Page 45 - May-June-2018

44 From delicate knits to 45 “There has been wariness about handling organic at very specific temperatures in order not to destroy
Success Story: Increase in solvents, but in the end, they’re not as difficult to their efficacy. now eclipsing the cost of paying people to operate

them,” says Mr Vohsdahl. “The ability of the Eco
coat on textile substrates as they are on plastic films
Production by Converting to the heavy duty membranes where they’re already widely used,” says Mr Hanel. Other materials, such as PTFE-coated filter Applicator to significantly reduce energy costs is the
key reason for its rapid acceptance on the market.
materials are also applied and then cured at
“And they offer a lot of possibilities for companies to
The unit itself does not actually save the energy, but
explore and develop entirely new products –
separate temperatures.
Card C 70 especially in fields such as medical Stretching by applying only the precise amount of functional
finish, ensures the subsequent drying time is shorter
and filtration.”
Another key feature of the technical textiles line at
– in some cases dramatically so.”
The ATC allows our customers to test their own textiles and technical
fabrics on Monforts dyeing and finishing machines under fully confi- Every single component within the chamber has to the ATC is the special stretching device which is
Rieter customer Honghai Hangzhou Textile Co., Ltd. test various parts with new technologies. One of dential, real production conditions. Using the results from these meet the standards of the European Union’s ATEX capable of pulling ten tons in length and ten tons in Compared with a padder system, where the initial
is aiming to become China’s largest manufacturer these parts was an aero-dynamically optimized trials, we are also able to make recommendations for improving directives for working in an explosive atmosphere. A width – a huge amount per square metre of fabric moisture content of the fabric entering the stenter is
on the market for air-jet-spun yarn. Despite profile, or “tongue”, that influences the transition of many fabric finishes. range of sensors linked to alarms operate at various and necessary in the production of materials such 60%, with the Eco Applicator it is reduced to 40%
increased energy and personnel costs, the the fibers from the card cylinder to the doffer. During levels within the chamber to ensure the specified as woven or 3D knits for high temperature filter and the system also has the shortest fabric path
company’s goal is to market a yarn offering a high the trial period, the company then ran two cards with Klaus Heinrichs lower explosion limit (LOL) is never exceeded and media. from the coating unit into the stenter.
level of quality and consistency. a high level of success, achieving a production rate Vice-President of Sales and Marketing, Monforts the ventilation adapts accordingly.
of 160 kg/h each while maintaining the sliver quality. Three weft straighteners – each with different key The Eco Applicator’s versatility also allows mills to
Honghai Hangzhou Textile Co., Ltd. is a fully invested Consequently, Honghai decided to upgrade its Advanced functions strengths – have been installed by Monforts ATC apply finishes to just one side of the fabric, or both,
subsidiary of the Hongfeng Textile Group, located in remaining 68 cards with the recommended partners Erhardt and Leimer, Mahlo and Pleva. the fabric edges prior to entering the stenter. and even to apply separate finishes to each side, or
Hangzhou, China. The company has invested in a technology parts. Since its opening in 2013, the €2.5 million Monforts digitally-printed soft signage to carbon fabrics for to specific areas of a fabric, for endless possibilities,
full system of semi-automated rotor-spinning Advanced Technology Centre (ATC) has proved an today’s high-performance composites, and from “This line has been engineered to provide the For conventional woven and knitted fabrics, the whether treating wovens, denim or delicate knits.
machinery from Rieter, producing an annual output The Benefits for Honghai: Developing Its invaluable resource to customers for achieving new filter media which must perform in extreme ultimate in precision coating finishing, in order to Monforts Eco Applicator has been highly
of 50 000 tons of Ne 10 and Ne 30 viscose yarn. The Market Position standards in fabric finishing. temperatures to flame retardant barrier fabrics. achieve the standards required by the medical successful since its introduction in 2011, both The next level
yarns are well-known and demand for them is high. Production at the spinning mill increased by 40% to companies, and also the quality standards in place integrated into new finishing lines and retro-fitted to “The ATC draws on all of the know-how of our
The yarns are sold in the Zhejiang, Fujian and 100% and the profitability of Honghai rose Over an area of 1,200 square metres, the Monforts “Then there are the heavy duty membranes which for aerospace and automotive grade materials,” existing ones. company in respect of fabric processing,”
Guangdong regions in China and are also exported substantially. The investment in the new technology ATC at the company’s headquarters in are employed in the collection and storage of said Mr Heinrichs. “We are always happy to discuss concludes Klaus Heinrichs. “Whatever your
to international markets (Brazil, Turkey, etc.). parts for all cards paid off in a short period of time. Mönchengladbach, Germany, houses two full methane in biogas plants, as well as materials existing possibilities and the development of new “In many textile mills globally, the cost of running company’s specialism, we have the technologies
The company was able to quickly adjust to meet the finishing lines, engineered to accommodate an equipped with sensors and electrical conductors concepts too.” integrated manufacturing lines – especially those for and the process knowledge to help you take your
The Challenge: Increasing the Production of market demands for viscose yarn and expand its extremely diverse range of processes, in addition to which are now used as base liners in DSC solar fabric finishing that can involve numerous business to the next level.”
Viscose Yarn position on the market. a Thermex range for the continuous dyeing of denim cells, to name just a few examples. Special features on the finishing line relate to further Knitwear sequences of heating and subsequent drying – is
In 2016, Honghai faced a very high demand for and other woven fabrics, a full colour kitchen and a advanced functions – the ability to treat materials The second production line at the ATC has been
viscose yarn. The C 70 card machines from Rieter, The Customer’s Statement number of lab-scale systems for smaller batch trials. “These very different materials, however, have one not only at temperatures of up to 320°C, but also to engineered with the state-of-the art production of
which already deliver a high level of performance, “The technological innovations made with the C 70 thing in common – they all require expert coating be able to treat the top and bottom faces of certain conventional knitwear in mind and is based around
processing 80 to 115 kg of sliver per hour, were and finishing for maximum efficiency and the materials at different temperatures within a single a Montex stenter with vertical chain return
unable to meet the demand. Rieter recommended Technical textiles technology to allow for ultimate flexibility and the pass through the machine.
enhancing the card production with new ability to switch quickly from one fabric formula to “Knitted fabrics must never be stretched and need
technological parts. It was extremely important to the the next, without compromising on the economical To achieve this, the first two chambers of the stenter to be treated in a relaxed state,” explains ATC
customer that the quality level of the sliver was use of energy or raw materials.” are fitted with special, heavy duty TwinAir ventilation manager Fred Vohsdahl. “As a consequence, the
retained, even at higher production speeds. motors and separate burners for individual 2.2 metre wide, four-chamber stenter incorporates a
Organic solvents top/bottom temperature. A temperature differential TwinAir nozzle system to ensure the relaxed fabric is
The Solution: Card C 70 of up to 60°C can be achieved between the upper kept at a suitable height in between the upper and
Upon Rieter’s recommendation, Honghai decided to and lower nozzles within the chamber. lower nozzle system, despite ‘bowing’. Exact
selvedge control with the minimum pinning in is also
There are many applications where employing two extremely important with knitted fabrics.”
The Montex stenter for technical textiles at the ATC separate temperature treatments is beneficial, such
A highly-controlled and contained environment was as floorcoverings – where the textile face fabric is Eco Applicator
a key consideration when constructing the special treated at one temperature and the rubber backing The line is also equipped with the company’s Eco
Mr. Xinfeng Cui, Mill Manager, Honghai Hangzhou Textile Co., line for technical textiles at the ATC. at another – as well as PVC flooring employing Applicator system which eliminates the need for a
make us more profitable. Production has increased “Technical textiles are extremely diverse in their chemical foams or for materials like black-out roller conventional wet-on-wet padder, instead employing
substantially although the costs for the conversions end-use applications and manufacturers can be Training session using the automated Monforts Qualitex visualization system blinds with heavy backings. trough and roller techniques to precisely apply the
were very low. As a result, we have bought more sets called upon to quickly produce a succession of The technical textiles line at the ATC incorporates a required amount of liquid/coating to the fabric.
of parts and upgraded all our cards. With Rieter’s materials with widely differing properties and Montex four-chamber, horizontal chain stenter and is At the same time, in the pharmaceutical industry
innovations and technology we can maximize our performance applications – often within a single fitted with an explosion-proof coating application there is a wide range of different applications for It is fitted with an advanced guidance system
profits,” said Xinfeng Cui, Mill Manager at Honghai shift,” explains Monforts Head of Technical Textiles, chamber in order to allow treatment to be carried out organic solvents such as anti-septic treatments specially-adapted to the needs of delicate
Hangzhou Textile Co., Lt Jürgen Hanel. “These range from substrates for with organic solvents and other volatile materials. which have to be treated very carefully and applied treatments and eliminating any possible ‘curling’ of
Rieter cards C 70 at Honghai Hangzhou Textile Co., Ltd.

May/June 2018 May/June 2018