Wichelhaus GmbH & Co KG Feuerbachstr.

12 D-42719 Solingen

wichelhaus@wichelhaus-co.de

Vario Line Jigger

-1Bank Details: Stadtsparkasse Solingen Account No.: 528 083 (Bank Code: 342 500 000), SWIFT-ADRESS SOLS DE 33 Competent court of jurisdiction and place of performance is Solingen. The company is based in Solingen. Register Court: Local Court (Amtsgericht) Solingen HRA 23144

Vario Line Jigger Textile Machinery Engineering of the Future

Dear ladies and gentlemen, thank you very much for your inquiry and your interest in our textile machinery products. Wichelhaus GmbH & Co KG has always been engaged in developing, designing, and manufacturing special production plants for different purposes. Recently we got involved in a project for developing a new kind of textile jigger machine, which led to today's division 'Textile Machinery' as new portfolio of Wichelhaus GmbH & Co. KG in Solingen in April 2011. For further information on our company please visit our website www.wichelhaus-co.de.

Tradition:
Processes such as pre-treating, scouring or dyeing of textile fabrics have been carried out on jiggers from the beginning of the textile industry. Textile finishing highly benefits from this simple but efficient technology. The jigger is especially suitable for the treatment of crease-sensitive, non-permeable, very fine as well as very heavy textiles mostly made of natural fibres. However, a traditional jigger machine does neither comply with the requirements of modern textile company's regarding its energy management nor with the quality requirements for high-class, mostly technical textiles.

Our Vision:
Our vision is to combine environment, energy and engineering matters with the existing procedure providing highest production efficiency while keeping energy and water consumption at its minimum and following ecological and economical aspects as guiding principles. A very critical environmentrelated factor was to ensure energy resource savings already during design and development of new machines. That means a significant energy-saving manufacturing of the plants and usage of recyclable materials, wherever possible. However, the most important aim was to achieve the reduction of current energy consumption during production process. We were aware of turning things upside down:

-2Bank Details: Stadtsparkasse Solingen Account No.: 528 083 (Bank Code: 342 500 000), SWIFT-ADRESS SOLS DE 33 Competent court of jurisdiction and place of performance is Solingen. The company is based in Solingen. Register Court: Local Court (Amtsgericht) Solingen HRA 23144

Current Situation:
The Vario Line Jigger brings together the benefits of traditional finishing technologies and high-tech mechanical engineering developments while complying with both economical and ecological demands. The usual treatment of natural fibres is added by the possibility of the optimum pretreatment and dyeing of polyamide fabrics, as well as blends with a high percentage of elastane.

Test Centre:
Effectiveness in the future requires on-going development and optimization. The installation of a ready-for-action Vario Line Jigger allows test operation and trial runs under production conditions, whenever required. We look forward to offering you both a demonstration of the machine's functionality and trials using your own materials.

Benefits:
Consistent temperature, fabric tension and fabric speed, processing time, dyestuff/ chemicals up-take and liquor ratio are some of the most important parameters to deliver best qualities. Reliable control of the whole process provides optimum safety. The Vario Line Jigger meets all these requirements: It is economical, user-friendly, eco-friendly and Made in Germany Consistent fabric tension Consistent fabric speed Optimum and consistent liquor ratio (for large & small batch sizes) Special expander construction Perfect monitoring due to large inspection windows Friction-free guide rollers bearing Insulated stainless steel liquor trough and economic dye trough Vario Master Roll reduces passages Automatic traversing Circulation pump for an even dispersion Filter station High-performance heat exchanger Add tank with mixer and rinsing tubes Programmable dosing system

Range:
The Vario Line Jigger has been designed for fabric widths from 1600 up to 4000 mm and for batching roller diameters of 1000, 1200, and 1400 mm. The liquor quantity can be set from 110 up to 2850 l. The machine provides an optimum use of space due to the arched design of its protection windows to be opened and closed overlapping in the roof area. -3Bank Details: Stadtsparkasse Solingen Account No.: 528 083 (Bank Code: 342 500 000), SWIFT-ADRESS SOLS DE 33 Competent court of jurisdiction and place of performance is Solingen. The company is based in Solingen. Register Court: Local Court (Amtsgericht) Solingen HRA 23144

-4Bank Details: Stadtsparkasse Solingen Account No.: 528 083 (Bank Code: 342 500 000), SWIFT-ADRESS SOLS DE 33 Competent court of jurisdiction and place of performance is Solingen. The company is based in Solingen. Register Court: Local Court (Amtsgericht) Solingen HRA 23144

Technical Design:
Basic Frame: The side walls are built of two solid tripods made of a special polymeric cast, providing best mechanical properties. Low thermal conductivity and effective heat capacity of this polymer material provide a high thermal stability. In comparison to steel constructions, polymeric casts neutralize vibrations ten times faster, the material is highly isotope and homogeneous, preventing tripods from getting deformed through loading. The machine-specific connecting parts (e.g. roller bearing, diagonal members, etc.) are made of stainless steel and integrally cast in the base frame. The large inspection windows are electrically driven and suit best for the operator to visually monitor the whole process. The hermetic sealing of the inspection windows ensures a consistent inside temperature. Both inspection windows are made of 14 mm safety glass providing excellent insulation values, too. The two fluorescent light tubes inside support process monitoring. Liquor Trough: The special design provides an optimum and consistent liquor ratio. The trough design allows an economic dyeing of small-sized batches. As a result, you are flexible to immediately respond to any requirement. Two large pneumatically controlled outlet valves enable quick liquor discharge. The unique Vario Master Roll (VMR), equipped with a third convex guide roller in the trough, increases the liquor exchange, reduces the number of passages by approx. 35%, resulting in a decreased liquid consumption. The system may be applied as required for large and small fabric batches and for difficult textiles.

Vario Master Roll (VMR) as schematic illustration Material Expander The construction of the two material expanders enables an improved dyeing and scouring result. The two expanders are adjustable within and allow very smooth material transport. The design of the expander lips protects even very sensitive textiles. Drive System Main Rollers: Two AC three-phase motors are responsible for the direct drive of the main support rollers. The braking energy is transformed into driving energy. The two main support rollers, featuring special bearings at the roller ends, are driven frequency-controlled. A high-quality stainless steel casing protects the roller core against aggressive agents. Guide Roller Bearings Like other components, the bearings are made of high-quality materials. The Vario Line Jigger features special two-rowed self-aligning ball bearings, made of ceramics with concave outer ring raceway to absorb radial and axial forces even more easily. The use of ceramic instead of carbon/ steel roller bearings allows an extremely smooth running of the machine's main rollers. This protects the textiles against suffering from standard high tension that may result in strong deformation and loss of elasticity. The rather large angle adjustability of the bearing units compensates small misalignments and shaft deflection without any problems, even at high temperatures. Ceramic roller bearings are nonmagnetic, non-conductive, and resistant to abrasion and corrosion. They do not require any oil or -5Bank Details: Stadtsparkasse Solingen Account No.: 528 083 (Bank Code: 342 500 000), SWIFT-ADRESS SOLS DE 33 Competent court of jurisdiction and place of performance is Solingen. The company is based in Solingen. Register Court: Local Court (Amtsgericht) Solingen HRA 23144

grease lubrication, independent from work temperature, which leads to much less maintenance of ceramic bearings. Automatic Traversing Automatic traversing enables the main roll to get shifted in the longitudinal direction resulting in a significant benefit for edge treatment. Control Panel: The control panel can be swivelled freely around for optimum operation of the machine. The control unit designed as a cabinet is located directly next the plant to ensure all conduits to be as short as possible. Alternatively, the control unit may be integrated into one of the side walls of the basic frame. The plant controller features a fully automatic process control DDC (Drive Dyeing Control) including integrated PLC and software, emergency system, touch screen monitor, stable operating system, machine visualization, Ethernet TCP/IP, possible network connection, Internet technology and USB interface. Temperature Measurement: The temperature within the hood and the trough area is measured by temperature sensors. Liquor Level Monitoring: A level sensor is a transmitter to reliably monitor the level of liquor in the bath. Circulation System: The liquor circulation pump equipped with rinsing tubes ensures a consistent temperature and a homogeneous dye concentration in the bath. The filter unit is integrated into the cycle of the liquor circulation, collecting any accumulation of fluffs from the liquor. The filter drag has to be cleared by hand. Heat Exchanger: The use of a state-of-the-art high-performance plate heat exchanger ensures the utmost heating-up or cooling-down of the liquor. The large surface enables a high energy transfer. The plate design allows an easy maintenance and a low risk of blocking through fluffs. These two factors considerably increase working efficiency. The working temperature is achieved very fast and continuously maintained due to perfect sealing of the Vario Line Jigger, resulting in considerably shorter processing times. Add tank: The stainless steel add tank has a capacity of 150 litres. Jigger-sided (liquor tubes and outlet) and outlet-sided, the add tank features automatic valves. The dosing device allows an exact dosage of dyes and chemical agents right from the add tank. Specification: Drive engines: 2x 5,5 KW; Pump: 1x 2,0 KW; Hoods: 4x 0,25 KW, Traversing: 1x 0,25 KW Heat exchanger: Liquor: 17,6 l; Pressure: 0-16 bar Pneumatics: Consumption approx. 16 l/min. Documentation: Design documentation: Assembly drawings including stock list, operating instructions and maintenance guide; CE-documentation including declaration of conformity documentation on the electric equipment. The documentation is completely available in digital forming any number of your choice. Additionally, it is available on our website via online access with your password-protected customer login. In German language.

-6Bank Details: Stadtsparkasse Solingen Account No.: 528 083 (Bank Code: 342 500 000), SWIFT-ADRESS SOLS DE 33 Competent court of jurisdiction and place of performance is Solingen. The company is based in Solingen. Register Court: Local Court (Amtsgericht) Solingen HRA 23144

Spare Parts: During the time of project realisation, wear parts will be defined, and then separately highlighted in the stock list. The scope of our delivery does not include a spare parts kit. Generally, the mounting positions of the replaceable wear parts are designed to provide easy access for replacement. Inspection and Acceptance : The operating and functioning inspection and acceptance of the machine will be carried out at the Wichelhaus company. The machine is considered to be inspected and accepted, when all features and motion sequences are fully delivered and the plant is complete and in good order after inspection carried out by the customer. The plant will be run in full operation mode but without production due to the lack of periphery. Initial start-up and final acceptance of the machine will be carried out on your production site. Your staff will be instructed how to operate the machine on the day of final acceptance. The machine is considered to be inspected and accepted, when all features and motion sequences are fully delivered and the plant runs trouble-free during a period of 5 hours. The acceptance report documents are prepared in advance, and will be provided. The customer supplies a sufficient amount of material for free to allow us running the complete initial start-up and acceptance procedures. Options: The following options present a range of variation and additional features to be selected according to customer's demands. Depending on the kind of application, we provide a number of further special designs, as our strength is the development of constructions suitable for practical applications meeting tailor-made our customer's demands, considering his manufacturing structure, and his individual business concept. => You feel there are lacking options - please feel free to contact us! Automatic Traversing Automatic traversing enables the main roll to get shifted in the longitudinal direction resulting in a significant benefit for edge treatment. Motor traversing: 1x 0,25 KW External Expander for Manual Loading and Offloading An expander is used to load or offload the batches, serving as additional support device to expand the textile between the main roller and the external batch. Central Lubrication The machine will feature an automatic central lubrication at the relevant points. The lubrication system is mounted on the machine. Trough Insulation The stainless steel trough features an additional GFR insulation to reduce the heat dissipation through the surface, resulting in heat loss to be minimized. Lock Roller Lock rollers serve as water deflector for sensitive, thin textiles with poor water permeability, and they are float mounted on the main rollers. Additional Equipment for Add Tank - Mixer To prepare solutions of granulated or powder chemical agents, the add tank will be additionally equipped with a mixer. Motor for mixer: 1x 0,25 KW Additional Equipment for Add Tank - Automatic Filling Filling the add tank with water will be automatically controlled through an additional valve. As usual, chemical agents feeding has to be carried out manually.

-7Bank Details: Stadtsparkasse Solingen Account No.: 528 083 (Bank Code: 342 500 000), SWIFT-ADRESS SOLS DE 33 Competent court of jurisdiction and place of performance is Solingen. The company is based in Solingen. Register Court: Local Court (Amtsgericht) Solingen HRA 23144

Dosing System In the finishing industry, the dosing system means to be a comprehensive subject that we are able to handle in accordance with your individual production processes. Please find the information on the relevant design for your individual application in the commercial documents attached. Putting into Operation On-site To be carried out on-site by a service technician in your production plant Putting into operation comprises the following works: - Vernier adjustment of the machine frame - Control of the supply lines - Function test of the drive units - Testing all features - Checking filters (if available) prior to and after one dyeing run - Dyeing process acc. to programme - General visual inspection for any machine damages (transport losses) - Drafting the acceptance report - Handing over the machine to the customer Within the customer's responsibility: - Main connections for the supply lines - Bringing in and positioning of the machine - All supply lines for current, water, steam and pneumatics have to be connected by the customer - The customer delivers a qualified fitter and electrician to be available on demand for putting the machine into operation. - Internet connection with Ethernet cable to run initial start-up and remote maintenance. Within the responsibility of Wichelhaus GmbH & Co. KG: - Control and calibration - Electrical and mechanical testing of all features - Test run with sample material delivered by the customer Delivery In compliance with your wishes we offer delivery free or EXW, unloading and bringing the plant into your production hall excluded. Due to our price proposed, we assume the installation of the supply lines (current and air) and the connection to the machine to be carried out by the customer.

Price:
Information on the relevant design concept meeting your individual application are available in the commercial documents attached. We hope the concept, as described above, meets your demands and fully attracts your interest. Should you have any questions about the concept or should there be any uncertainty, please do not hesitate to call us. We will be glad to help you with further information, or try to find other technical design concepts together with you. We are looking forward to receiving your feedback. Kind regards from Solingen Wichelhaus GmbH & Co. KG Jrg Demtrder

-8Bank Details: Stadtsparkasse Solingen Account No.: 528 083 (Bank Code: 342 500 000), SWIFT-ADRESS SOLS DE 33 Competent court of jurisdiction and place of performance is Solingen. The company is based in Solingen. Register Court: Local Court (Amtsgericht) Solingen HRA 23144

-9Bank Details: Stadtsparkasse Solingen Account No.: 528 083 (Bank Code: 342 500 000), SWIFT-ADRESS SOLS DE 33 Competent court of jurisdiction and place of performance is Solingen. The company is based in Solingen. Register Court: Local Court (Amtsgericht) Solingen HRA 23144