Page 41 - TEXtalks International October/November 2022

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R ota pray
Rota
pray
K
O Holding
Member of WE
Member of WEKO Holding
Weko's Innovative
Weko's Innovative
RotaSpray Dyeing
RotaSpray Dyeing
Technology for
Technology for
Sustainable Textile
Sustainable Textile textile industries. Among these industries, worldwide
textile industries. Among these industries, worldwide
textile production suffers from immense cost
textile production suffers from immense cost
pressure and is driven by high volumes of fresh
pressure and is driven by high volumes of fresh
, energy
water, energy, and chemicals with comparatively slow
water
, and chemicals with comparatively slow
production speeds. An estimated 100–150L of water
production speeds. An estimated 100–150L of water
Production is needed to process 1 kg of cotton textile.
Production
is needed to process 1 kg of cotton textile.
F
urthermore, a high amount of toxic effluent
Furthermore, a high amount of toxic effluent
generation from textile factories is another important
generation from textile factories is another important
concern that needs to be addressed properly
concern that needs to be addressed properly.
O and RotaSpray present the latest
Therefore, WEKO and RotaSpray present the latest
Therefore, WEK
technology to promote sustainable textile
technology to promote sustainable textile
manufacturing with cost and significant
manufacturing with cost and significant
An Interview with Adil Ghani about his experience with
An Interview with Adil Ghani about his experience with
resource-saving potential.
World’s first Patented Spray System for Fabric Dyeing
World’s first Patented Spray System for Fabric Dyeing The non-contact systems are running at different
The non-contact systems are running at different
locations globally to serve different sectors, including
locations globally to serve different sectors, including
textile dyeing and finishing. In 2019, Nishat Dyeing
textile dyeing and finishing. In 2019, Nishat Dyeing
and Finishing (NDF) Lahore Pakistan, installed the
Since 1953, WEKO has been developing and
Since 1953, WEK O has been developing and W eko's focus has always been on the lowest
Weko's focus has always been on the lowest
world’s first RotaSpray continuous fabric dyeing
producing non-contact application systems for textile
possible, exact, and replicable use of the respective
producing non-contact application systems for textile possible, exact, and replicable use of the respective
system. TEXtalks International interviewed the focal
resources, enabling customers to perform industrial
product optimization and surface finishing with
product optimization and surface finishing with resources, enabling customers to perform industrial
person Adil Ghani, Technical Director NDF, to learn
.
different fluids and powdery substances. Weko
production in a more environmentally friendly manner
different fluids and powdery substances. W eko production in a more environmentally friendly manner.
and explore more about the RotaSpray system, its
Holding GmbH has taken over RotaSpray GmbH in
Holding GmbH has taken over RotaSpray GmbH in The application areas are the nonwoven, paper,
The application areas are the nonwoven, paper
,
advantages, and its potential.
tissue, printing, wood fiber boards, foils, metal, and
January 2021 to further expand its textile segment.
January 2021 to further expand its textile segment. tissue, printing, wood fiber boards, foils, metal, and
October/November 2022
October/November 2022
Adil Ghani, T echnical Dir ector
Adil Ghani, Technical Director
TEXtalks: Can you share the histor y and work of
TEXtalks: Can you share the history and work of
Nishat Dyeing and Finishing?
Nishat Dyeing and Finishing?
Adil Ghani: Established in 2002, Nishat dyeing and
Adil Ghani:
Established in 2002, Nishat dyeing and
finishing is part of Nishat Mills Limited. NDF is one of
finishing is part of Nishat Mills Limited. NDF is one of
the most sophisticated dyeing units globally
, with
the most sophisticated dyeing units globally, with
. state-of -the-art systems. The Nishat group was
state-of-the-art systems. The Nishat group was
akistan's most
established in 1951 and is one of P
established in 1951 and is one of Pakistan's most
modern and largest vertically integrated textile
modern and largest vertically integrated textile
companies. The Nishat Mills Limited is engaged in
companies. The Nishat Mills Limited is engaged in
the business of textile manufacturing, including
spinning, combing, weaving, bleaching, dyeing,
spinning, combing, weaving, bleaching, dyeing,
the business of textile manufacturing, including
printing, stitching, apparel, buying, selling, and
printing, stitching, apparel, buying, selling, and
resource-saving potential. otherwise dealing in yarn, linen, cloth, and other
otherwise dealing in yarn, linen, cloth, and other
goods and fabrics made from raw cotton, synthetic
goods and fabrics made from raw cotton, synthetic
fiber , and cloth and to generate, accumulate,
fiber, and cloth and to generate, accumulate,
distribute, supply and sell electricity
.
distribute, supply and sell electricity.
TEXtalks: What is RotaSpray dyeing, and why did
and Finishing (NDF) Lahore P akistan, installed the
NDF choose this?
world’s first RotaSpray continuous fabric dyeing
Adil Ghani: As NDF truly believes in sustainable
system. TEXtalks International interviewed the focal
production, NDF chose the RotaSpray for the best
person Adil Ghani, T echnical Director NDF , to learn
possible benefits of innovative technology.
and explore more about the RotaSpray system, its
advantages, and its potential. Sustainable practices in th e textile industry include
Sustainable practices in the textile industry include
October/November 2022
October/November 2022
using fewer amounts of water , hazardous chemicals, and continuous pad-dry -pad-steam process. Using 60-70 kWh of energy , while RotaSpray takes only advantages, including fast processing and reduced the future of sustainable dye
and continuous pad-dry-pad-steam process. Using
using fewer amounts of water, hazardous chemicals,
60-70 kWh of energy, while RotaSpray takes only
advantages, including fast processing and reduced
the RotaSpray System, the intermediate drying is
adopting eco-friendly production processes; using
adopting eco-friendly production processes; using
the RotaSpray System, the intermediate drying is
the future of sustainable dye
05kWh of energy consumption. This is to indicate one
energy, water, and auxiliaries consumption.
05kWh of energy consumption. This is to indicate one
energy
, and auxiliaries consumption.
, water
less energy for production processes; and
eliminated, as normally used in the classical
eliminated, as normally used in the classical
less energy for production processes; and
Furthermore, RotaSpray systems can be used for
urthermore, RotaSpray systems can be used for
of the advantages of this machine.
of the advantages of this machine.
F
introducing the 3 Rs - Reduce, Reuse, and Recycle.
introducing the 3 Rs - Reduce, Reuse, and Recycle.
pad-dry
-chemical or pad-steam process. This leads
pad-dry-chemical or pad-steam process. This leads
TEXtalks: How does the RotaSpr
TEXtalks: How does the RotaSpr
light to medium shade without problems and with
light to medium shade without problems and with
Thus, RotaSpray reduces the resource consumption
to significant energy savings and much lower
to significant energy savings and much lower
Thus, RotaSpray reduces the resource consumption
for space and yet provide cost
for space and yet provide cost
TEXtalks: What are the key advantages of the
excellent reproducibility
TEXtalks: What are the key advantages of the
.
excellent reproducibility.
.
investment costs.
for NDF
for NDF. investment costs. eko is completely RotaSpray Systems you would like to share with the TEXtalks: How do you rate the innovative RotaSpray Adil Ghani: The RotaSpray eli
Adil Ghani: The RotaSpray elim
RotaSpray Systems you would like to share with the
process, reducing machine cost
process, reducing machine cost
industry?
y?
TEXtalks: How do you rate the innovative RotaSpray
industr
TEXtalks: What is the main difference between
TEXtalks: What is the main difference between
Proudly, NDF is the first industry globally who choose
Proudly
, NDF is the first industry globally who choose
shorter process, and saving en
shorter process, and saving en
It has been three years since we have
Dyeing System?
Adil Ghani: It has been three years since we have
Dyeing System?
Adil Ghani:
RotaSpray and the conventional system?
RotaSpray and the conventional system?
RotaSpray for bulk production of woven fabrics.
RotaSpray for bulk production of woven fabrics.
only 30% of the capital invest
only 30% of the capital invest
been using the system. It works 24 by 7 and has less
Adil Ghani:
RotaSpray dyeing system is a revolution
Adil Ghani: RotaSpray dyeing system is a revolution
been using the system. It works 24 by 7 and has less
Adil Ghani:
The RotaSpray by W
Adil Ghani: The RotaSpray by Weko is completely
RotaSpray is a Patented Spray Dyeing for Yarn and
conventional setup and require
downtime and easy maintenance. The results are
in continuous dyeing. It reduces resource
different and innovative compared to the
Fabric. The non-contact spray application also allows
F
abric. The non-contact spray application also allows
maintenance. Thus, the RotaSpr
maintenance. Thus, the RotaSpr
RotaSpray is a P atented Spray Dyeing for Y arn and different and innovative compared to the downtime and easy maintenance. The results are in continuous dyeing. It reduces resource conventional setup and require
, and produces
consumption, as mentioned already
consumption, as mentioned already, and produces
excellent, with an additional saving of 30-35% in
excellent, with an additional saving of 30-35% in
conventional dyeing systems. In conventional
conventional dyeing systems. In conventional
the defined application of high-affinity optical
space for installation and ope
the defined application of high-affinity optical reactive dyeing, the process requires enormous energy consumption, chemical consumption, and reproducible results, which is of the utmost space for installation and ope
energy consumption, chemical consumption, and
reproducible results, which is of the utmost
reactive dyeing, the process requires enormous
brighteners, fixing agents, functional chemicals, amounts of salt to facilitate dye exhaustion and reduced carbon footprint. RotaSpray avoids the importance for a dyeing house. In today's processes, results are similar to the con
brighteners, fixing agents, functional chemicals,
results are similar to the con
reduced carbon footprint. RotaSpray avoids the
importance for a dyeing house. In today's processes,
amounts of salt to facilitate dye exhaustion and
special neutralization agents, dyes, and oxidation
special neutralization agents, dyes, and oxidation
without auxiliaries (salt), so
without auxiliaries (salt), so
conventional dyeing route, enabling industries to
huge liters of dyeing and washing bath volumes are
absorption ranging from 40 to 100 g/l. The treatment
chemicals. Significant water, chemical, and energy
chemicals. Significant water , chemical, and energy absorption ranging from 40 to 100 g/l. The treatment conventional dyeing route, enabling industries to huge liters of dyeing and washing bath volumes are economical and feasible. F or
economical and feasible. For u
typical. Also, permanently re-feeding fresh dyestuffs,
save big, and the short process means fewer
typical. Also, permanently re-feeding fresh dyestuffs,
save big, and the short process means fewer
of colored salt effluent is one of the scorching issues
of colored salt effluent is one of the scorching issues
savings can be achieved by optimizing the spraying
savings can be achieved by optimizing the spraying
P
Pandemic situation, I think th
andemic situation, I think th
production times. The RotaSpray can easily do
chemicals, auxiliaries, or water are needed during
in the textile processing house as it significantly
parameters in the RotoDyer and RotoCoater spraying
almost four years regarding th
parameters in the RotoDyer and RotoCoater spraying in the textile processing house as it significantly production times. The RotaSpray can easily do chemicals, auxiliaries, or water are needed during almost four years regarding th
reactive and vat continuous dyeing that is beyond the
processing to keep quality results stable from start to
processing to keep quality results stable from start to
reactive and vat continuous dyeing that is beyond the
increases the carbon footprints along with the cost of
increases the carbon footprints along with the cost of
technology in finishing textile fabrics and warp yarn
TEXtalks: What is RotaSpray dyeing, and why did technology in finishing textile fabrics and warp yarn dyed goods. However , the RotaSpray eliminates salt reach of conventional dyeing processes. F or stop. Draining all the dye bathes, especially sulfur
reach of conventional dyeing processes. For
stop. Draining all the dye bathes, especially sulfur
dyed goods. However, the RotaSpray eliminates salt
dyeing. The newly developed PS2 Pad-Spray-Steam
TEXtalks: For which applicatio
NDF choose this? dyeing. The newly developed PS2 P ad-Spray -Steam utilization without compromising shade depth to example, the cold pad-batch method can be applied and reactive, results in high water treatment volumes TEXtalks: F or which applicati
example, the cold pad-batch method can be applied
and reactive, results in high water treatment volumes
utilization without compromising shade depth to
Process for yarn and fabric enables salt
-free
RotaSpray Technology?
Adil Ghani: As NDF truly believes in sustainable Process for yarn and fabric enables salt-free make it more sustainable. Because of the spray for reactive dyeing, but the cold pad-batch process is and costs after each production lot and wastes our RotaSpray T echnology?
for reactive dyeing, but the cold pad-batch process is
and costs after each production lot and wastes our
make it more sustainable. Because of the spray
continuous dyeing of Reactive dyes without limitation
Adil Ghani: Using RotaSpray Te
production, NDF chose the RotaSpray for the best continuous dyeing of Reactive dyes without limitation technology , RotaSpray reduces water and energy not possible for vat dyes. However , with RotaSpray , natural resources of fresh water. However, Adil Ghani: Using RotaSpray T
. However
natural resources of fresh water
,
not possible for vat dyes. However, with RotaSpray,
technology, RotaSpray reduces water and energy
of color depth. The diffusion behavior of the dyes is
doing reactive and vat dyeing.
possible benefits of innovative technology . of color depth. The diffusion behavior of the dyes is consumption. A pad-thermosol normally takes about customers can do reactive and vat dyeing without with Weko RotaSpray's technology, all the limitations doing reactive and vat dyeing.
customers can do reactive and vat dyeing without
with W
eko RotaSpray's technology
, all the limitations
consumption. A pad-thermosol normally takes about
ad Batch dyed material
comparable with the Cold P
was developed for vat dyes, an
comparable with the Cold Pad Batch dyed material compromising performance. The process has serval are no more, making this technology was developed for vat dyes, an
are no more, making this technology
compromising performance. The process has serval