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PRODYE-R rope dyeing unit

is setting new standards in

everyday production

fewer chemicals, e.g. around 20 % less hydrogen
sulphide, are required. The rebeaming process is 15
% to 20 % faster. In addition, the PRODYE-R requires
a significantly shorter dyeing section. Enzo Paoli, the
Managing Director of KARL MAYER ROTAL, KARL
MAYER’s center of excellence for denim, expects
fresh impetus for further business transactions.

More efficiency, fewer dye boxes
The PRODYE-R has only 8 to 9 instead of 12 dye (L to R) Roland Kohn, President of the BU Warp Preparation, CEO Arno Gärtner and Enzo Paoli,
Managing Director at KARL MAYER ROTAL, open the new competence centre in Italy for denim customers
units, but reaches colour depths of up to 5.5 %. Also
thanks to the fluted rollers in the sky oxidation the The BALL WARPER draws the yarns from the
indigo dyestuff is extremely solid physically bonded, bobbins, brings the threads together to form a rope,
and the colour shade is bright. Due to the shorter dye and winds up the rope in cross lapping to a ball.
section, it is possible to reduce the total volume of During this cycle, the computer-controlled system
the indigo dye bath by more than 25 % and also to ensures an operation that is gentle to the material,
reduce the energy consumption. The result is a with a constant, smooth run. Afterwards the ropes are
KARL MAYER’s BALL WARPER
marked drop in costs. This is based on targeted removed from the balls, and guided through the dye
KARL MAYER belongs to the top manufacturers of technical optimizations regarding the feeding of the section. During this procedure, a perfect tension
indigo dyeing equipment worldwide. With its dye liquor and the rope guiding through the bath. control by load cells facility that is adapted to the
PRODYE-S slasher dyeing unit, this company has Besides, the special recirculation of the dye liquor material, ensures that the compact, uniform structure
already become firmly established as leading requires less chemicals such as caustic soda; and of the ropes is not adversely affected. In the dryer
provider in the high-fashion denim sector; with its by means of the special ECO section the conventional belts were replaced by
PRODYE-R for the rope dyeing process, the wash box design it is possible KARL MAYER’s LONG CHAIN BEAMER motors to ensure a perfect tension control, keeping
company is on the way to the top of the market also to reduce water consumption the right elasticity of the yarn. At the exit of the dryer,
in the genuine/standard segment. Only in April 2019, by roughly 30 %. number of LONG CHAIN BEAMERS. An important a coiler with circular motion ensures a uniform
a renowned denim manufacturer put a PRODYE-R in prerequisite for this fact, however, are technical storage/stacking of the ropes in cans. This step also
operation, thus, marking an important milestone. The Homogeneous ropes, high solutions that ensure a homogeneous buildup of the contains design know-how. Coilers with linear bars
machine impresses by its performance in the rebeaming speeds ropes during their passage through the machine. replace the commonly used mechanic gear coilers,
powerful denim player’s everyday production. The The rebeaming process of the Ropes consisting of threads that stick together
PRODYE-R scores with respect to comparable PRODYE-R convinces by its considerably, can only be separated slowly after offering highest flexibility instead of long reaction time.
machines with a high speed during the opening of speed. The possible time dyeing. Otherwise, it comes to yarn breakages, which Within a very short period, it is possible to adjust the
the yarn ropes after dyeing – the so-called rebeaming saving compared to have to be repaired by knotting, resulting in inferior rope twist to different machine speeds and rope
– and also with a reduced number of the required conventional similar plants is quality and efficiency losses during weaving. Special weights. The result: yarn compound structures without
attention is paid to a uniform rope structure already
dye boxes. This opens up far-reaching efficiency and Loading and doffing device 15 % to 20 %, which can be threads sticking together, that can be separated at high
used for reducing the required
savings potential. Among other things, significantly of the BALL WARPER during the feeding of the material to the machine. speeds, and that can be wound onto a warp beam.
November/December 2019 November/December 2019