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Recent Developments In Dyeing
F or centuries, water has been the most important element in textile f inishing. Today, it constitutes an
increasingly expensive medium.
Germany-based Then Maschinen GmbH's Airf low dyeing concept was invented by Wilhelm Christ and
subsequently patented in 1978 by Then, which produced the f irst prototype. Over the years, the system
was developed f urther according to the requirements of the industry.
The long tube design, superior fabric displacement
and gentle polytetrafluoroethylene rods contribute
to the success of smooth treatment meeting high
quality demand for Then Maschinens newly
developed Airflow Lotus 200 dyeing machine.
Air Instead Of Water
Airf low was the key element of the technology, as air is an
ideal transport medium. The replacement of dye liquor
with air as a method of transporting piece goods in jet-
dyeing machines was a big step toward reducing water
and chemicals consumption. Compared to the jet system in which the nozzles are f illed with liquor, nozzle
pressure is negligible, thus of f ering optimum protection of sensitive textile surf aces. At the same time, the
use of the mass f low principle provides a major improvement in f abric hank laying, thus preventing creasing.
The moisture-saturated airf low ensures the unif orm distribution of temperature on the f abric and in the
machine, constituting a prerequisite f or even and reproducible dyeing. Moreover, the low level of liquor in
the dyeing boiler means the f abric is lighter than in conventional machinery and can theref ore be
accelerated quickly to high speeds. Thus, the risk of draf t or strain is minimal, which is particularly
advantageous with regard to the f inishing of items containing elastane f ibers.
The high transportation speeds of the f abric result in very short f abric turn time. High heating-up gradients
are possible because a very low liquor ratio is maintained. The unique ability to use a hot drain system and
rinsing with f resh water in a running wash system considerably reduces the time required f or the dyeing
process.
The Airf low technology represents the combined result of the entire range of possibilities provided by the
technology. Through the interplay of all technical possibilities and f unctions, economic and ecological
advantages over the traditional dyeing technology are achieved. The main advantages are as f ollows:
unlimited f lexibility with regard to all f iber - except pure wool - and f abric weight classes between 30
and 800 grams per square meter, as well as all standard market dyestuf f s;
the lowest liquor ratio on the market: approximately 1:2 f or man-made f ibers and 1:3 to 1:4 f or
natural f ibers, depending on the article and structure;
energy savings of up to 40 percent, thanks to a f requency converter, and the use of air as a
transport medium, while all other systems need water;
a reduction in the overall process time of approximately 25 percent; and
lowest water/wastewater levels.
The New L-shape Airflow
However, the Airf low dyeing machine had one disadvantage: dyeing of extremely delicate f abrics didn't give
a perf ect result. Current and f uture trends pointing toward more and more lightweight f abrics with high
contents of elastane in f inest yarn counts and gauges prompted the next stage of Airf low machinery
design.
To meet the required voluminous hand as well as top-grade quality standards, the world's f irst long-tube
Airf low machine, the Airf low Lotus 200, was developed. The new dyeing machine incorporates the latest
advances in Then's Airf low technology and operates according to the original aerodynamic principle. The
dye liquor passes the self -cleaning f ilter and is then evenly applied and f inely distributed as a mist with the
aid of the blower, assuring outstanding penetration, according to Then.
Schematic drawing of the Airflow
technology: Air is the key element, and is said
to be the ideal medium to transport piece
goods in dyeing machines.
Handling Delicate Fabrics
The Airf low Lotus 200 is said to be especially
suitable f or the wet f inishing of delicate cellulose-
and man-made-f iber knitwear and woven f abrics
with a high percentage of elastane. Such f abrics
are used in the automotive, lingerie, sports-,
leisure- and swimwear segments. Close attention
has also been paid to the achievement of
signif icant savings of precious water and energy
resources -- similar to the Airf low Synergy dyeing
machine.
Extremely saf e and gentle product running and outstanding displacement comprise Airf low Lotus 200's
characteristics. With its concept in machine design, unmatched results in process technology and
unparalleled achievements regarding economy and ecology, the new machine will substantially extend the
f ield f or aerodynamic applications, Then reports.
The newly designed dome blower ensures that the f abric is transported just by air. This means the liquor
actually is used to do what it is meant to do: dyeing only. The liquor ratio is reduced to between 1:2 and 1:5
and provides savings in terms of water and water treatment, chemical, and energy costs. This will bring up
to 80-percent savings of liquor compared with costs associated with outdated hydraulic machines, as well
as signif icant savings of time. Shortest cycle times and loadings of up to 1,200 meters f or lightweight
f abrics and up to 200 kilograms f or average articles allow high daily production rates.
Polyamide Dyeing
Most of the f abrics f or lingerie, swimwear and automotive applications are made of polyamide. That's why
the new L-shape dyeing machine handles f abrics made of 100-percent polyamide with the same results as
previously mentioned f abrics. Then's Roland Adrion, senior sales manager, says that "current and f uture
trends point towards more and more lightweight f abrics with high contents of elastane in f inest yarn counts
and gauges. Meeting the [voluminous hand specif ications] as well as top-grade quality standards were
there when we developed the world's f irst long tube Airf low machine, the Airf low Lotus." Perhaps a more
appropriate name f or the new machine would have been "Longf low."
March/April 2010