At ITMA in Milan, Italy, from June 8–14, 2023, Weko and RotaSpray, two of the industry’s top producers of rotor spray minimum application systems for textile dyeing, finishing, coating, and moisture control, will have a booth at Hall 14, Stand B103.
According to Jayanta Sanyal, head of technical sales and processes at Weko, “the global textile industry is suffering from COVID-19 impact, the highly unsustainable use of water, energy, and chemicals, as well as an immense cost pressure.”
Because of this, Weko and RotaSpray have examined current operations in dyeing and finishing mills to identify areas for growth in sustainability, efficiency, and profitability.
One of the primary dyeing methods used today is discontinuous and uses much water and a lot of manufacturing time and drainage. The current continuous dyeing range solutions use a lot of energy and chemicals and put much strain on the wastewater treatment facilities. The business stated in a news release that cost- and scrap-efficient manufacturing of tiny batches is virtually feasible in a typical continuous dyeing range.
A minimum rotor spray application technique developed by the German firms Weko and RotaSpray might reduce this gap.
These technologies combine several advantages, including minimal pick-up, no tailing (contact-free application), steady and accurate production, low drainage, significant energy cost reduction, absence of centre-side variation, absence of hydrolysis, concerns with substantivity or compatibility, and single and dual side dyeing.
The reactive, Sulphur, pigment, VAT, and dispersion dyeing on fabric or denim yarn stage might be done using the rotor spray method. Using novel procedures created by Weko and RotaSpray is the essential answer in addition to the unique spray technology. For instance, the PS2 process in place of the conventional PDPS process, the PSB35 process in place of CPB, and many others.
Compared to the traditional PDPS method, the PS2 process might cut the start-up scrap rate by 90% and save up to 1.350 tonnes of CO2 emissions annually. A novel approach of a compact slasher colouring range for denim was recently created and will be showcased at the upcoming ITMA 2023. A continuous polyester disperse and pigment dyeing process employing, yet another newly developed technology is the most recent advancement, made in collaboration with partners: Weko-Spray plus Weko Dry plus Weko Fix.
Advanced near-infrared (aNIR) light energy, high-performance NIR energy management, and precisely timed moisture extraction comprise the Weko Dry-E and Weko Fix-E technologies. The aNIR principle responds quickly and with relatively little energy. Since electromagnetic waves have the most significant energy densities and affect molecules of other substances much more quickly than cotton, viscose, or polyester fibres, the technique is still widely used in many different sectors.
Weko Dry-E and Weko Fix-E are powered exclusively by electricity. These units may be employed with renewable energy sources to achieve carbon-neutral manufacturing.
The method may be used for many dyeing and finishing lines, but when combined with a simple rotor spray application system, it reaches its fullest potential. Consider the energy savings that can only be attained by the format setting and rapid start/stop feature. Additionally, water molecules are removed up to six times quicker in several procedures like standard stenter frame drying. “This could be a huge step forward in textile processing to reduce the carbon footprint,” Sanyal continued.
