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Sucker, Indigo Dyeing and Sizing Machine, 2003, 1800mm Width, 8 Dyeing Boxes, 2 Sizing Boxes

Sucker, Indigo Dyeing and Sizing Machine, 2003, 1800mm Width, 8 Dyeing Boxes, 2 Sizing Boxes

Description

  1. Overview
    1. Sucker indigo dyeing and sizing machine
    2. Width 1800 mm
    3. Year 2003
    4. Frequency 60 Hz
    5. Voltage 440 VAC
    6. Control voltage 24 V DC
    7. Operating capacity 1,900,000
    8. Energy consumption 48 kWh
    9. Steam consumption 4800 lb/h
    10. Water consumption 18 m³/h
    11. Machine speed 25-35 m/min
  2. Process Description
    1. The process consists of indigo dyeing and sizing as preparation for the weaving process.
    2. The machine has 2 creels at the entry, where 16 warped cylinders are positioned in one and 14 in the other.
    3. The material passes through a desizing box to remove impurities from the raw material and previous processes, improving dyeing quality.
    4. The process continues in the washing boxes to remove traces of the desizing process.
    5. After washing, the dyeing process begins in 8 boxes (which can be lifted mechanically for easier maintenance).
    6. 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).
    7. 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.
  3. Entry And Exit Cylinders
    1. Entry and exit rollers are 1800 mm wide
    2. 1 box for desizing
    3. 8 dyeing boxes
    4. 5 washing boxes
    5. 2 sizing boxes
    6. Control system: Siemens S7400
  4. Accumulator
    1. Two independent sections, one can accumulate while the other is at rest. Each section consists of 24 grooved cylinders.
    2. Everything is operated by a hydraulic system with a pump and control valves to regulate flow, with hydraulic system cooling through water.
    3. Transmission is carried out via gears and chains, synchronized by a gear motor and control system.
  5. Box Descriptions
    1. Desizing box: 1200 L volume, foulard Ø 288 mm, 6 cylinders for material transport, submerged cylinders supported by bearings and bushings.
    2. Washing box: foulard Ø 288 mm at the exit, 3 cylinders for material transport inside the box, 4 extractor cylinders, cylinders supported by bearings and bushings, cascade-type water feed flow.
    3. Dyeing box: 1000 L volume, foulard Ø 288 mm at the exit, 6 cylinders for material transport, submerged cylinders supported by bearings and bushings, flow rate between 1-3 L/min.
    4. Sizing box: 150 L volume, auxiliary foulard Ø 212 to 240 mm, main foulard Ø 211 to 240 mm, 6 cylinders for material transport inside the box.
  6. 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: 16 Teflon-coated drums, rotary joint and drainage system, chain and gear transmission system powered by a gear motor.
    3. Head: 1 take-up cylinder Ø 253 mm nominal, width for 2200 mm, warp comb system.
    4. Hydraulic system with pump and control valves to regulate flow, cooling by water.
    5. Transmission via gears and chains, synchronized by a gear motor and control system.
    6. Indigo dosage: 50,000 L tank for storing pre-reduced indigo and feeding the dye boxes.
  7. Creels
    1. 2 creels – one with 16 warped cylinder positions and another with 14 positions.
    2. Introduction system: unwinding cylinder for feeding into the desizing box, 1 cylinder Ø 212 mm.
    3. Extraction system: 5 extractors along the machine – 3 in the pre-drying section and 2 in the drying section.
  8. Cylinders
    1. Infeed squeezer: nominal hardness 75, nominal diameter 212 mm, current diameter left 212.5 mm, center 212.5 mm, right 212.5 mm, current hardness left 70, center 70, right 70
    2. Padder 1 scouring box squeezer: nominal hardness 85, nominal diameter 243 mm, current diameter left 239.2 mm, center 239.2 mm, right 239.2 mm, current hardness left 88, center 88, right 88
    3. Padder 1 scouring box ebonite drive roller: nominal hardness 100, nominal diameter 256 mm, current diameter left 256 mm, center 256 mm, right 256 mm, current hardness left 100, center 100, right 100
    4. Padder 2 wash box 1 squeezer: nominal hardness 85, nominal diameter 243 mm, current diameter left 240.2 mm, center 240.2 mm, right 240.2 mm, current hardness left 86, center 86, right 86
    5. Padder 2 wash box 1 ebonite drive roller: nominal hardness 100, nominal diameter 256 mm, current diameter left 252.5 mm, center 252.5 mm, right 252.5 mm, current hardness left 100, center 100, right 100
    6. Padder 3 wash box 2 squeezer: nominal hardness 85, nominal diameter 243 mm, current diameter left 241 mm, center 241 mm, right 241 mm, current hardness left 87, center 87, right 87
    7. Padder 3 wash box 2 ebonite drive roller: nominal hardness 100, nominal diameter 256 mm, current diameter left 249.4 mm, center 249.4 mm, right 249.4 mm, current hardness left 100, center 100, right 100
    8. Padder 4 dye box 1 squeezer: nominal hardness 85, nominal diameter 243 mm, current diameter left 243.8 mm, center 243.8 mm, right 243.8 mm, current hardness left 85, center 85, right 85
    9. Padder 4 dye box 1 rubber drive roller: nominal hardness 85, nominal diameter 256 mm, current diameter left 249.6 mm, center 249.6 mm, right 249.6 mm, current hardness left 87, center 87, right 87
    10. Padder 5 dye box 2 squeezer: nominal hardness 85, nominal diameter 243 mm, current diameter left 236.7 mm, center 236.7 mm, right 236.7 mm, current hardness left 88, center 88, right 88
    11. Padder 5 dye box 2 rubber drive roller: nominal hardness 85, nominal diameter 256 mm, current diameter left 252 mm, center 252 mm, right 252 mm, current hardness left 88, center 88, right 88
    12. Padder 6 dye box 3 squeezer: nominal hardness 85, nominal diameter 243 mm, current diameter left 239.1 mm, center 239.1 mm, right 239.1 mm, current hardness left 88, center 88, right 88
    13. Padder 6 dye box 3 rubber drive roller: nominal hardness 85, nominal diameter 256 mm, current diameter left 251.7 mm, center 251.7 mm, right 251.7 mm, current hardness left 86, center 86, right 86
    14. Padder 7 dye box 4 squeezer: nominal hardness 85, nominal diameter 243 mm, current diameter left 245 mm, center 245 mm, right 245 mm, current hardness left 91, center 91, right 91
    15. Padder 7 dye box 4 rubber drive roller: nominal hardness 85, nominal diameter 256 mm, current diameter left 252 mm, center 252 mm, right 252 mm, current hardness left 88, center 88, right 88
    16. Padder 8 dye box 5 squeezer: nominal hardness 85, nominal diameter 243 mm, current diameter left 245.2 mm, center 245.2 mm, right 245.2 mm, current hardness left 85, center 85, right 85
    17. Padder 8 dye box 5 rubber drive roller: nominal hardness 85, nominal diameter 256 mm, current diameter left 249.6 mm, center 249.6 mm, right 249.6 mm, current hardness left 87, center 87, right 87
  9. Specifications
    1. Serial number: 12020048