Vacuum Technology – The Principle - ViBiNeT
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Division Textile Vacuum Technology
Transcript of Vacuum Technology – The Principle - ViBiNeT
Division Textile
Vacu
umTe
chno
logy
Vacuum Technology – The Principle
Evac systems integrated intoopen-width textile ranges willimprove fabric quality, increaseproduction speed, significantlylower production cost permeter, and lessen the overallenvironmental impact of textileprocesses. Following are just afew examples of how vacuumtechnology can achieve theseadvantages for the textile pro-ducer.
Improved Fabric Quality
Vacuum technology improvesfabric quality by removing lintand dust when dry, and byimproving chemical penetrationin wet processes. Lint or dustremoval can be very advanta-geous in printing where »stick-ins« result in second qualityfabric. In chemical finishing andpigment “dyeing”, vacuum canpull the chemicals deep insidethe fabric, where the end-userappreciates them most. Vacuumtechnology also prevents the“windowpane” effect, or chemicalbuild-up between yarns.
Increased Production Speed
By lowering residual moisturebelow the level of typical pad-mangles, vacuum technologyallows stenters and other dryingdevices to dry fabric faster, thusincreasing production speed, orlessen the energy consumption.
Lower Production Costs
In washing, vacuum technologyseparates contaminants from the washing line before they are carried into following washingboxes. The effect: less cleanwater is needed, which alsoresults in less energy consump-tion for hot washing purposes. In finishing, vacuum technologyremoves the chemicals suspendedbetween fabric yarns. The chemi-cals stay inside the fiber bundlesof the yarn, not in between theyarns, and can, easily be recycled.Therefore, fewer grams of chemi-cals per square meter of fabricare required when using vacuumtechnology in finishing thanwhen using the padder alone.
Reduced Environmental Impact
In washing parts of the counter-flowing dirty liquor is sent toseparate treatment by using thevacuum system. PVA size, bleach-ing chemicals or unfixed dye-stuffs are removed from the washing line before they enterthe succeeding wash boxes.
Likewise in finishing, by removingchemicals such as fluorocarbons,resins, softeners and even pig-ments normally left in betweenfabric yarns, very little chemicalsremain to become vaporized andexhausted as emissions out ofthe stenter’s exhaust outlets.
Easy to Handle – SafeOperation
The operator only selects thevacuum pressure needed and theEvac automatically adjusts pumpspeeds and airflows to ensureconsistent pressure and produc-tion results. Pumps as well asseals and separators need onlyminimal, routine maintenance.
More than 20 Years of Experience
It is not just the quality of ourvacuum systems that makes usnumber one world-wide. It is alsothe process experience behindthe Evac system designs that en-sures that the customer receivesa vacuum system that is tailoredto his specific needs, for as yarncharacteristics and fabric con-structions vary tremendously,so too do the potential effects of vacuum pressure vary fromfabric to fabric. Take advantageof Evacs knowledge in vacuumtechnology!
chemically bound portion
vacuum
highefficiencysqueezer
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resi
dual
moi
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100% 75% / 25% 50% / 50% 25% / 75% 100%
blends syntheticcotton
transition zone
resi
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CO230 g/m2bleachedworkwear
CV140 g/m2dyed plain
PA100 g/m2dyedtaffeta
PES120 g/m2dyed twill
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Residual moisture of representativefabrics
Vacuum Applications: Evac Advantages
Water Extraction- high line-speed increases with
synthetics and blends- prior to drying cans, stenters
or tensionless dryers- prior to bleach saturators for
high chemical add-on- superior process control
through even wet pick-up- gentle on fabric piles or deli-
cate woven structures
Washing- after Cold Pad Batch desizing
or bleaching- after preparation steamer- after print washing- after dye washing- after stabilization in merce-
rizing- removal and separation of up
to 80% of contaminants
Finishing- even application of chemistry
through fabric width- improved hand due to deep
penetration of chemistry intofiber bundles
- no waste of chemicals due to filtering and recycling ofchemicals
- faster stenter speeds due tolower wet pick-up
- elimination of drying step withWet-On-Wet System
- automatic vacuum regulationfor consistent process control
Pigment “Dyeing”- dyestuff and chemical appli-
cation in one stenter pass- excellent wet and dry crock- minimal capital investment- no migration or clip marks
Lint Removal- prior to printing to reduce
second quality prints- prior to singing to improve
singe- after shearing or sanding for
fabric cleaning- reduces lint and dust build-up
on downstream rolls, washboxes, dryers
The more synthetic fibres, the better theresults of vacuum units
Superiority of Evac SystemModules
Evac provides you with processcapability and reproducibility at low running cost due to thefollowing System Modules:
1 Patented EvacSlot- prevents blockages- homogenous effects over entire
width- ideal for pigment dyeing- low friction UHMW nozzle- converging-diverging nozzle
orifice for maximum efficiency- suitable for high temperatures
and chemicals- automatic cleaning feature- teflon-coating inside and out
for ease of maintenance
2 Evac Separators- 95% efficient, blockage-free
design- no in-line filters- external filter system- filter change possible without
stopping system or range- automatic signal on control
panel for filter change- automatic rinsing during lot
changes
3 Evac Pumping Station- water-cooled pump- high volumes of air possible- long operating life- inverter compatible- savings in electricity- sound enclosure included
4 Evac System Controls - inverter-integrated vacuum
pressure control- minimized electricity con-
sumption- PLC (Siemens) operated.- automatic cleaning features- automatic signals for filter,
separator and drain pumpmaintenance
No other vacuum system available today contains all of these design features, whichmake Evac systems the superior choice in overall performance. Ask for an individual paybackcalculation based on your production today!
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Pumping Station Characteristics
1 Rotary Piston Pumping Station
- maximum vacuum pressure for KWH input on most fabricconstructions
- water injection for maximumvacuum efficiency, cooling andcleaning
- compatible with inverter controls for energy savings
- complete with sound enclosurefor operation without noisediscomfort
2 Stage Turbine Pumping Station (Blower)
- low to medium vacuum pressure
- high air volume- lint and dust removal on dry
fabrics- moisture removal on openly
constructed synthetics such as sheers or light-weight curtains
3 Liquid Ring Pumping Station- high vacuum pressure possible- limited inverter compatible- high water consumption- lower initial investment cost– durably, maintenance-friendly
execution
The operating principle of the three (3) different pumping stations determines both thepotential vacuum pressure andair volume that a pumping station can create. The three (3) types of pumpingstations therefore have differentadvantages and characteristics.
Standard EvacInstallations
Wet-On-Wet+Stenter- only one stenter pass after
dyeing- chemical recycling- independent vacuum pressure
control at each EvacSlot
Dyevac+Stenter- pigment “Dyeing”+ finishing
in one stenter pass- pigment and chemical
recycling- no mercerizing- low initial investment vs.
thermosol range- excellent for Low-Add-on
finish application as well
Vacu-Washer as MercerizingUpgrade- boiling two-chamber washing
box- vacuumed water recirculated
to first washing chamber andoverflowed
- live steam and vacuumedthrough fabric
- removal of up to 80% of residual contaminants
- less acid necessary for neutralization
General Evac Assisted Washing- in desizing, bleach and
scouring ranges- after dye and after printing
wash ranges- removal of up to 80% of
contaminants with oneEvacSlot
- less water+energy per meterof fabric
Single-Slot Ultraknit+Stenter- completely tensionless water
extraction- completely tensionless chemi-
cal application- compatible with all fabric
spreading devices such asTandematic
Wet-on-wet+ stenter
Dyevac+ stenter
Vacu-Washer as mercerizing upgrade Evac in desizing
Evac assisted washing
Single-Slot Ultraknit+ stenter
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Global Customer Service andSpare Parts Distribution for the Küsters Wet FinishingInstallations
Service is at the heart of asustained and successful partner-ship:
We undertake technical andtechnological consulting, repairs,modification, training and offerspares for Küsters wet finishinginstallations and, of course, setting-up and commissioning.This comprehensive service is thecore competence that supports a strategic overall concept, assuring that Küsters in future,too, will stand among the world’s leading suppliers of wet finishingranges.In addition to the comprehensiveservice our customers can drawon the wide range of productsand the extensive wealth ofexpertise and individual solutions.And when in urgent need, just call us on our 24h-hotline +49-2151-34-3434.
Headquarters
Eduard Küsters MaschinenfabrikGmbH & Co. KGEduard-Küsters-Straße 147805 KrefeldPostfach 10 12 5547712 KrefeldGermanyPhone [email protected]
www.kuesters.com
Subsidiaries
Küsters Zittauer Maschinenfabrik GmbH, Zittau /DPhone [email protected]
Küsters Machinery CorporationSpartanburg, S.C. /USAPhone [email protected]
Zima CorporationSpartanburg, S.C. /USAPhone [email protected]
Kusters Calico Machinery Ltd.Mumbai / IndiaPhone [email protected]
Kuesters Far East Ltd.Hong KongPhone [email protected]
Kuesters Shanghai Co. Ltd.Shanghai / P.R.ChinaPhone [email protected]
