    4. Padder 2 washing box 1 D200 squeezer: nominal hardness 85, nominal diameter 288 mm, current diameter left 288.8 mm, center 288.8 mm, right 288.8 mm, current hardness left 90, center 90, right 90.
    5. Padder 2 washing box 1 D200 ebonite drive: nominal hardness 100, nominal diameter 260 mm, current diameter left 259.9 mm, center 259.9 mm, right 259.9 mm, current hardness left 100, center 100, right 100.
    6. Padder 3 washing box 2 D220 squeezer: nominal hardness 85, nominal diameter 288 mm, current diameter left 285 mm, center 285 mm, right 285 mm, current hardness left 91, center 91, right 91.
    7. Padder 3 washing box 2 D220 ebonite drive: nominal hardness 100, nominal diameter 260 mm, current diameter left 259.8 mm, center 259.9 mm, right 259.8 mm, current hardness left 100, center 100, right 100.
    8. Padder 4 washing box 3 D240 squeezer: nominal hardness 85, nominal diameter 288 mm, current diameter left 286 mm, center 286 mm, right 286 mm, current hardness left 87, center 87, right 87.
    9. Padder 4 washing box 3 D240 ebonite drive: nominal hardness 100, nominal diameter 260 mm, current diameter left 258 mm, center 258 mm, right 258 mm, current hardness metallic.
    10. Padder 5 color box 1 D400 squeezer: nominal hardness 85, nominal diameter 288 mm, current diameter left 287.3 mm, center 287.3 mm, right 287.3 mm, current hardness left 70, center 70, right 70.
    11. Padder 5 color box 1 D400 metallic drive: nominal hardness 100, nominal diameter 258 mm, current diameter left 258 mm, center 258 mm, right 258 mm, current hardness metallic.
    12. Padder 6 color box 2 D420 squeezer: nominal hardness 85, nominal diameter 288 mm, current diameter left 286.8 mm, center 286.8 mm, right 286.8 mm, current hardness left 60, center 60, right 60.
    13. Padder 6 color box 2 D420 metallic drive: nominal hardness 100, nominal diameter 258 mm, current diameter left 258 mm, center 258 mm, right 258 mm, current hardness metallic.
    14. Padder 7 color box 3 D440 squeezer: nominal hardness 85, nominal diameter 288 mm, current diameter left 288.9 mm, center 288.9 mm, right 288.9 mm, current hardness left 67, center 67, right 67.
    15. Padder 7 color box 3 D440 metallic drive: nominal hardness 100, nominal diameter 258 mm, current diameter left 258 mm, center 258 mm, right 258 mm, current hardness metallic.
    16. Padder 8 color box 4 D460 squeezer: nominal hardness 85, nominal diameter 288 mm, current diameter left 288.9 mm, center 288.9 mm, right 288.9 mm, current hardness left 95, center 95, right 95.
    17. Padder 8 color box 4 D460 metallic drive: nominal hardness 100, nominal diameter 258 mm, current diameter left 258 mm, center 258 mm, right 258 mm, current hardness metallic.