PAD THERMOSOL

This is one of the most important machines used for continuous dyeing of blended
fabric mainly polyester- cotton. It can be used for 100% cotton fabric.
MAIN SECTIONS OF THE MACHINE:
The main sections of the machine are
1. Entry
2. Padding
3. Airing
4. Infra red
5. Drying
6. Curing
7. Exit
Parameters for Thermosol process

Pad dry cure Process

Pad Dry & Cure Temperature Pad-dry
Temperature
Reactive 160 to 180 C 120 C to 130 C
Disperse 190 to 210 C 120 C to 140 C
Pigment 150 to 170 C 120 C to 140 C

SPECIFICATIONS OF MACHINE

GSM OF FABRIC DYE SPEED m/min I NTENSITY OF IR TEMPERATURE OF C

HAMBERS ( C )
1 2 1 2 3 4 5
100-170 Disperse or Disperse + reactive 70(disperse) & 65 (disperse + re
active) 20 30 115 130 160 200 200
170-270 Disperse or Disperse + reactive 45 30 35 115
130 160 200 200
100-170 Reactive 55 (100% cotton) & 65 (PC) 20 30
115 125 140 160 160
170-270 Reactive 45 30 35 115 125 140
160 160
% Of Dyes in g/l Dyeing recipes in g/l
Soda Bicarb Urea M/agent
Primasol FFAM or Eqv Sequestering agent Resist salt Soda Ash
0.5 10.00 40.00 5.0 1.0 0.5 10.00
1.0 10.00 40.00 5.0 1.0 1.0 12.00
5.0 12.00 50.00 8.0 1.0 1.5 15.00
10.00 15.00 60.00 8.0 1.0 1.5 15.00
20.00 - 70.00 10.0 1.0 2.0 20.00
30.00 - 80.00 10.0 1.0 2.5 20.00
Constant Parameters for Thermosol Process
Pick up 65% - 70%
Bath (trough) temperature 35-40 C (Room Temperature)
. Ph 7.5—8.0 / Neutral

DESCRIPTION OF THE MAIN SECTIONS:

FABRIC ENTRY COMBINATION:
The fabric entry combination is the complete unit from the loading of the fabric
into the machine up to the inlet of the treatment machine. The fabric entry com
bination serves the optimized and pretreated feed of the fabric into the machine
.
Depending on the particular requirements for a machine, the entry combination ca
n contain a wide range of different assemblies. Their configuration is determine
d essentially by the different production conditions and the local situations.

MAIN PARTS OF THE ENTRY SECTION:

The main parts of the entry section are
1. Tensioner
2. Draw roller
3. Scray
4. Compensator Roller
5. Guide rollers
6. Web Guiders
7. Brake Roller
TENSIONER:
The tensioner can be infinitely adjusted by hand so that the requisite longitudi
nal tension in the fabric can be created
DRAW ROLLER:
Depending on the type and design of the machine, one or more draw rollers instal
led at inlet. Electrical motors with speed reduction gears drive the draw roller
.
SCRAY:
It’s a J shape box. Feed compensation devices store the fabric reserve necessary t
o allow a fabric change to be carried out with machine running.
Depending on the type and configuration, the J box at the inlet may have one or
two draw rollers at its entry.
The drive comes either directly from an electric motor with gearbox or have an a
dditional drive unit
COMPENSATOR:
The compensator is used to ensure even speed running. It is infinitely pneumatic
ally variable so that the necessary longitudinal tension can be produced in the
fabric.
GUIDE ROLLER:
Guide rollers serve to deflect the fabric web in the desired direction. A motor,
thus reducing the fabric tension, supports the movement of the guide rollers.
WEB GUIDERS:
The web guides are used to automatically guide the fabric with straight selvedge
s and without creases into the production machine. The web guides are operated p
neumatically with filtered compressed air. The roll contact pressure can be adju
sted to different fabric qualities through control unit.
ADJUSTMENT SUPPORT WITH HAND WHEEL:
The adjustment support serves to mount and adjust the width of example fabric we
b guiders. It consists of the guide tubes with integral adjustment spindle. Adju
stment is done by hand wheels.
BRAKE ROLLER:
When unbaked, the brake roller is driven by the fabric. Actuating the pneumatic
brake slows the roller movement and thus increases the fabric tension.
WET PICK UP MEASUREMENT AND DYE PADDER CONTROL:
In all continuous dyeing process involving a padder, the objective is to achieve
uniform dyeing both across the width as well as throughout the length of the fa
bric run. It is generally true for all padding processes involving the applicat
ion of substances dissolved in water or solvents, that the quantity applied (in
the case of % dye) related to the textile substrate weight it is dependant on th
e liquor pick up and concentration of the liquor.
So in continuous dyeing, the desired applied quantity of dye primarily dependent
on dye liquor concentration and the liquor pick up or moisture level. Assuming
that the concentration of dye liquor during the dyeing is kept constant within c
ertain limits then the liquor pick up remains the decisive parameter. In continu
ous dyeing this again is mainly determined by the padder nip pressure.
So before entering into the airing section the wet pick up of the fabric is chec
ked from left, right and center by AF310.
MEASURING PRINCIPLE OF AF 310 OF PLEVA:
The AF 310 fabric moisture measurement device is based on the principle of micro
wave absorption by water. A special semi conductor based oscillator produces mic
rowave in the 10GHz region. The fabric being measured is radiated with this high
frequency current, which is of only low power (approx 5mW), via three emitter h
eads. Corresponding receiver heads are located on the opposite side of the fabri
c. In the measurement zone between the emitter and receiver heads, a part of the
emitted microwave energy is absorbed depending on the quantity of water molecul
es.
In this way, the absorption, which is a measure of the absolute water content of
the fabric, is reproduced in the form of scale divisions. The absolute moisture
content in the center of the fabric (0-100 scale divisions) is indicated and ad
ditionally, the moisture level differences at both edges of the fabric (-10 to +
10 scale divisions) are given on the panel of the machine.
The adjustment of the padder pressure can be automatic or manual. With out contr
ol, there is the possibility to recognize faults arising in the pre treatment an
d also eliminate them at that stage. The application of a control system compens
ates or them, as long as the faults are not too large.
AIRING:
The airing section consists of 6- 8 top and bottom rollers. Theses rollers are f
reely driven. The purpose of this section is to little bit dry the fabric before
entering into the IR.
PRE DRYER (IR):
Depending on the type and configuration of the machine, several pre dryers may b
e arranged in series. There are two pre dryers installed at the machine. The dra
w roller is located at the outlet of the each pre-dryer, which transports the fa
bric out of the pre-dryer.
The fabric is dried by gas heated radiators rows in the pre dryer. The heaters c
an be swung in or out. The burner power and thus the radiation intensity can be
infinitely varied.
Actually there is a ceramic plate, which is heated by gas and thus produces infr
ared radiations
COMBUSTION PROCESS OF IR:
There is a pipeline through which Sui gas is coming and the line has a pressure
reducer, which reduces the pressure of gas than this gas is passed in the mixer.
Where the air from the combustion air fan is coming.
Each pre dryer has a combustion air fan. This fan is used to ensure a controlled
supply of air and thus create a constant drying temperature in the pre dryer.
The air and gas mixture from mixer is passed in the IR from two points where spa
rk is provided by spark plug. Finally the combustion gases strikes the ceramic p
late and infrared radiations are produced.
There is a separate gas line, air fan for each IR
EXHAUST FAN:
Each pre-dryer is linked through a duct to an exhaust fan which discharges part
of the treatment air into the atmosphere. The discharged air is replaced by fres
h air. If several pre dryers are connected in series, only one fan is required.
DRYING AND CURING CHAMBERS:
GUIDE ROLLER DRIVE:
Guide rollers serve to deflect the fabric web in the desired direction. A motor,
thus reducing the fabric tension, supports the movement of the guide rollers.
TRNSPORT ROLLERS IN TREATMENT CHAMBER:
The transport rollers in the treatment chambers are motorized, thus reducing the
fabric tension.
DIAGNOSTIC DISPLAY OF FABRIC TRANSPORT SYSTEM:
The complete fabric transport system is monitored by a diagnostic display. The c
lear and logic arrangement of the indicator lights simplifies troubleshooting. T
he number of indicator light varies, depending on the type and configuration of
the machine.
TOP AND BOTTOM AIR:
In the air circuit, the heated treatment air is guided onto the fabric through t
he nozzle sets as top and bottom air. In “zero” position the ratio of top to bottom
air is equal.
AIR CIRCULATION FANS:
The two circulation fans and, in conjunction with the burner heating systems whi
ch are also arranged symmetrically, are ideally designed for the treatment proce
sses drying, thermosol fixing and condensing.
The air necessary for the process is circulated in the treatment chamber by air
circulation fans.
BURNERS:
The two burners per thermex unit are arranged symmetrically. The burner assembly
consists of the following main parts.
1. Gas inlet pipe
2. Fan for air
3. Pressure switch
4. Servo motor
5. Mixing chamber
6. Spark plug
7. Sensor
8. Transformer
9. Programmer relay
DESCRIPTION OF COMBUSTION PROCESS:
As the machine start fan of air start to provide air in the mixing chamber. The
pressure switch ensures the supply of air. If air is not passing into the mixing
chamber it will trip the burner. If the air is supplied in the mixing chamber i
t pass a signal to programmer relay and then programmer relay give the signal to
servo motor which control the damper of gas pipe and the gas is passed in the m
ixing chamber.
Transformer converts the 220-volt supply into the 7.5 KVA for spark plug. Spark
plug ignites the air fuel mixture. Sensor insures that either flame produce or n
ot if flame is produced than it hold the system at that condition otherwise pass
a signal to programmer relay which trip the system.
INTAKE SIDE CONTROL BUTTERFLIES:
The intake side control butterflies allow the volume of air circulated and thus
the air directed to the fabric to be infinitely varied. The control butterflies
are adjusted from the outside through adjustment mechanism.
SCREENS:
The screens prevent fluff, lint, etc. transported by the fabric from entering th
e air circulation. Depending on the type and configuration of the machine, it ma
y be equipped with double or single screens.
Machines with double screens have basic screens, which can only be removed after
Opening the service door and auxiliary screens which can be pulled out whilst th
e machine is in operation. Machines with single screens have only auxiliary scre
ens. On this thermo sol only auxiliary screens are mounted.
NOZZLE EDGE COVER:
The hot circulating air is directed onto the fabric as top and bottom air. In or
der to achieve a uniform treatment of the fabric even in the fabric selvedge are
a, motorized adjustable plates cover the nozzle outlet openings.
DIRECT GAS HEATING:
The chamber should be heated up only with the rollers running.
The air circulation fans must always continue to run after switching off the hea
ting until the ambient air temperature has dropped to below 100 C.
With direct gas heating the combustion gases from the fan burners heat up the ci
rculating air to treatment temperature.
Pt 100 SENSOR:
This sensor is used to control the temperature of the circulation air. If the te
mperature of the circulating air rises above the maximum possible value, the ove
rheating protection device that is Pt 100 switches off the corresponding burner.
Pt 100 is the common abbreviation for the most common type of resistance tempera
ture sensor used in the industry. It has a specified resistance of 100.00 ohms a
t 100 C and is made up of platinum, which has an accurately defined resistance v
s. temperature characteristics.
Pt 100 sensors were originally made with platinum wire wound on a ceramic former
but are now made more cheaply by depositing a platinum film onto a ceramic subs
trate.
MANFOR-MATIC:
The Monfor-Matic system is used for correct detection of the fabric temperature
during drying and thermosetting.
The Monfor-matic serves to optimize the drying and dwell process.
The Monfor-Matic measures the temperature difference between the air arriving at
the fabric and the exhaust air at two points. When the fabric has reached the t
emperature of the ambient air, the difference is zero.
When the nominal temperature is reached, the fabric must remain in the treatment
chamber for a short time. This time is referred to as the nominal dwell time.
Using these values, the fabric speed is controlled such that the fabric remains
in the treatment chamber only for the necessary nominal dwell time.
EXHAUST FAN:
Depending on the type and configuration of the machine, the hot flue chamber is
connected through a duct system to one or two exhaust fans.
On the left and right sides at the end of the treatment chamber, each thnermex u
nit have an exhaust air duct integrated into the chamber with control butterflie
s which can be adjusted from outside the chamber.
The exhaust fan draws the exhaust air with the evaporated water and any finishin
g agent vapors out of the heat treatment chamber and discharges them into the at
mosphere. The exhausted mixture is replaced by fresh air.
EXIT OF THE MACHINE:
The exit of the machine consists of following main parts
1. Measuring Roller
2. Cooling drum
3. Antistat
4. Folder
MEASURING ROLLER:
The measuring roller is a non-slip coated idle roller. Through a belt system, it
drives a counter for the transported fabric length.
DRIVEN COOLING ROLLER:
The cooling roller is used to reduce the temperature of the fabric. The cooling
roller is driven through a multiple-disc clutch system.
ANTISTAT:
The ionization system serves to eliminate static charges such as can occur parti
cularly when working with the synthetic fabrics.
FOLDER:
The folder consists essentially of the draw roller with pressure roller, the piv
ot arms, and the crank drive elements for draw roller and crank drive.
Depending on the type and configuration of the machine, the folder can be combin
ed with other fabric discharge units.
PRESSURE ROLLER AT FABRIC FOLDER:
In order to achieve an adequate and uniform fabric tension at the fabric folder
draw roller, the fabric is clamped between draw roller and pressure roller. The
contact pressure can be varied and thus adapted to the different fabric qualitie
s.