Textile Industry

Cone Dyeing Machines

Cone Dyeing/ Package Dyeing machine is used mostly for dyeing cotton or polyester yarn. This equipment is used for dyeing natural yarns that have been wound on perforated spools that are dyed in a pressurized tank. This machine consists of a common heat exchanger, which is used for both heating and cooling of dye liquor in the process

Typical issues in cone dyeing include:

  • 3-4% higher energy consumption due to temperature overshoots, higher steam pressures, condensate evacuation issues, and reduced condensate temperature from mixing with cooling water.
  • Productivity loss caused by longer batch times and increased fabric reprocessing/rework.
  • Equipment downtime due to frequent failures of heating coils and heat exchangers, resulting from stagnant cooling water and water hammering.
  • Frequent steam trap failures due to the mixing of high TDS cooling water with condensate.

 

Our Solution:

Forbes Marshall offers a comprehensive solution to optimise the performance of the cone dyeing machines. This includes

Optimising steam supply pressure to the machine
Precise control of process temperatures and gradients
Accurate control of liquor ratios based on measured water quantity
Effective segregation of cooling water and condensate and effective condensate evacuation
Complete recovery of condensate and flash steam
Heat recovery from liquor

Benefits

Consistent temperatures and gradients

Energy savings

Water savings

Lower effluent loads

Lower rejections and reworks

Enhanced condensate recovery factor at higher temperature

Optimum batch time

High equipment heat exchanger uptime

Multi-utility Process Trap MuPT

QualSteam™

FLASHJET™ Pump

EverSense for Plant-wide Performance

EverSense for Condensate Recovery Factor

Forbes Marshall Care

Forbes Marshall Design Consultancy

Thermal Energy Audits