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Improved benefits for knitted fabrics from Monforts
In optimizing its stenter ranges for knitted fabrics, Monforts has introduced a number of key benefits such as reduced wastage. Further, its recently introduced Toptex also offers improved shrinkage.
The new improved pinning, glueing and trimming devices for knitted fabrics from Monforts offer a significant reduction in wastage by up to 60%.
New optical sensors ensure that the knitted fabric is always pinned as close to the fabric edge as possible reading 4,000 measurements/ second even at the maximum machine speed.
An alternative device for glueing from the top of the fabric instead of the bottom is also introduced to reduce the area of glue applied.
Additionally a new edge trimmer features optical detection of the pinning trace to determine a further reduction in trim cut.
Together these three solutions offer up to 60% reduction in fabric wastage when comparing, for example, a classical cut of 15 mm with the new solution of 6 mm on both sides of the fabric.
Air nozzles have also been designed to create an air cushion for the fabric to float in the inlet section instead of being supported by a belt.
Improved shrinkage
A completely new redesigned compressive shrinkage sanforisor for knitted fabrics, Toptex offers increased residual shrinkage, higher production speeds, automatic grinding of the rubber blanket, reduced water consumption for cooling and substantial time savings for blanket changes.
The new redesign also allows faster rubber belt changes taking just a single shift compared with two days for the industry standard. The simplified belt removal is accomplished by an integral lifting device to lift the rollers instead of their complete removal.
With the necessity of grinding the belt at least 5-6 times throughout its life, a new automatic grinder ensures only a minimum of rubber is ground thereby increasing the efficiency and life of the belt.
It also eliminates the need for a skilled craftsman/operator in manual grinding techniques.
The new sanforisor offers simplified and faster installations with improved access for maintenance procedures. All steam and water connections, for example, are centralised, eliminating the ‘plumber’s nightmare’ with a streamlined installation.
This, together with filtration and recovery techniques of the used cooling water on the shrinkage range has provided a conservative use of water, resulting in a 40% reduction in water consumption of cooling water. For minimised water consumption only water lost by evaporation or absorption by the fabric has to be topped up.
An innovative edge cooling system prevents the edges of the rubber belt becoming brittle if not covered by fabric during the shrinkage process; increasing the service life of the belt.
The edge of the belt is cooled by a width-adjustable water spray mist, creating a more homogeneous temperature profile over the complete rubber belt width.
The water used can be recycled in a water recovery plant, ensuring there is no increase in cooling water consumption.
The fabric shrinkage factor is also increased with a larger diameter heated drum ensuring an extended contact area of fabric between the shrinkage cylinders and the rubber belt.
New soft coating solution
A new soft coating process suitable for many knitted fabrics provides energy savings with reduced liquor application.
The new process using trough and roller techniques, applies just the required amount of liquid/coating to the fabric via contact with the roller.
It has been designed for three options – to apply a liquid/coating to one side of the fabric; to apply a liquid to both sides of the fabric; and to apply a liquid to one side and a different liquid to the other side.
Applications include nano coating, water repellancy, softeners and pigment dyeing. Used primarily for clothing applications, the soft coating process can, for example, apply soil-or water-repellency to one side of the fabric and softener or water absorption, respectively, to the second side.
The new Monforts process, in some cases, eliminates the need for a conventional padder, applying the liquid/coating via a roller. A twin-roller is used for double-sided applications.
Compared with a padder operation, the initial moisture content of 60% is reduced to 40% using the Monforts soft coating process; ensuring a reduction in drying times and reduced energy costs.
Energy solutions
With energy representing more than 60% of the total costs of a thermal system over a period of 10 years, it provides a constantly increasing expenditure. Consideration also has to be given to the cost factor for discharging the cleaned / recycled exhaust air into the atmosphere.
With energy costs currently increasing month-on-month, Monforts offer continually updated economy calculations for payback periods of its equipment. Today, for example, the benefits of heat recovery – fitted as standard on most Montex stenters – becomes even more attractive with further reduced payback due to the continually rising fuel costs.
The latest Monforts heat exchanger is integrated into the roof construction of the stenter for no heat loss. Exhaust air heat is converted in the heat exchanger to heat the fresh combustion air. Heated fresh air enters at the inlets of the stenter via integrated fresh air ducts.
Up to 60% of the fresh air required by the stenter can be preheated in this way providing an energy saving of between 10% and 30% depending on the production process.
Rising costs
As the price of heat energy rises, so too will the cost for electricity. It is therefore natural that the Montex stenter should feature frequency controlled exhaust air fans to avoid unnecessary fan speeds.
Most electric energy is consumed by the recirculation fans in the stenter.
To control and optimise the electrical energy, A. Monforts Textilmaschinen engineers have developed the Monformatic - a controlling tool for continuous drying, fixing or condensation processes. The unit ‘knows’ the zone in which the fabric has obtained the process temperature and automatically calculates the fabric transport speed so that a predefined time for fixing or condensation is maintained.
If this so called heat setting time is shorter than defined, quality is poor, if it is longer, too much electricity is consumed and heat energy wasted.
‘Golden’ stentering chains
The new ‘Golden’ Hercules stentering chain offers even further improved long term lubrication extending re-greasing intervals to more than 12,000 hours, depending on the treating processes.
Fully encapsulated bearings ensure that the roller chain runs dry through the stenter and requires minimum lubrication thanks to Monforts patented direct lubrication system; with lubricant injected directly into the bearing.
The interval for re-greasing has been extended from 6,000 hours to more than 12,000 hours under average performance conditions of 160°C and 70 m/min.
The new ‘Golden’ Hercules chain features further improved sealing for the bearings. This ensures a reduction of grease loss due to heat dissipation by more than 60%.
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