Auxiliary Machine #3617287

After weaving, the Denim fabric must be chemically and mechanically treated to give it a soft and pleasant handle and correct dimensional stability, both in the warp and the weft, to prevent shrinkage in subsequent washing. SWASTIK has recently introduced a continuous Denim De-Sizing and Finishing Range putting together a Singeing machine - Impregnator - Steamer - Washing Range - Pre-Drying and Shrinking machine to work as a continuous line.

The plant can be supplied with different preparation and dosing tanks for softeners and sensors to visualize and control the shrinkage, control fabric moisture facilitate the shrinkage of denim and obtain the best quality and productivity of the plant. The range is normally equipped with a pneumatically operated positively driven Unwinding device with a stainless steel scray for continuous operation at the feed end and a stainless steel scray with a Big Batching and Plaiting device at the Delivery end. Gas Singeing Machine essentially incorporates Slit type Water Cooled Burners suitable for Natural/Petrol Gas firing with possibility of penetrating or floating flame; Water cooled Rollers after the Burner; Brush Rollers positively driven by direct coupled motors with a Suction device and Exhaust for dust removal. and an impregnator with a Squeeze Nip for de-sizing chemicals.

The Steamer which follows the Impregnator is equipped with a Steam Conditioning Unit, Steam Seal at fabric entry and Water Seal at the outlet. A well insulated Steam Chest is provided to avoid water condensation. Steamer capacity 30-60-90-120 meters as may be required. Washing Tank : Stainless Steel Wash Tank STN-15-STN-20-STN-25, equipped with AC Invertor Drives are provided to wash the De-sized fabrics. Please refer individual catalogues for full details. A Pre-Dryer with an adequate number of Drying Cylinders with a Heavy Squeezer and a width shrinking device follows the Washing Range. This is Followed by the Shrinking Range.

Though fabric singeing is a well established and long known process, it's relevance today to the modern finisher is greater than ever before. The constant demand for better quality fabrics, particularly blended fabrics with their susceptibility to pilling, has focused more attention on the singeing machines. SWASTIK's singeing machines, running in the industry for well over 35 years, are suited to process all types of fabrics from lightweight voiles through to heavyweight denims woven from a wide variety of fibers including cotton, polyester, viscose, wool, linen and blends of these as well as other fibers.

Mercerising can be done at different stages during the pre-treatment process. This could be after Desizing or after Scouring or after Bleaching. When done after desize-washing, it induces maximum lustre onto the fabric. However, contamination of lye can occur, which reduces life of the caustic lye. High degree of whiteness can be achieved if the bleaching process is done after mercerisation. Mercerisation after scouring and bleaching prevents contamination of caustic lye but effects the whiteness and absorbency. Mercerising can be done either on wet fabric with a lye concentration controller or on dry fabrics. Mercerising could be done with either cold lye or with hot caustic.

FABRIC FEEDING

Fabric feeding through Guiding and Centering devices. Positively Driven Batching-off unit with / without J scray for low tension and continuous working. Combination of three individually easily adjustable Curved Bar Rubber Expanders to feed Fabric in stretched condition.

LYE IMPREGNATOR

Made from Stainless Steel unless otherwise specified. Caustic lye impregnation with rollers dipped in lye as well as by caustic filled nips formed between top and bottom rollers. Grooved Bottom Rollers for better width stability. Dwell time control by speed adjustments. Driven rollers at regular intervals can be supplied for tension control. Can be equipped with chiller / heater for lye temperature control. Equipped with automatic / manual continuous filtering arrangement. Automatic fresh lye addition to maintain uniform caustic lye consistency to pre-adjusted concentration.

IMPREGNATOR WITH DWELL ZONE

Mercerisers Model M-10 and above have the Impregnating zone subdivided into a Impregnating zone and a Dwell Zone. It is possible to use caustic lye in all sections or use caustic lye in the first Impregnator and use the second as a dwelling zone. For specific fabric tension requirements, drive to the intermediate bottom rollers can be provided to reduce tension in the fabric under process, ensuring better control on width.

TENSION CONTROLLED DRIVE

Facility to over-feed fabrics to ensure better width stability. Programmable / pre-set speed between various individual drives. Multi-point Variable Frequency Drive with encoders to maintain uniform tension. Constant fabric tension.

STABILISER

Excellent cascading throughout the passage in Stabiliser. Intensive Neutralisation with the help of fast liquor circulation in each cascade. Grooved Bottom Rollers for better width stability. Precise temperature control near boiling point guarantees best caustic removal from fabric. Excellent dimensional stability after stabiliser. Constant and uniform concentration of overflowing wash liquor.

SQUEEZING AFTER IMPREGNATOR / STABILISER

Nip formed with Wear resistant Stainless Steel / Ebonite roller and special Rubber Roller for excellent caustic removal and longer life. Adjustable nip pressure upto 30-50 kg-cm. Automatic opening of nip when machine stops. Drive through direct-coupled Motor-Gearbox with Variable Frequency Drives.

WASHING

Various options and combination of wash boxes are available depending on fabric quality like STN 18 for Normal woven fabrics / STN-25 CP for heavy fabrics / Drum washer for delicate fabrics. Precision control can be achieved with load cell and encoder for closed loop tension control to prevent linear and width shrinkage. Minimum water consumption through excellent counter-current water flow between washing sections. Intensified Washing action with elevated temperatures and counter flow of wash liquor. Powerful interchange between wash liquor and fabric with fast liquor exchange in the fiber. Highly efficient removal of residual caustic. Highest washing efficiency at all speeds.

SQUEEZING AFTER WASHING

Each Washer is equipped with: Intermediate Squeeze Nip for bath separation. Low tension crease-free fabric movement. Fabric Expander before ni p. Stepless pressure regulation. Final nip is heavy duty, high pressure and of special design for excellent and uniform extraction throughout the width. Drive through direct-coupled Motor-Gearbox with Variable Frequency Drives.

LIQUOR CIRCULATION

A suitable pump with a filtering arrangement is provided in the Impregnator, which delivers the filtered caustic lye back into the Impregnator through a distribution system located between each Roller. On request, the machine can be equipped with a continuous auto cleaning filter. The stabiliser is compartmentalised and each compartment is provided with a Stainless Steel Pump which collects the hot wash liquor from the first washing compartment and pumps it to the last section of the stabiliser. This liquor is spread onto the fabric. Similarly from this last section, the liquor is collected, filtered and pumped to the preceding section. This continues till the first stabilising section, where the accumulated liquor is taken for recovery / disposal. The flow of liquor in the direction opposite to the movement of the fabric ensures excellent removal of caustic. SALIENT FEATURES Modular design, tailored to suit individual requirementsGrooved Bottom Rollers for better width stability. Low width shrinkage with excellent dimensional stability. Mercerised fabric has excellent lustre, high absorbency, better handle, uniform and repeatable finishing results. Can be equi pped with PLC controls for different functions such as fabric tension in Impregnator and Stabiliser, Shrinkage-Controller-cum Indicator etc. pH Indication / Control at the end of Washing, dwell time control by controlling speed flow control for walls & NaOH concentration control etc.. Lower Lye, Water and Steam Consumption. Low maintainance . Lower incidence of re-dyeing ACCESSORIES WET-ON-WETThe SWASTIK Merceriser can be provided with a NaOH preparation tank, chilling arrangement for the lye and a caustic recovery plant, if required. The machine can be supplied with acid neutralization system in the washer and a Dryer. WET-ON-WET MERCERISINGDesize Impregnated Fabric can be Mercerised right away in our Wet-on-Wet Merceriser WWM-X. The number of WashingCompartments depends upon the quality of fabric and the production required. In cases where the fabric is Mercerised after Scouring, Wet-on-Wet mercerising is possible using only one Pre-wash Tank. Washing after mercerising remains standard. A heavy duty Squeeze Nip "Hi-Squeeze" with anti-deflection roller prior to the Impregnator enables uniform mercerising results. Impregnator for Wet-on-Wet Merceriser is equipped with an automatic Lye concentration controller. HOT MERCERISINGBeing a cost effective measure, the tendency to use Hot Mercerising is on the increase in recent years. Hot Caustic lye (at about 60C) penetrates better and more evenly to the yarn core (of the fabrics). Swelling is better as compared to cold Mercerising which helps to improve the dimensional stability of fabrics. Hot Mercerising ensures even Dye penetration and imparts a softer handle and better appearance. Shorter impregnation time requirement reduces investment cost. For Hot Mercerising, the Impregnating section is equipped with an indirect steam heating system with a temperature controller to maintain uniform temperature. THE COLD IMPREGNATION PROCESSThe traditional cold impregnation process imparts more lustre to the fibre than the hot impregnation system mainly due to the greater shrinkage and high tensions needed the re-stretch the fabric to the desired width. WIDTH STABILITYcan be achieved by differential speed setting of the squeezing units, controlling the shrinkage or elongation of the fabric. This can be done manually or through automation, using PLC. COMBINED CHAIN AND CHAINLESS MERCERISERBesides Lustre, Depth of Colour and fabric feel, dimensional stability of the fabric is the most essential objective of mercerization today. These can be fulfilled with the Combined Chain and Chainless Merceriser. The length and width of the fabric can be controlled at will (within physical limits) using the combination of Chainless driven rollers with fully controlled drive and a stenter frame. The layout of the machine is shown in the layout drawing below. The intensive impregnating zone is followed by a reaction zone. Up to this point the fabric guidance is on the chainless princi ple. A part of the stabilizing zone is a stenter section using the pin chain princi ple. Final stabilization compartment is again chainless and is followed by the normal high-efficiency washing and neutralizing compartments. In the Stabilizing Zone, the uniformly applied lye is removed. Hot weak lye is first sprayed onto the fabric. Gradually reducing the shrinking force. In this condition the fabric can be stretched to the desired width with a comparatively less force. The possibility of stretching on the stenter ensures uniform shrinkage and even distance between warp yarn from the selvedge to the center. This is an important advantage of the Combined Chain and Chainless Merceriser if dyed woven or striped fabrics are to be processed. Increase in fabric width can also be achieved. The pin chain permits stretching by increasing the speed or shrinkage through fabric overfeed. AUTOMATION SWASTIK offers a fully automated machine with the most modern PLC control system which ensures optimum production. Thelevel of automation can be designed for specific requirements of individual customers. Typical level of automation to access andcontrol basic machine parameters, functions and displays using PLC with Graphic Colour Screen Display of various functions ona Touch Screen, can be as follows: Drive synchronisationAutomatic Speed Control of machine through programmed Dwell timeLye Dosing and concentration control as per set parametersLiquor/Water Flow proportionate to fabric weightLevel controlTemperature controlFabric Tension control by overfeeding in the Impregnator and StabiliserAcid Dosing with pH control. The system can be interconnected to a host computer or to other PLC for networking or data monitoring. Remote access of the control system is possible through use of a modem connected to the PLC. Automatic operation and control with necessary sensors provide extremely efficient operations. Lye concentration and dwell time control with perfect temperature regulation, ideal water flow regulation, level control etc. provide for excellent mercerising effect. A pH controller helps achieve neutral fabrics before drying and a Moisture Controller prevents unnecessary over-drying of the fabrics.

Equipped with Pre Washers, Hi-Squeeze Mangle, a unique design of Impregnator with MAT technology permitting over 100% pick-up with dosing system and automatic controls. Combi-Steamer with Roller Bed Conveyor and tight strand passage. Efficient Washing Units and Dryers. Drive is fully synchronized with tension Control Cells- and AC Frequency Controller. Working Width : 1200mm-3200mm.Combi-Steamer Capacity : 900 to 1800 meters.Tight Strand : 60 to 200 meters

For more than 40 years SWASTIK has been engaged in manufacturing. Wet processing Equipments. SWASTIK has been always ahead of others in India in designing and manufacturing. Modern and latest equipment, be it a continuous Dyeing plant or a loop steamer or a Rotary Screen printing Machine or a compressive shrinking Range. Therefore it is not a coincidence that in 1978, SWASTIK was the first in India to launch Combi-Steamer, a concept which has now been adopted internationally. The Present open Width Scouring and Bleaching installation offered by SWASTIK can claim considerable economical and technical advantages. The first continuous Bleaching plant with CombiSteamer has been in operation for over 12 years now.

Main Features

Flexibility carefully engineered Robust construction- standardized components minimal and controlled cloth tension- optimum attainable absorption of chemicals along with low consumption of chemicals. SWASTIK offers pre treatment plant in single of multiple stages and in combination with various units to cater to small production of 30, 000 mts/day to full size Range for 1, 00, 000mts/day production.

PRE-TREATMENT RANGE

Impregnator

SWASTIK Impregnators are designed for M.A.T. and equipped with Wiper Rollers of suitable rubber to obtain 100% or more pick-up (up to 130% ) A vacuum slot is located at the entry of fabrics in impregnator from preceding Hi- squeeze Nip for certain qualities of fabrics. Fabric from Vacuum Slot / Hi-squeeze Nip passes through the trough with minimum liquor for light interchange dip before being subjected to a spray of chemicals with designed concentration and quantity with the help of a well designed, fully automatic dosing system. A set of wiper Rollers are provided to enable uniform add on, as may be required.

Universal Combi-Steamer CS-4

The SWASTIK CombiSteamer is designed keeping in view present day requirements and is a multipurpose reaction chamber for continuous open width preparation range. The combi-steamer is provided with a steam lock the at entry end and a water seal arrangement at the delivery end. Fabric is fed from the bottom, through the steam seal, using steam DOME principle. The heavier air sinks downwards, displaced by lighter steam, making the steamer absolutely air free which simultaneously results in lower steam consumption. The air-free atmosphere ensures optimum fabric temperature, which results in chemical reactions at optimum speed. The SWASTIK combi- steamer has exceptionally low steam consumption steam required to heat up the fabric, and the steam required to heat up the fabric, and the steam required to compensate for the unavoidable heat losses. A Roller Bed CombiSteamer Steamer (With Horizontal and vertical Tight Stands) designed keeping in view present day needs is a multipurpose reaction chamber for Continuous fabric preparation range for all kinds of fabric.

Tight Strand Passage

Fabric delivered through the wiper rollers is guided to the CombiSteamer through a steam lock to maintain air-free atmosphere in the steamer. A small horizontal run on fight strands, ideally suited for M.A.T. precedes the larger tight strand section. Tight strand passage is provided with single / double loop threading, depending upon capacity requirements, and can be equipped with multiple (from 2-5 ) sections and having 60 meters 240 meters holding capacity. Recipe related dwell times, from 1-10 minutes, on tight strands, complete with Tension Control devices acting on Frequency controlled AC Drive of each section are adjustable. Roller Bed conveyor consisting of positively driven stainless Steel Rollers transports fabric in small loops from one end to the other in absolute Relaxed condition, for pre-determined dwell times varying from 10 to 40 minutes or more, as may be required. Holding capacity varies from a few hundred meters to 1800 meters depending upon the number of sections. Precise and crease-free fabric delivery through Infra Red full width sensors (European origin) located at the delivery end of the Combi-Steamer. Automatic synchronization with precise and minimum tension through out the CombiSteamer and entire range. Quick change to Tight strand passage only easily achievable. Ideal Steam Condition with dry saturated steam condition in air free atmosphere . A suitable steam conditioning device placed outside near the machine feeds dry saturated steam at atmospheric pressure. The steam distribution system in CombiSteamer is, both economically and technologically very important. The SWASTIK Roller Bed Combi-Steamer has no sump. But direct saturated steam is injected which heats faster and consequently has lower down times. There is no risk of marks caused due to liquor splashing. The Roof is provided with indirect heating to avoid condensate dropping.

Washing

CombiSteamer outlet is attached to special Stainless Steel Washing System where crease-less fabric coming out from CombiSteamer passes on to a wash tank through a water seal arrangement without coming in contact with Air, and without losing much heat. This acts as a water lock for steamer and helps wash fabric impurities / effluents efficiently, at almost reaction temperature. This effectively prevents possibility of coagulation of saponified waxes or emulsified impurities. Number of Washing tanks can be installed depending upon production requirements. For further details of washing compartments please refer our catalogue of Washing Ranges.

Automation

SWASTIK Pre Treatment Ranges can be equipped with various Automatic Controls.Temperature Controllers in Washing Tanks, and CombiSteamer.Level Controller in Impregnator. PLC / Micro Processor Controlled Full Automation for Dosing chemicals based on fabric Weight and recipe, complete with storage tanks, mixing tank and re circulating system, pH indicator of indicating controller for final washing can also be provided.Steam Conditioning unit CombiSteamer with Level and Pressure Controller.

Available for all kinds of wet processing treatments like De-sizing, Scouring and Dyeing. Equipped with an adjustable Tension Control Device, the Maxi-Jig Electronic, operates with absolute controlled tension. Available in 1400-1000-800-300 batch diameter capacities.

For more than 40 years SWASTIK has been engaged in manufacturing. Wet processing Equipments. SWASTIK has been always ahead of others in India in designing and manufacturing. Modern and latest equipment, be it a continuous Dyeing plant or a loop steamer or a Rotary Screen printing Machine or a compressive shrinking Range. Therefore it is not a coincidence that in 1978, SWASTIK was the first in India to launch Combi-Steamer, a concept which has now been adopted internationally. The Present open Width Scouring and Bleaching installation offered by SWASTIK can claim considerable economical and technical advantages. The first continuous Bleaching plant with CombiSteamer has been in operation for over 12 years now.

Tension

The pre-set programmed tension remains constant throughout the process. It can be selected for every programme step and remains constant even when reversing, and can be displayed on screen.

Speed

The programmed speed remains constant and is independent of the load . Speed for each step can be programmed as desired and displayed on screen.

Oscillation

When the programme demands a stoppage or at the end of the final run, the machine switches to an oscillating movement. Oscillation can be set between 1 to 5 revolutions, always on the bigger batch side.

Re-Circulation

Bath re-circulation with a stainless steel pump, to obtain uniform dyeing and to improve chemical exchange, can be provided. On request a small chemical addition tank can also be provided.

Dosing

Dye-stuff and chemical are added as programmed with the help of a dosing system which can be controlled by a PLC. Maxi-Jig Electronic MJE 1400 is the most innovated machine for preparation, pre-treatment and dyeing of fabric in open width. The machine is completely manufactured from Stainless steel and is suitable for all the processes where constant speed and tension of fabric are absolutely required. The Maxi jig Electronic MJE-1400 is suitable for processing Cotton Viscose-Silk wool Polyester, flax and its blends. The Maxi-jig Electronic is equipped with individual motors controlled by special frequency controller. Tension is adjustable between 25-250 gms./cm. (linear). Maxi-jig. Electronic is equipped with a PLC /Micro Processor, Re-circulating device and filter and is fully automatic.

Salient Features

1. Completely made of heavy gauge stainless steel quality AISI 316. 2. Water tight panoramic doors, Pneumatically operated. 3. Self supporting structure on Stainless Steel AISI 304 plates. 4. Stainless Steel Draw Rollers of strong construction made of AISI 316 pump. 5. Rocker arm in Stainless Steel with shift regulated by batch diameter. 6. Direct control of Tension through load-cells acting on Torque controlled motors. 7. Trough also suitable for very small capacity for dyeing smaller lots. 8. Speed controlled through PLC/Micro processor up to 180 meters/minutes. 9. Auxiliary tank for bath preparation- on request.

A suitable Feeding Device with a Stretcher at Entry, a Caustic Treatment Section with wet fabric Stretchers - specially designed to feed fabric in creaseless manner, followed by a dwell zone. A pneumatic Squeezer is provided at the end of dwell zone. Squeeze Rollers are made from special rubber to get better squeeze. A highly efficient washing system with tower washers, with rows of water spraying devices, a large water collecting tank, with a filter and pump is provided for re-circulation. A suitable overflow system is provided to collect the residual caustic from the tank, which is taken to caustic recovery system. The number of Washers depends upon the production requirement. A small Neutralizing Tank is provided before the last tank

SWASTIK Balloon padder is a strong and sturdy machine, equipped with various devices. It is a available in two different models, one with Single Squeezer for extraction and the other with Double Squeezer, first for squeezing and final for chemical treatment.Main frames are fabricated, and lined with stainless steel (optional) which house the requisite components. The Squeezer Rollers, Which are 1.4 meters wide are covered with special synthetic Rubber PU compound, to obtain uniform and high squeezing effect with low pressure. The resulting finish is excellent.

SWASTIK Balloon padder is a strong and sturdy machine, equipped with various devices. It is a available in two different models, one with Single Squeezer for extraction and the other with Double Squeezer, first for squeezing and final for chemical treatment. Main frames are fabricated, and lined with stainless steel (optional) which house the requisite components. The Squeezer Rollers, Which are 1.4 meters wide are covered with special synthetic Rubber / PU compound, to obtain uniform and high squeezing effect with low pressure. The resulting finish is excellent. Ballooning device consists of an Air Injection Device and a few pairs of S.S. Guide rollers which control the Ballooning effect. Drive to the machine is provided with individual motors for infeed device, and to each Squeezer. All drive motors are controlled by A.C. Invertors to obtain Tension-free working, with speed ranges from 0 to 50 Mtrs./min. or as may be desired. Delivery is by means of a plaiter and equipped with a conveyor.

Equipped with Pre Washers, Hi-Squeeze Mangle, a unique design of Impregnator with MAT technology permitting over 100% pick-up with dosing system and automatic controls. Combi-Steamer with Roller Bed Conveyor and tight strand passage. Efficient Washing Units and Dryers. Drive is fully synchronized with tension Control Cells- and AC Frequency Controller.