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International Standards Organization (ISO) created compressor provides operators with significantly
ISO 8573-1 to provide manufacturers with the ability lower maintenance requirements, including:
to define the level of tolerance for air purity in their • Fewer ancillary air system components to maintain.
compressed air system. This standard outlines the • Longer timeframes between oil changes.
levels of solid particulates, water, and oil allowed • Elimination of expensive oil filters to clean the
based on the classification. compressed air.
• Elimination of oily condensate management.
Class 0, the most stringent of these classes, • Longer desiccant life of downstream air filters.
guarantees compressed air will contain <0.01 • Minimized downstream labor and outage-related costs.
mg/m3 of total oil. The key is to select the
classification most appropriate for your facility. Reduce energy costs
The more energy-efficient the compressor, the more
KARL MAYER is technology and market leader as well width from 136" to 186" has increased output even Manufacturing benefits of oil-free air
as driving force for innovations in textile machinery more. The output is also higher than weaving mills. At Eliminates risk of contamination direct impact the machine will have on lowering
building. The manufacturer offers perfect solutions for a width of 186" and a speed 800 min−1, the TM 4-TS • Delivers Peace-of-Mind – There is always a risk of operating expenses. Since energy costs are generally
warp knitting, technical textiles and warp preparation EL has a daily production rate of about 1,800 kg of contamination when compressed air encounters an 60-75% of the total life-cycle costs of an air
for weaving and under the KM.ON brand digital terry fabrics at a weight of 400 g/m2, 250% more than end product; the best way around this is never to compressor, overall cost savings from efficiency
solutions for all customer groups. The customers are on an air-jet loom. introduce oil into your airstream in the first place. alone can result in several thousands of dollars in
active in the most diverse areas and in all parts of the Class 0 air allows manufacturers to avoid life-cycle savings. Oil-flooded machines also require
world. Especially for textile companies in Pakistan Moreover the TM 4 TS-EL consumes roughly 87% less contamination risks, such as an oil filter breakthrough several oil filters and oil separators in the air path to
KARL MAYER offers the warp knitting machine for energy per kilogramme of produced fabric than air-jet from post-filtration, that would lower product quality, clean the manufactured compressed air. Each one of
producing terry fabrics from staple-fibre yarn, the TM looms, which require a large amount of energy to increase the risk of product recalls and result in these items will cause a pressure drop across the Ad
4 TL EL, the sizing machine PROSIZE® and the produce the compressed air. And the production of unnecessary downtime. Contamination risks can filter, resulting in lower air pressure delivery
indigo dyeing machine PRODYE, which give them warp-knitted terry fabrics requires no sizing process. harm your brand reputation, your bottom line and downstream in the plant. The decrease in pressure
advantages in local and international competition. This saves on textile chemicals, effluent and energy to even worse, the health of your customers. means the compressor must work harder to maintain
the value of roughly 0.20 US dollars/kg. This its high operator convenience and perfect process size application is perfect, despite the yarn density as • Protects Your Assets – Oil-lubricated compressors the demand needed for the plant creating lower
The TM 4 TS EL, the fastest way to fluffy fabrics corresponds to a share of roughly 30% of the control; the sized warp beams ensure maximum ends/cm is higher than the known limit given by will always have a trace amount of oil in the air they efficiencies and higher energy costs.
The TM 4 TS EL can efficiently produce terry fabrics production costs (without the yarn) when producing efficiency in weaving. Combination size boxes with conventional technology. The higher size uptake and produce. Trace oil can build-up on pneumatic
Karl Mayer PRODYE
equipment and other valuable assets that use
with long repeats, hems and borders. This new the raw fabric. and without prewetting device ensure short yarn associated yarn coverage density means that the compressed air, which in turn increases maintenance Why do industries choose oil-free air compressors?
turbulent application zones, dead zones are avoided
produce less waste and enable deeper, brighter
machine is extremely efficient and is proving itself well paths. Machine designed as one-box version process can be changed over from double to single and replacement costs. Compressed air comes in contact with nearly
indigo shades to be produced. The dye add-on as a
The TM 4 TS EL can suit every company strategy for (floor-type execution) and as double-box version size box processing in the denim, home textiles and and concentrations, temperatures and viscosities are everything, including finished products. Avoiding the
percentage of the total yarn weight is 5.5 % maximum.
equalised. The size film formation is uniform and the
producing terry goods on the basis of (overhead execution) can be offered in different clothing sectors, for example; this is beneficial to the Reduces environmental impact risk of oil contaminating the air supply is especially
warp in the wedge absorb size on the upper and
This warp preparation equipment is also highly
tried-and-tested principles. In this case, there are two constructions to meet every requirement. Cylinder sizing result. The onebath system simplifies process • Minimize Oil Usage – Oil-flooded screw important to the textiles. A quality stream of
productive. The PRODYE-S can double output when
lower sides. Furthermore an extremely efficient filter
general approaches. On the one hand, there is the driers in various arrangements guarantee a rapid and control and the adjustment of the wetting quality. compressors require 55 gallons of oil every six to compressed air for spinning machines and air-jet
processing lightweight denim. The market has been
system guarantees the fresh and filtered size
production of heavy fabrics for the high-end segment, gentle drying of the yarn. The sizing machine. When producing bed linen, for example, high-quality twelve months for an oil change. This oil must then looms is crucial to prevent fabric staining and
application on to the yarn. This performance causes
extremely impressed by the performance offered by
where high demands are placed on durability. This sized warps can be produced in a working width of be properly disposed of following the appropriate production loss. Mandating the highest class of air
an increasing of power anchor over the width and
KARL MAYER ROTAL’s indigo dyeing machines.
innovative four-bar terry tricot machine can produce The heart of the PROSIZE® are the size boxes HSB 2,800 mm, and there is no risk of the yarns sticking governing authority guidelines. Oil-free compressors purity is essential for delivering high quality, oil-free,
length of the warp, which is beneficial for the
fabrics having weights of up to 600 g/m². On the other and VSB. The size boxes operate with an application together. do not require oil as part of the compression process manufactured products.
subsequent stages in the value-added chain. Much
hand, some manufacturers specialise in producing system for which a patent has been applied and and as a result, only need oil changes every two to What makes PRODYE so interesting is that it is based
on well-thought-out components. One of these
less fiber fly is generated in sizing and weaving ,
textiles having low weights and less dense granted. A new feature is that an immersion bath is no The clever process design allows a saving of the size three years. Is oil-free air right for you?
which increases efficiency considerably.
innovative elements is the Double Vario dyebath,
constructions. When producing lightweight terry longer used. Instead of the usual immersion bath, the material upto 10 % and the possibility to reduce as • Eliminate Condensate Disposal – When operating Rastgar invites you to allow the application engineers
which operates on the basis of a well-thought-out
goods, the high loop stability of warp-knitted fabrics size is applied in three, highly turbulent, homogeneous max as possible the liquor level in the box. That an oil-flooded compressor, significant amounts of for compressor life-cycle cost calculation to find out
Sophisticated technology for the denim sector
cross-flow system for perfect dye liquor circulation to
compared to woven fabrics is a particular advantage. application zones, with spray bar technology and a permit to decrease effluent loads in sizing and oil-contaminated condensate must be properly what you are currently spending at your plant and
KARL MAYER offers one-stop solutions for slasher
give a uniform dyeing result. Additionally, the Quick
Generally speaking, the loop stability of warp-knitted subsequent application/squeeze roller system. The finishing. Thanks to no immersion system splashing disposed of to safeguard the environment. To ensure review what you could potentially save by
and rope dyeing with its Centre of Excellence for the
Oxidation zone operates with temperature-controlled
on the market. The high speed of the TM 4 TS EL is terry fabrics is quite unique - thanks to the stitch so-called sponge effect comes into play here: in the is not present anymore. The ergonomic design of the compliance, governing authorities often monitor and transitioning to oil-free technology.
denim sector, KARL MAYER ROTAL. Compared to
particularly evident when producing bath towels and
tying-in arrangement. Thanks to the EL control
Manufacturers around the world are tasked with Oil-free air compressors are becoming more and first zone, the dry yarn is dipped into the wedge of new size boxes allows an easier access by the regulate the disposal of contaminated condensate. air flow to guarantee uniform dye uptake. Rejects are
conventional machines available on the market, the
also reduced and the colour tone of the warp yarn
system, and particularly to the repeat function, the
robes with loop-free stripes and long repeats. The
finding opportunities to lower their operating costs more popular for their ability to reduce maintenance liquor between the two rollers, squeezed, and then operator, also in case of wider working width. Vertical Condensate from oil-free compressors can be easily Rastgar & Co is authorized distributor of Gardner
PRODYE-S and PRODYE-R indigo dyeing machines
sheet is more uniform than with conventional
length of the hand towels can be changed very
modern EL system enables this terry tricot machine to
while maintaining a consistent, high-quality product and energy costs, minimize environmental footprint impregnated again in the second zone. The moist yarn pass also means that the VSB makes even more discarded or even recycled for other uses within the plant. Denver’s CompAir brand of Oil-Free Air Compressors
techniques.
produce large fabric webs with flat sections and hems
quickly to suit customer requirements.
with little to no impact on the environment. For many and the possibility of product contamination. yarn can then absorb the sizing agent more space available for carrying out simple manual from KARL MAYER ROTAL consume less water, in Pakistan with complete aftermarket support. Learn
in the lengthwise and crosswise directions at a
industries, employing an air compressor that effectively. Thanks to that a yarn coverage factor of adjustments. The operative also has an unrestricted Reduce maintenance costs more https://rastgar-co.com/products/oil-free/
Perfect weaving results, thanks to PROSIZER®
production rate that is 30% higher than its
provides ISO 8573-1 Class 0 certified oil-free air is The degree of air purity required varies based on the 100 % is possible, 20 % higher than with the view of the entire process. Switching from an oil-flooded to an oil-free air (by Mr Imtiaz Rastgar).
Typical features of the sizing machine PROSIZE® are
predecessor, the KS 4 FBZ. Increasing the working
one way to achieve these objectives. risk tolerance for any industrial process. The conventional immersion process. The uniformity of Thanks to the intensive size circulation in the highly
May/June 2020
July/August 2019