Union Minister Shri Giriraj Singh officially took charge of the Ministry of Textiles, here today. Former Union Minister of Textiles Shri Piyush Goyal handed over the charge to Shri Singh in the presence of Minister of State, Shri Pabitra Margherita.
Smt. Rachna Shah, Secretary, Ministry of Textiles along with other senior officers of the Ministry were also present.
On the occasion of assuming charge, the Union Minister for Textiles, Shri Singh said, “Textiles sector has huge employment opportunities. The industry also holds a large share in terms of global exports as well.” Shri Singh further asserted that textiles industry is also linked to the farmers and there will be efforts under the guidance of Prime Minister Narendra Modi to take the industry forward.
The Lenzing Group, a leading supplier of regenerated cellulose fibers for the textile and nonwovens industries, learned today that Lenzing’s main shareholder B&C Group and the Brazilian pulp producer Suzano S/A have signed a long-term partnership in connection with the majority stake in Lenzing. As part of this agreement, Suzano S/A will take over a 15 percent stake in Lenzing AG from B&C Group. Suzano is the world’s largest pulp producer based in Sao Paolo and recently achieved annual sales of more than EUR 7 billion.
Lenzing’s management welcomes the proposed transaction and looks forward working with another core shareholder.
Stephan Sielaff, Chief Executive Officer of the Lenzing Group, says: “Lenzing and Suzano are two companies that have come to know and appreciate each other in recent years as relevant players on the international pulp market. Based on the core competencies in the area of pulp production and operational excellence, Suzano can make a valuable contribution to the successful implementation of our strategy. For us, the constellation of the two strong core shareholders B&C Group and Suzano S/A is definitely a win.”
LMW and Sri Lakshmi Ganesh Spinning Mills’ longstanding partnership for OE Recycled fibre processing has been instrumental in setting benchmarks for producing recycled yarn. LMW’s smart series machinery has enabled Sri Lakshmi Ganesh Spinning Mills to process recycled fiber efficiently while ensuring the highest productivity & quality.
The inspiring journey of Sudhan Group traces its origin back to a humble yarn trading venture in 1985, the ethos of quality and growth has remained unchanged. Today, under the dynamic leadership of Mr. K C Chandrasekaran, Managing Director, and Mr. A C Hariharan Sudhan, Joint Managing Director, Sudhan Group has blossomed into a multifaceted enterprise, encompassing every stage of textile production. With over 1200 dedicated employees, Sudhan Group has evolved into a powerhouse, catering from fiber to fabric to trade, with an unwavering commitment to quality and customer satisfaction.
“Our partnership with LMW has been instrumental in transforming our spinning mill. With their latest technology and innovative solutions, we’ve boosted efficiency and cut operational costs. Most importantly, their support has led to a quicker return on investment, fueling our growth and setting new standards in our industry.” Mr. K C Chandrasekaran, Managing Director Commencing with a modest setup of 960 rotors for cotton processing, Sri Lakshmi Ganesh Spinning OE division mill quickly recognized the need for sustainable practices in the industry. With a forward-thinking approach, they transitioned into recycled fiber processing, aligning with global demands for eco-friendly solutions. Today, their capacity has surged to a remarkable 10,000 rotors, with M/s. Sri Lakshmi Ganesh Spinning Mills contributing 5,000 rotors and M/s. Sudhan Yarns adding another 5,000 rotors to the group’s portfolio.
entral to their sustainable journey is the integration of LMW’s Smart machines, meticulously designed for efficiency and environmental consciousness. LMW’s cutting-edge technology, including the revolutionary Autoblend LA10 system, has been instrumental in optimizing resource utilization while ensuring uncompromised quality. With a production capacity of 40 tons per day and a range spanning from 2s to 36s Ne recycled yarn, the mill caters primarily to domestic markets, championing the cause of sustainable fashion at a grassroots level.
LMW’s State-of-the-art machinery at Sri Lakshmi Ganesh Spinning Mills
LMW has recently supplied its state-of-the-art preparatory machinery for processing regenerated fibre at the mills. The installation includes Blowroom Line comprising of AUTO BLEND LA10, MIXING OPENER MODEL LB3/7, UNIMIX MODEL LB7/4 & LB7/6, Card LC361 – 5 nos. and Autoleveler Draw frame LDF3 S – 2 nos.
Autoblend LA10
The Gentle Blowroom line from LMW ensures efficient opening, cleaning, and homogeneous blending. This highly flexible blowroom line, can process Regenerated fibres, Cotton, Manmade Fibres, Blends, and Special fibres with high cleaning efficiency. The Blowroom line is equipped with Autoblend LA10 and assures high accurate blending up to 1% range and has a high production capacity of 2000 kg/hr, effective micro dust extraction and continuous feed to the Card.
The Gentle Blowroom line from LMW ensures efficient opening, cleaning, and homogeneous blending. This highly flexible blowroom line, can process Regenerated fibres, Cotton, Manmade Fibres, Blends, and Special fibres with high cleaning efficiency.
The Blowroom line is equipped with Autoblend LA10 and assures high accurate blending up to 1% range and has a high production capacity of 2000 kg/hr, effective micro dust extraction and continuous feed to the Card.
Maximum, 4 Feeder
Blending ratio up to 99:1
Blend accuracy of +/- 1%
Two-line output possible with two different blend %
Direct measurement using load cells
Min. 100 gms to a maximum 3000 gms per drop
Max. handling of material in Blending Chamber is 5500 gms/sandwich block (Depends on Tuft Size & Blend%)
Manpower reduction in mixing department
Blend Accuracy +/- 1% : Accurate weighing of material
Lot size can be set for each blend
Two lines with different blend ratios are possible Online weight variation monitor which monitors weight & stops the machine if there is weight variation
Card LC361 – Equipped with single licker-in and is designed for higher productivity and quality with distinctive features for every variety of cotton, man-made fiber, recycled fiber, and blends. The machine has a special profiled Arcual combing arrangement for lesser lint loss, the Highest number of working flats (36 nos.) and the Highest Active Real Carding Area of 1.296 mtrs result in 20% higher carding area. The robust manufacturing and design of the card ensures the reliability of the parts during the processing of recycled fibers.
Autoleveller Draw Frame LDF3 S – Equipped with a servo drive arrangement and a well-synchronized drive system with a timing belt. It is specifically designed to operate at a maximum delivery speed of 1,100 mpm (mechanically), enabling high productivity while maintaining consistent sliver quality for counts up to Ne 36s in recycled hosiery and woven applications. The advanced Duo Digital Autolevelling system optimizes the process, resulting in consistently improved sliver quality at higher speeds.
“The exceptional performance of LMW’s products, particularly the Autoblend system, meets and exceeds our expectations in productivity, quality, and related deliverables. The Autoblend’s perfect blending capabilities have streamlined our processes and saved manpower. LMW’s solutions have been invaluable.” says M J Senthil kumar, General Manager
Mr.M J Senthil kumar, General Manage
LMW’s Sustainable Smart Solutions for Spinning Success (4S), supported by a culture of innovation, empowers mills with a technological and competitive advantage. This is achieved through mission-critical automation, real-time data, analytics from connected machines, compatibility with all applications, and reliable performance under diverse operating conditions.
At LMW, Sustainability & Circularity is a way of life,
LMW consistently strives to minimize the impact of its manufacturing processes on the environment. As sustainability has become an integral part of its DNA, LMW has pledged its time and resources towards this worthy cause. Sustainability also means extending the lifecycle of the products and LMW has been producing machines that are built to last.
LMW RESPIN
Transforming the textile value chain into one that is sustainable, and circular will allow manufacturers to address the environmental and social impacts, while also supporting people, prosperity and equity. The Smart Series machines from LMW, the Trendsetter in recycled fibre processing is suitable for mechanical recycling and is the most popular one with over 100 installations globally.
Premium lifestyle brand Napapijri has released a range of sustainable summer essentials for men, women, and kids, using Good Earth Cotton.
Good Earth Cotton is a production system that has been verified as having a positive Net Zero position.
Available online and in select stores from 6 June 2024, the partnership between Napapijri and Good Earth Cotton highlights the brand’s aim to source 100 percent of its materials from regenerative, responsibly sourced, renewable, or recycled sources by 2030. The range includes premium knitwear including T-shirts, polos, and more.
“Napapijri interprets sustainability as a new form of creativity, an inspiration for new ideas, paths, and innovation. Our product and design teams work hand in hand to stay ahead of the curve and be receptive to new possibilities in the textile world. Our partnership with trailblazing Good Earth Cotton represents yet one more step in this direction”, explained Silvia Onofri, president of Napapijri.
The Australian-grown Good Earth Cotton program focuses on regenerative farming that improves soil health, enhances biodiversity, and sequesters carbon ensuring that it not only has a neutral impact on the environment but net positive one.
“Teaming up with Napapijri feels like the perfect match. Our verified regenerative Australian cotton allows Napapijri to create summer essentials from fibre that is kind to the planet” Good Earth Cotton Founder Dani Statham said.
“Powered by FibreTrace technology, the Napapijri Good Earth Cotton range lets consumers witness supply chain sustainability and integrity firsthand. With a quick scan of a QR code, they can trace the garment’s journey from soil to store.”
“Good Earth Cotton is not just about producing high-quality cotton; it’s about fostering a regenerative approach that positively impacts the planet. We believe measuring sustainability in the fashion and textile industry is everyone’s responsibility” Statham added.
One of the most innovative aspects of Good Earth Cotton is the use of FibreTrace technology, a real-time verification of fiber integrity.
Unlike other traceability technologies, FibreTrace embeds luminescent pigments into raw cotton, creating a unique signature to verify the fiber and track it across the global supply chain.
Luminescent pigments are pigments that create physical traceability locked to a scanning device.
As the leading authority and voice for the retail industry, NRF analyzes economic conditions affecting the industry through reports such as the Global Port Tracker.
FibreTrace also validates data on raw cotton fiber and sustainability improvements through the supply chain.
Each product in Napapijri’s Good Earth Cotton range comes with a QR code on the label which can be scanned to display the product’s supply chain journey from fiber to store.
Texcyle, a pioneering Indian sock supplier, officially launches into the global market, proudly introducing the first-ever use of Bio-Elastane in the production of socks. Founded in 2023 by Raunak Hasnani, an ambitious entrepreneur with a passion for revolutionizing the sock industry, Texcyle is committed to producing 100-percent organic socks and partnering with brands dedicated to sustainable and ethical practices.
Texcyle’s mission goes beyond just providing socks; it aims to eliminate greenwashing claims in the fashion industry by offering a transparent and eco-friendly manufacturing process. The company’s unique selling point lies in its dedication to a low carbon footprint, top-notch quality, and customization services.
The socks produced by Texcyle are crafted from a combination of Organic Cotton, Recycled Polyester, and revolutionary Bio-Elastane, making them pioneers of low-carbon footprint socks. The company ensures a sustainable manufacturing process from start to end by sourcing ethical and certified materials. Texcyle has also taken a bold step towards sustainability by eliminating all virgin plastic packaging for shipping and distribution and replacing it with eco-friendly alternatives such as recycled paper, cotton, and compostable plastic.
Texcyle operates on a B2B model, collaborating with eco-conscious retailers, sustainable fashion brands, and companies committed to promoting ethical practices. The company provides custom sock design services, allowing businesses to incorporate their identity while adhering to their sustainability goals.
“What sets Texcyle apart is our unwavering commitment to sustainability, quality, and customization,” said Raunak Hasnani, CEO of Texcyle. “We’re not just selling socks; we’re selling a vision of a greener, more sustainable fashion world. We invite businesses who share our vision to join us in this journey.”
Texcyle’s dedication to ethical practices and environmental sustainability makes it stand out in the socks industry. The company aims to inspire positive change by collaborating with like-minded businesses and individuals who prioritize clean sourcing.
By choosing Texcyle, brands are not only sourcing socks but also doing their share of responsibility. Join the Texcyle movement for a greener future.
Nakagawa Chemical Inc. established the “cutting and pasting” culture in the industry with its Cutting Sheet (CS). The company was founded in 1975 as a spin-off from the New Materials Development Department of its predecessor, Nakagawado Co., Ltd., a sign manufacturing company. The company’s main business was the manufacture and sale of decorative sheets.
In addition to cutting sheets, the company now offers a lineup of “Foglas” frosted glass-like sheets, “Materio” decorative sheets made of real materials, as well as various inkjet media. The company also holds the “CS Design Award,” a design award, every two years as part of its efforts to raise awareness of the town’s aesthetics and good design.
The company has been utilizing inkjet printers for about 15 years for output and verification on its products. The company mainly outputs highly designed visuals such as artwork by famous artists and award-winning works.
In June 2022, the company introduced Mimaki Engineering’s latest eco-solvent printer, the JV330-160. We asked a Nakagawa Chemical representative how the printer was adopted and what it is like to use.
From left: Mr. Daichi Shiina, Head of Technical Center; Mr. Daisuke Shinshi, Deputy General Manager, Sales Planning Department; Mr. Yasutaka Saito, Technical Advisor, Technical Center; Ms. Mei Hirano, Designer, Sales Planning Department
What kind of prints do you usually do?
Shinshi: Since we are a sheet manufacturer, we do not usually print general advertisements or signs. We use inkjet printers as a means of expression in combination with our own products.
Hirano: For the exhibitions we hold at the CS Design Center, which is our showroom, it is important to showcase art and artwork in the best possible way. We design them by consulting with each other on which media to print and in what form to reproduce the artwork. In many cases, we print on our “C-001A” transparency film in the highest image quality mode.
How did you introduce “JV330”?
Shiina: Until recently, we had been using the “JV300.” It was a model with white ink, and it was very useful, but we wanted a multicolor model from the standpoint of reproducibility of works. After considering and examining various printers, including those from other companies, we decided to introduce Mimaki’s latest flagship model, the “JV330,” last June.
Saito: The deciding factor was that the 8-color machine, including orange and light black, produced very satisfactory colors. The body is solid and stable, and Mimaki’s RIP “RasterLink7” can be configured and adjusted in detail to produce the colors we want is also highly rated. The ability to share ink with the “JV300” was also a driving force behind the introduction of the JV330, as there is the hassle of storing and ordering ink inventory.
Six months have passed since the introduction.
Saito: It is really comfortable to be able to produce colors that could not be produced before. The level of color generation, color gamut, and saturation is so high that even a non-specialist can tell at a glance. I was not concerned about productivity before installing the printer, but the printing speed is very fast. When outputting the same or better quality than before, the finishing time has been reduced.
Shiina: Since its introduction, “JV330” has been working very well, and we have not called Mimaki’s technical support even once. Currently in the technical center, we operate by using “JV330” for prioritizing reproducibility and “JV300” when using white, differentiating their usage accordingly.
The work “Otaka no mori” by Kozue Haraki, winner of the Grand Prize in the Spatial Graphics Division of the Nagareyama Otakanomori S/C Graphic Award 2023, was reproduced on the actual site. It was printed by “JV330” on transparent decorative sheet “IROMIZU.”
Future development of your business.
Shinshi: We are developing our business with a special focus on “design.” In order to expand the range of expression, we would like to explore the use of clear and white ink in the future. As companies, we are actively exploring what we can do in response to the growing necessity for environmental sustainability. We look forward to Mimaki continuing to listen to the opinions and requests of users like us, and to bringing even more innovative products to the market in the future.
FibreTrace, a real-time verification solution for fibre integrity, today announces an innovative partnership with Target Corp. and Cargill.
Cotton ginning is the initial stage of cotton processing, where FibreTrace integrates luminescent pigments into the raw cotton, creating a unique signature where the pigments are then tracked and identified across the global supply chain. By leveraging FibreTrace’s technology, Target Corp. can trace and verify the origin of fibre in real-time, promoting accountability throughout the global textile supply chain, and increasing the value of digital-only traceability solutions.
The partnership will mark 50,000 metric tons of U.S. and Brazilian raw cotton in the first year, after first marking U.S. cotton in November 2023. This collaboration is set to pave the way for real-time verification of U.S. and Brazilian cotton, ensuring trust and credibility throughout the entire production lifecycle.
“FibreTrace is thrilled to partner with Target and Cargill to deliver innovation, transparency, and fibre integrity for U.S and Brazilian cotton,” said Mitch Standen, Head of Americas for FibreTrace.
“We hope that this partnership will inspire a ripple effect of change, demonstrating to other companies what is possible,” said Danielle Statham, Founder & Managing Director of FibreTrace. “We encourage the level of traceability this partnership provides to customers for other brands to follow our lead.
The partnership between FibreTrace, Target, and Cargill underscores a shared commitment to sustainability and transparency in the apparel and home products industries.
“Achieving full visibility to where the cotton used to produce our products is grown is among the top priorities of our sustainability goals,” said Bill Foudy, senior vice president, and president, Owned Brands, at Target. “Our partnership with FibreTrace and Cargill is an important step to improve traceability for the industry and will enable us to accelerate those efforts with our suppliers.”
FibreTrace uniquely connects physical and digital traceability to provide unparalleled results, starting with the integration of patent luminescent pigments into the raw cotton at ginning, imparting a unique signature on the fibre. Pigments are then scanned and tracked at each point across the supply chain, with real-time onsite identification and verification. Data is securely uploaded to Blockchain and shared through the FibreTrace platform, or a digital platform of the brand’s choice.
“Cargill plays a crucial role as the supply chain partner, ensuring FibreTrace is implemented in our process at the gin and then delivering that specific cotton to Target,” said Matt Dunbar, managing director, Cargill Cotton. “We are excited to have the opportunity to build a traceable supply chain that helps Target pinpoint where their cotton is sourced building on the technology provided by FibreTrace.”
The three-way collaboration represents a significant milestone for the cotton and textile industries, opening a pathway for brands to gain access to real-time verification, enabling substantiation of U.S. and Brazilian cotton claims, authenticating the origin of the fibre, and instilling trust and confidence in consumers.
Lenzing Group, a global producer of wood-based specialty fibers, has partnered with technology start-up Exponent Envirotech to introduce ECOHUES, a waterless dyeing technology to wood-based cellulosic fibers. The technology, regarded as a possible alternative to conventional water-based dyeing, can be applicable to cotton and linen yarns. Through collaboration with Lenzing, for the first time, ECOHUES is applied to cellulosic fibers, namely TENCEL branded lyocell and modal fibers, as well as LENZING branded viscose fibers, which are certified with the EU Ecolabel for environmental excellence. Joining forces with Hong Kong-based innovative knitwear manufacturer Cobalt Fashion, the dynamic trio is setto bring the scientific breakthrough to the mainstream textile market.
“At Lenzing, we are constantly collaborating with partners to identify innovative solutions that not only ensure product quality but also strive to reduce the usage of our planet’s resources. The collaboration with Exponent Envirotech and Cobalt Fashion is a testament to such dedication, as we bring scalable innovations to the textile value chain,” said Rex Mok, Director of Technical Marketing and Development, Global Textiles Business, Lenzing. “We are excited to incorporate ECOHUES a revolutionary dyeing technique, to lyocell, modal and viscose fibers for the first time. With the availability of such technology, we are taking a crucial step towards systematically reforming conventional practices within the textile value chain.”
ECOHUES: an innovative solution that improves resource efficiency and ensures color vibrancy
For every ton of yarn, 120 tons of water is required in the traditional dyeing process. This usually involves pre-treatment, water-based dyeing, washing, and finishing in a chemically intensive environment. ECOHUES technology effectively replaces the use of water in the dyeing process with a non-aqueous solvent that is 99.8% reusable and streamlines the pre-treatment and finishing processes by nearly removing the need for soap washing after dyeing. This helps to reduce the overall water usage by 95% compared to traditional dyeing methods. The simplified process not only lowers water and energy consumption but also boosts cost-effectiveness and production efficiency by significantly reducing the traditional dyeing duration from 12 hours to 6-8 hours.
Additionally, ECOHUES eliminates the use of salt as a common dyeing assistant to address the industry’s long-standing issue of high salinity in textile wastewater. With a 40% dyestuff saving, ECOHUES greatly reduces the amount of dye required while ensuring a color fixation rate of over 97% which outperforms the average rate of traditional water bath dyeing by more than 30%, maintaining a stable color performance of the yarn. Complementing the use of yarns made of TENCEL and LENZING ECOVERO fibers which are made with at least 50% less carbon emissions and water consumption4 and further reduce the overall energy and chemical usage compared to cotton by skipping the bleaching process with its natural white colour, it offers a more responsible choice for customers and brand partners.
“As a company dedicated to sustainable and energy-optimization solutions for the industry, Exponent Envirotech has been a champion of environmental-friendly innovation since day one,” said Wesley Choi, Chairman, of Exponent Envirotech.
“This project integrates sustainable production practices with responsible materials, forging a new standard for resource-efficient and environmentally friendly fashion production within the industry.”
Power of collaboration to systematically reform to conventional practices within the textile value chain
While the ECOHUES technology could be applied to almost all segments including innerwear, ready-to-wear, activewear and footwear in which cellulosic fibers are widely used, knitwear has been chosen as the application to bring the results of the collaboration to life. Produced by Cobalt Fashion, the knitwear collection is crafted with yarns made with Lenzing fibers dyed with ECOHUES technology demonstrating how Lenzing’s cellulosic fibers, when combined with the technology, can enhance the performance of knitwear, meeting the demands of consumers who seek both styles and sustainability.
As we strive to lead in sustainable fashion, Cobalt Fashion relentlessly pursues innovative yarns that reduce carbon emissions and water usage while maintaining performance and affordability,” remarked Andrew Dixon, Senior Vice President of merchandising, at Cobalt Fashion. “Non-water dyeing methods often require less energy when compared to conventional dyeing techniques. This energy efficiency can lead to cost savings for textile manufacturers and contribute to a more sustainable industry. This partnership is an important first step as we join hands to create far-reaching impact and bring systematic change across the textile industry.”
TextileGenesis, offers a pioneering platform for fashion and textile players to ensure the traceability of the materials they use. The Lectra Group company today announced a major new collaboration with the Forest Stewardship Council (FSC). It will enable the implementation, via the TextileGenesis platform, of new solutions to ensure the traceability of cellulose fibers from responsibly managed forests.
In fashion, many textiles such as viscose, lyocell, and modal use man-made cellulose fibers. These fibers are themselves made from wood pulp, the production of which can contribute to deforestation.
Founded in 1994, the Forest Stewardship Council (FSC) is an international NGO whose mission is to promote responsible forest management worldwide. In particular, the organization offers certification for products and raw materials which have been obtained from wood grown in responsibly managed forests and comes from supply chains where the social rights of workers, communities, and indigenous peoples have been safeguarded.
Amit Gautam, founder, and CEO of TextileGenesis, explains: “We’ve already been working with Man Made Cellulosic Fiber Producers for several years to facilitate, thanks to our blockchain-inspired technology, the traceability of fibers manufactured by the most virtuous producers, and we’ve integrated their analysis criteria into our platform. By also becoming an FSC partner today, we’re taking things a step further. This new collaboration will support companies in the traceability of FSC-certified fibers and support the administration and data management of FSC Chain of Custody certification. All players in the value chain will benefit from increased transparency and much more reliable upstream data. Fashion brands will be able to demonstrate much more easily that their garments use textiles made from responsibly sourced man-made cellulose fibers.”
Fabian Farkas, FSC International Chief Commercial Director, adds: “We are seeing a rapid increase in interest in FSC certification from the textile industry, marking a very positive trend. Through this collaboration with TextileGenesis, we aim to simplify the administrative part of FSC certification for companies within the textile supply chain by automating many required data processes. Our goal is to empower brands to identify opportunities for seamless progress in meeting their FSC procurement policies.”
Following the signature in October 2023 of a memorandum of understanding with the International Cotton Association (ICA) and the launch last January of two consortiums with footwear and leather players, and more recently the announcement of its partnership with the Aid by Trade Foundation (AbTF), the initiator of The Good Cashmere Standard (GCS), TextileGenesis confirms, with this new collaboration with the FSC, its central place in the ecosystem of players mobilizing for more sustainable and responsible fashion.
Energy consumption is an important success factor for textile companies. For finishing companies, it can lead to costs of up to 15% of turnover. The industry average for energy expenditure is around 5%.
For both economic and sustainability reasons, manufacturers are increasingly looking for innovative technical solutions. When it comes to the energy-intensive drying processes in warp preparation, the KARL MAYER GROUP has the answer: The global player has developed a sophisticated system for considerable energy savings when operating the cylinder dryers in its PROSIZE sizing machines and BLUEDYE dyeing plant.
Saving costs with inline energy recycling
The innovation is called CASCADE and focuses on steam as a heating medium in cylinder dryers. And for good reason: according to the IPCC report by ITMF Zurich, one tonne of steam cost between USD 20 and just under USD 27 internationally in 2021. The new solution relies on reuse to reduce the amount of process energy required.
Karl Heinz Vaassen
“CASCADE recirculates parts of the process steam in cylinder dryers, enabling genuine, efficient energy recycling within the machine,” explains Karl-Heinz Vaassen, Head of Textile Drying at KARL MAYER.
The customer benefits from significantly lower energy costs and CO2 emissions. With a view to the Asian market, a dryer with 14 cylinders and a running time of 7,000 working hours can achieve cost savings of up to USD 17,000 per year.
Precise, real savings values are available when looking at the machine dashboard. A sensor provides real-time data on the amount of steam circulating in the circuit, from which the corresponding reduction in CO2 equivalents can be calculated.
Utilizing the pressure drop
CASCADE reuses part of the invested process energy and uses the flash-steam in conjunction with the pressure ratios, which – nomen est omen – decrease in cascades in the different zones of the cylinder dryer.
The highest working pressure prevails in the first cylinder section. The heat transfer medium steam emits large amounts of energy for yarn drying and condenses without temperature loss.
The resulting hot condensate is not immediately discharged from the machine, but is instead fed into a flash tank, where vapor exhaust is formed as a result of the pressure reduction. In conventional systems, the carrier medium for gases is only created in the return line towards the boiler house and is eliminated as undesirable. Instead of being utilised in the process, it escapes into the environment. With the CASCADE system, this “freshly recycled steam” is used for the heat supply in the second cylinder section, but not without prior treatment.
In the system patented by KARL MAYER, the recycled steam is intelligently mixed with live steam and thus raised to the level of the required process conditions for use in the cylinder section at the end of the dryer. Here, the fabric moisture is reduced to the desired residual value at medium pressure and temperature conditions.
Market launch is underway
CASCADE was filed for patent by the KARL MAYER GROUP. It was published in September 2023.
The innovative solution at no extra charge was presented at ITM 2024 in Istanbul and was a visitor highlight at the KARL MAYER GROUP stand.
From January 2024, CASCADE will be part of the PROSIZE as standard. The first sizing machine with the upgrade for greater energy efficiency will be delivered in the second quarter of this year. It will go to a manufacturer in Europe. In the next step, CASCADE will be integrated into other dryer types and will also be available for the BLUEDYE.
