BEN-WASH Solubilizing. Diffusion. Dilution.

BEN-WASH Solubilizing. Diffusion. Dilution.

BEN-WASH
Solubilizing. Diffusion. Dilution.
BEN-WASH
The EXTRACTA principle:
High washing efficiency with low water usage
The EXTRACTA principle divides the
washing process into stages that can be
repeated with accuracy. Besides making
the whole process easier to follow it also
makes it amenable to calculation. In each
of the separate washing chambers the
dirt or chemical liquor present in the cloth
is exchanged 50 to 80% for wash liquor,
which is loaded commensurately with dirt
and chemicals. Entrainment of the contaminated liquor with this cloth is prevented
by the EXTRACTA roller. In the next
chamber the liquor exchange is repeated
but with much lower dirt concentration in
the wash liquor. Together with the known
freshwater throughput, this predictable
action provides the basis for calculating a
washing operation in advance.
Minimal fresh water consumption
leads to saving in water, effluent and
energy costs
Capital investment and operating costs
determine the economy of washing
machines. The water consumption for a
defined washing effect is depending on
the type and number of washing
compartments. Our palette of compartment types permits a machine configuration that is as flexible as it is economical.
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The right machine combination for
every requirement
The diversity of washing compartments
available and the modular design provide
the means for every industrial textile
washing need. By correct selection of
type and number of washing compartments, the plant layout is adapted to any
customer requirement.
With Benninger, crease-free operation is a matter of fact
A crease-free fabric run is guaranteed
■ Large guide roll diameters and adapted
roll spacing that prevent the fabric from
skewing and guarantee crease-free
treatment from entry to exit of the range
■ Computer controlled tension force
from 100–500 N with press rolls or,
200–600 N without press rolls
■ Screw expanders with separate drive
■ Free running outer bearings with minimal friction
■ on bath rolls
Self-aligning ball-bearings, life-time
lubricated, with carbon sliding ring
seals;
■ on upper rolls
Self-aligning ball-bearings; life-time
lubricated, with PTFE labyrinth seals;
■ on press rolls
Self-aligning roller-bearings; life-time
lubricated, with PTFE labyrinth seals.
Drive control via swiveling
compensators and load cells
Intermediate squeezers (pulling/squeezing device) are controlled via swiveling
compensator and frequency converter
in the next compartment. The upper roll
single drive is controlled with a separate
frequency converter; in compartments
followed by a pulling/squeezing device
via a measuring roll with a load cell;
in compartments without subsequent
pulling/squeezing device via the swiveling compensator of the following compartment.
Angle detector of Swiveling compensator for drive
control
Load cell
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BEN-WASH
Energy saving starts in the washing compartments
High-efficiency washing compartments DA with intermediate squeezer
DA 3
Fabric content 13 m
DA 5
Fabric content 23 m
DA 7
Fabric content 32 m
High-efficiency washing compartments DA C without intermediate squeezer
DA 3C
Fabric content 15 m
DA 7C
Fabric content 34 m
DA 5C
Fabric content 25 m
These high-performance, double loop
washing compartments with rubber coated press rolls, especially recommended
for medium to heavy fabric, achieve a
maximum washing effect.
In each washing chamber, the fabric is
immersed twice in the washing liquor
which is then pressed through the fabric
in the nip pools between roll and fabric.
The intensive liquor exchange in the fabric is supported by the cross flow in the
chambers.
Good accessibility to the washing
compartments, covers can be lifted easily
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The single driven upper rolls with press
rolls (EXTRACTA squeezers) are a fully
fledged drive. Thus no other additional
drive in the form of an intermediate
squeezer is needed, as is the case with
sliding clutch and relax drives.
No steam escapes from the steamtight
EXTRACTA washing compartments
even at high temperature. The steam
sealing of the entire washing range
leads to a better washing effect, and
energy consumption is distinctly
reduced.
The variety of compartments gives you flexibility
High-efficiency washing compartments EA with intermediate squeezer
EA 3
Fabric content 9 m
EA 5
Fabric content 15 m
EA 7
Fabric content 20 m
High-efficiency washing compartments EA C without intermediate squeezer
EA 7C
Fabric content 9 m
EA 7C
Fabric content 20 m
EA 5C
Fabric content 15 m
The EA high-performance washing compartments use the same principle as the
DA compartments, with press rolls
(EXTRACTA squeezer) and individually
driven upper rolls.
Washing compartments with 3-, 5 or 7
chambers with single loop, upper roll drive
and press rolls for best liquor separation.
Single loop provides better accessibility
to the cloth and easier handling. As only
one immersion per chamber is possible,
the washing effect with the same amount
of water (per cloth weight) is lower than
with double loop. This effect is compensated for by the greater number of washing chambers per compartment. The
residence time in the EA washing
compartments is, however, lower than
with double loop.
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EXTRACTA
The plain wash compartments with stripper roll
Washing compartments E with intermediate squeezer
E3
Fabric content 9 m
E7
Fabric content 20 m
E5
Fabric content 15 m
Washing compartments E C without intermediate squeezer
E 3C
Fabric content 9 m
E 5C
Fabric content 15 m
E 7C
Fabric content 20 m
No rubber coated press rolls
The advantage of this model lies in the
low maintenance costs, as these compartments have no rubber coated press
rolls (EXTRACTA squeezers).
Optional single drives
For tension sensitive styles, upper roll
single drives are available as an option,
whereby the number of drives is freely
selectable.
The plain wash compartments with stripper roll for liquor separation are used with
individual drive for open and lightweight
cloths with single liquor separation.
Liquor exchange and washing efficiency
are much lower for reduction washing
than with the EXTRACTA roll system.
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EXTRACTA compartments enable most economical washing
Reaction compartments D with intermediate squeezer
D3
Fabric content 13 m
D5
Fabric content 23 m
D7
Fabric content 32 m
Reaction compartments D C without intermediate squeezer
D 3C
Fabric content 15 m
D 5C
Fabric content 25 m
D 7C
Fabric content 34 m
This disadvantage can be compensated
only by making the machine longer or
using more water.
The high-performance ‘D’ wash compartments follow the principle of the ‘E’ compartments.
‘D’ compartments are used mainly for
post-dye washing, where good diffusion
and long reaction time are demanded.
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Profit from these advantages
■ Flexible machine layout due to the
variety of models and the modular
design
■ Operationally reliable and functional
design
■ Calculable washing effect
■ Controlled reproducible results
■ Closed steamtight machine
■ Best possible washing effect
■ Compartments with two separate
sections
■ Low water and power consumption
■ Only single drives applied
■ Constant fabric tension
■ Crease-free operation
FORTRACTA
High-performance washer for surface contamination
The FORTRACTA prewasher is a further
development of the proven Benninger gap
technique for washing-out contamination.
The cloth web is led upwards in two ducts.
The wash liquor flows down by gravity
similar to a waterfall. A strong washing
action is obtained by this counterflow principle in the duct. Liquor separation is
effected by stripper rolls and flat jet nozzles
at the exit from the FORTRACTA compartment.
Since the fabric carries large amounts of
chemicals especially at the beginning of
the wash, rubberized rolls are not provided in this compartment. The short distances between rollers and the large roll
diameters assure creaseless cloth
running.
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Economics determine the washing procedure
BEN-CONTROL Speak with data
With the classical roller vat washing
process where the fabric is moved
through stationary liquor with only short
reaction times, costs can hardly be
reduced. In this process high molecular
weight substances are fully swelled and
as consequence lead to an increase in
viscosity, conglutination and therefore a
high water consumption.
The Benninger patented concept on the
other hand, is based on a significantly
lower water and steam consumption and
minimum use of chemicals. As opposed
to conventional methods, comparable
results are better and achieved substantially quicker.
A quite natural washing process
The fabric passes through a narrow casing divided into two shafts. Steam and
water are directed onto both sides of the
fabric, either individually or in any desired
combination. Due to the slot and shaft
geometry high flow speeds are caused
which create a high kinetic energy.
According to the process used, operation
can be with counter-flow water only from
the following washing compartment and a
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liquor circulation system. The INJECTA
offers numerous process variations and
thus a high degree of flexibility in styles.
Through the shock heating of the wet
fabric to 100°C in the INJECTA the high
molecular weight substances swell up
immediately, with a simultaneous reduction in viscosity through the effect of the
high kinetic energy. This means that they
are removed with a significantly smaller
quantity of water.
INJECTA
Rationalized removal of high molecular weight substances
Optimized desizing
The size is removed to the extent that subsequent processes can be carried out in
the best possible manner and without difficulty. Water-soluble sizes such as PVA,
PAC, PES and CMC, and also unmodified,
water-insoluble starch sizes are removed
with a very high removal rate and low
water application of 3–5 l/kg. 100% synthetic fabrics can also be successfully
desized in this manner. Airbag fabrics are
cleaned to the required residual content
of < 0.5% by the INJECTA.
Do you wish to wash out conventional size
and printing thickeners, that is, high molecular weight and adhesive substances with
a high swelling capability? Or must PVA,
PES sizes, spinning or spooling oils be
removed from synthetic fabrics? You can
solve all your critical tasks with the new
INJECTA washing system.
To facilitate infeeding the fabric the shafts can
be opened
The INJECTA makes the single-stage
BEN-BLEACH concept feasible: In one single step! – from
greige to finished, dry fabric.
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Clean washing is a matter
of superior technology
Profit from INJECTA advantages
■ Significantly lower water and steam
consumption
■ Highly concentrated effluents provide
ideal conditions for partial flow disposal or size recycling
■ The washing effect of a single
INJECTA compares to that of a
multi-chamber high-performance
full-width washing machine
■ Printing after treatment is no problem
with no danger of staining the ground
■ Continuous desizing of
water-insoluble starch sizes
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TRIKOFLEX
Low-tension open-width treatment
Benninger, the leading manufacturer of
roller vat washing machines, is also
your best advisor for drum washing
machines.
The TRIKOFLEX system, ensuring low
tension treatment of knitted, pile and
woven fabrics, has set new standards in
textile finishing.
Incorporating a range of system improvements, Benninger has found the best way
to meet increased market requirements.
The TRIKOFLEX LT-DB in a few words
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Flexibility due to modular concept
Box design with excellent torsion and
floor stability
No transmission drives nor friction
clutches; only single motor drives
Separate intermediate squeezer
Connectable with EXTRACTA
compartments
Excellent accessibility to the squeezers
and compartments for cleaning/
maintenance
The entire machine is steamtight
Optimum shrinking results ensured by
single motor drives
Two side washing, specially important
for dense fabric
Large guide roll diameter and proper
spacing ensure crease-free operation
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Liquor separation due to two circulating
systems
Counter-flow by gravity possible over
the whole washing range
Spray pipes adjustable from the outside
Functional, modern design
Level of automation as required
For mono- and bi-elastic woven goods
Result:
The new Benninger TRIKOFLEX generation enables the finisher to treat the entire
range from mono- and bielastic, as well
as crease sensitive woven fabrics without
problems and at low tension. This concept also offers savings on water and
energy.
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TRIKOFLEX
Flexibility in the structure
TRIKOFLEX LT-DB
TRIKOFLEX LT-DB C
TRIKOFLEX LT-DB C-R
with intermediate squeezer
1 liquor circulation
Cloth content 8 m
without intermediate squeezer
1 liquor circulation
Cloth content 7 m
with reaction zone
1 liquor circulation
Cloth content 12 m
TRIKOFLEX LT-DB C2
TRIKOFLEX LT-DB 2/2-R
without intermediate squeezer
2 liquor circulation
Cloth content 7 m
with reaction zone for neutralisation
2 liquor circulations
Cloth content 12 m
TRIKOFLEX LT-DB 2
with intermediate squeezer
2 liquor circulations
Cloth content 8 m
Taylor made concepts
Depending on the fabric and the process,
the modular build system TRIKOFLEX
can be delivered in various versions.
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LT-DB with one liquor circulation
with 60 m3/h
LT-DB 2 with two liquor circulations
with 2 x 30 m3/h
LT-DB with intermediate squeezer
LT-DB C without intermediate squeezer
Direct steam heating, or indirect heating with heat exchanger
Mechanical, or automatic self-cleaning
filters
Various drive systems
Grooved drum
Drawing of the active washing
principle with grooved drum
1 Closed drum body
2 Groove profile
3 Mesh belt
4 Fabric
5 Outer liquor film
6 Spray pipe
The heart of the TRIKOFLEX washing
system is the grooved drum with a combination of grooved profile and mesh
covering.
It serves as a supporting element for the
fabric. The large surface of the drum
ensures smooth and low-tension fabric
passage over a long contact path. The
enclosed design prevents impurities from
entering the drum.
The result:
The washing liquor penetrates the fabric
and forms a liquor film on the front and
back side. In this way, impurities on both
sides are quickly removed. At the same
time a cleaning effect within the mesh is
created. The washing effect, compared
to standard mesh and screen drum systems, is considerably increased.
Further features:
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Minimum deflection points
Short fabric path in the area of the
drum, trough and compensating roll
Large roll diameter
Low tension fabric transport through
controlled single motor drives
4 spray pipes are arranged around the
grooved drum and integrated into the circulating system. These ensure the extremely high washing efficiency at great
circulating capacities.
The drum surface forms the groove profile with a mesh covering. As the fabric
passes through the spray section, it is
supported by the drum surface and is
thus unable to avoid the hydrodynamic
water pressure.
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Spray battery
The spray battery with adjustable spray
angle is decisive for the optimum washing effect, in addition to the grooved
drum. The washing liquor is constantly
circulated through the spray pipes within
the compartment by means of a pump.
This produces a cross-flow and a heavyflowing liquor film on both sides of the
fabric. This ensures optimum mass transfer and removal of the substances being
washed off.
TRIKOFLEX
Maximum washing efficiency through circulation and counter-flow
A meandering liquor guidance principle,
similar to that found in vertical washing
machines, has been used for the first
time in the TRIKOFLEX drum washing
machine. The liquor guidance, in conjunction with the spray line mechanism,
results in the high washing effect of the
basic LT-DB model.
Compared to the LT-DB, the washing
effect of the TRIKOFLEX LT-DB 2 is increased by the addition of a second,
independent circulation flow and bath
separation.
This bath separation allows the temperature of the liquor to be varied within
the drum washing compartment. This
is especially important for even fabric
shrinkage.
The washing effect of the TRIKOFLEX
washing machine has been tested under
production conditions. Results show a
40% increase in the washing effect attributable to bath separation and second
circulation flow.
TRIKOFLEX LT-DB 2 with two liquor
circulations and bath separation
TRIKOFLEX drum washing machine comparison,
one (LT-DB), two circulation system (LT-DB 2) and EXTRACTA (DA 4)
Co/LY 97/3%
Twill 2/1 - 240 g/m2
V = 40 m/min
T = 95°C
Water: 4 l/kg
Number of chambers
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Shrinking with lowest fabric tension
Continuous shrinking, desizing and washing of Filaments (PA 6.6, PET, PTT, PBT, PP)
Multi-flexible pre-treatment and washing range for tension-sensitive fabrics
Washing after
Vat-printing
Rinsing
Washing after
Disperse-printing
Rinsing
Washing after
Reactive CPB, Dyeing
Rinsing
Oxidation
Cold/Hot, Caustification
Rinsing
Of Viscose
Washing after, CPBRinsing
Bleach + Shock-bleaching
Soaping
Washing, Neutralizing, Rinsing
Reductive cleaning
Washing, Neutralizing, Rinsing
Washing, Neutralizing, Rinsing
Impregnation, Caustification
Washing, Neutralizing, Rinsing
Impregnation, Bleaching
Washing, Neutralizing, Rinsing
Washing, Neutralizing, Rinsing
Washing after
CPB-Bleach
Use of the TRIKOFLEX drum washing
machine is called for when fibre materials show a high shrinking potential or
if an increased risk of creasing exists
in a roller vat.
Shrinkage occurs at the first contact with
hot water. The rate and degree of shrinking is dependent on the temperature.
Dimensional changes (length/width) in the
fabric must not be inhibited during this
stage of processing.
The TRIKOFLEX makes processing at
different temperatures possible within a
washing compartment. The advantage
is that a slow and even shrinking can be
attained across the entire width of the
fabric.
The drive technology plays an equally
important role in achieving an optimal
result. TRIKOFLEX drums are controlled
by rotary magnet motors, or tension
control (load cells).
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Should longer washing and dwelling
times be necessary the TRIKOFLEX can
be complemented with the EXTRACTA
roller vat washing compartments. Larger
fabric contents lead to longer diffusion
times. A high degree of washing efficiency is guaranteed by separating the liquor
in different chambers.
REACTA
Diffusion washing processes
Washing in spray and reaction aggregates
Efficient washing is of central
importance during textile finishing and
is defined by the factors mechanical
action, time, temperature and water.
Depending on the washing task the
weighting of the individual factors varies.
Often the term washing is only associated with dilution washing whose success
essentially depends on the water temperature and mechanical washing action.
On the other hand, reaction processes
require a specific amount of time for the
chemical reactions to take place. The
fastness wash for obtaining wear-, wash-,
or water fastness falls under the term
diffusion wash. Objective of this washing
process is to bring the unfixed residual
dye in the core of the fibres to the fabric
surface and to remove it. Here time and
temperature are key factors.
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Weighting of the factors that affect textile washing processes
Machinery-related requirements and
equipment for the diffusion wash
Temperature
Diffusion washing processes cannot be
undertaken satisfactorily using common
washing systems; the investment
required is also excessive.
The fabric content is not sufficient, to
perform a soaping process for 2-8 minutes. Time-consuming washing processes can be performed significantly
better in dwelling compartments.
Fresh water
Time
For diffusion washing and reaction
processes Benninger relies on roller bed
dwelling compartments with additional
spraying areas. The washing principle
applied by Benninger is based on the
principle of seeping wash, where liquor
is applied to the textile substrate and
slowly seeps through the fabric.
Mechanical washing action
Dilution wash
caustic soda, salts, H2O2,
emulsified oils
Unlike storage racks, accumulator belts
or chains, the roller bed used by
Benninger has the major advantage that
the pile of fabric is continuously in motion
and is passed from roller to roller. The relative motion within the individual fibres
and threads improves the penetration of
the capillary spaces by the seeping water.
Fastness wash (diffusion
wash) reactive dye, etc.
Reaction processes
demineralisation, oxidation,
neutralisation, emulsification
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HYDROVAC
Economic water removal with Vacuum Systems
The Hydrovac vacuum technology
is applied in situations where an efficient
bath separation is required. Simultaneous
to the extraction of water, lint, emulsified
and dispersed contaminants, hydrolysed
dyestuff and sizing agents are removed.
At the same time, the possibility exists to
separate this polluted liquor from the
process water. The fresh water consumption is considerably reduced due to the
increased degree of concentration that
develops during the ensuing washing
processes. Partial disposal of this highly
polluted liquor can reduce waste water
contamination (COD) considerably.
Separator
The cyclone separator with pre-separator and the newly developed air flow
system guarantee optimum separation.
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1
3
2
1
2
3
4
5
4
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Suction tube
Pre-separator
Water separator
Diaphragm pump
Rotary pump
Increased washing efficiency and simultaneously reduced impact
on the environment
Suction tube
The conical construction prevents the
accumulation of contaminant residues.
The fabric is exposed to practically no
friction at all as it passes over the slot
opening, which is adjustable and easily
accessible from above.
Rotary pump blower
The so-called ‘Roots’ pump is the most
economic and efficient vacuum system
available.
Blower aggregate
The noise reduction hood offers easy
access to the blower aggregate and its
various components, e.g. the suction
silencer.
Air control
A secondary air adjustment valve is
utilised to control the system (a frequency converter is used in some cases).
The efficiency of a vacuum system is contingent
upon the type of fibre and construction.
The table below shows average rates of residual
moisture achievable.
The advantages at a glance:
Acetate
Acetate Filament
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Cotton
Lyocel/Tencell
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Polyacryl
Polyamide Filament
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Polyamide Staplefibre
Polyester Filament
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Polyester Staplefibre
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Polyester/Cotton
Polyester/Viscose 65/35
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Polyester/Wool 55/45
Viscose Filament
Viscose Staplefibre
Wool
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Partial flow recycling is achieved
by separating the concentrated
polluted liquor
Removal of contaminated liquor
from the process water enables
increased washing efficiency
Emulsified and dispersed
contaminants are removed
Especially suited to remove
printing thickener and size
High dewatering values particularly
for synthetic fabrics
Possibility for size recovery
Locations
Head office
Uzwil, Switzerland
Subsidiaries
Mumbai, India
Shanghai, China
Zell, Germany
Zittau, Germany
Representative office
Moscow, Russia
The Swiss company Benninger has been the textile industrys leading partner across the globe for one hundred and
fifty years with global branches and service representatives. Benninger develops and manufactures textile finishing
and cord production ranges as well as providing complete system solutions. As the market leader Benninger will
continue to rely on its comprehensive process know-how in order to be able to offer high-quality installations with
excellent customer service.
Benninger AG
9240 Uzwil, Switzerland
T +41 71 955 85 85
F +41 71 955 87 47
[email protected]
Benninger Zell GmbH
Schopfheimerstrasse 89
79669 Zell i.W., Germany
T +49 7625 131 0
F +49 7625 131 298
[email protected]
www.benningergroup.com
Benninger Zittau
Küsters Textile GmbH
Gerhart-Hauptmann-Strasse 15
02763 Zittau, Germany
T +49 3583 83 0
F +49 3583 83 303
[email protected]
Benninger AG
Moscow Office
Leningradsky pr-t 72
Bld. 4, Office 802
125315 Moscow, Russia
T +7 495 721 18 99
F +7 495 721 30 84
[email protected]
Benninger India Ltd.
415 /416 & 417
Sunshine Plaza
Dadar (East)
Mumbai 400 014, India
T +91 22 4322 7600
F +91 22 4322 7601
[email protected]
Benninger Textile Machinery Co. Ltd.
Room 904, Tower A
City Center of Shanghai
100 Zun Yi Road
Shanghai 200051, P.R. China
T +86 21 6237 1908
F +86 21 6237 1909
[email protected]
You can feel it’s Benninger