Karl Mayer, provider of machines for warp knitting, technical textiles, and warp preparation for weaving, has unveiled the PRODYE-R, a customised dyeing machine for the rope dyeing process, used in denim-dyeing. The PRODYE technology combines technical achievements of three years of development work and delivers maximum performance during indigo dyeing. Compared to similar systems available on the market, this innovative technology reduces water consumption by roughly 30 per cent in practice, decreases yarn wastage, and produces deeper indigo shades during the slasher-dyeing process. The productivity is almost twice as high when processing lightweight denim. With this type of product, customers can achieve an output of up to 70 m/min.
The unique performance is the result of a number of technical features, including the Double Vario dyeing unit. The application system is the key element of the PRODYE system. Its optimised flow patterns and efficiency result in flexible and process-specific immersion lengths and times during pretreatment and dyeing. The technical features of the Double Vario include a well-thought-out cross-flow system for perfect dyebath circulation and an integrated system for raising the immersion rollers. The latter simplifies handing, minimises cleaning times, and guarantees stable liquor baths during machine downtimes.
An integrated, indirect heating system also enables a range of dyeing techniques, such as reactive, sulphur and indanthrene dyeing, to be carried out reliability and flexibly. Finally, squeeze roller pairs operating at 100 kN, which are harmonised with each other, at the end of the processing sequence in the dyeing machine guarantee uniform fabric transport and avoid variations in the circumferential speed at the textile material.
Karl Mayer can also supply all the other machines and equipment needed for rope dyeing. The full one-stop package consists of various creels, the Ball Warper, the Long Chain Beamer, and the Prosize sizing machine. The Ball Warper forms the ropes for producing beams having a maximum diameter of 1,500 mm and operates in a controlled, tensionregulated, gentle and precise way. The technical features that are responsible for improving performance include, for example, pneumatically controlled disc brake technology for synchronous braking, and an integrated suction system for removing fly and other contaminants.
The Long Chain Beamer produces beams having a maximum diameter of 1,000 mm. A pneumatically operated, selfcentring, sharply tapered beam mounting, and an infinitely adjustable presser roller device, including an automatic kickback facility, guarantee reliable processing and easy handling. An integrated, reverse-driven compensator also enables the operating status during rope feeding to be changed at constant rope tension levels.
The PROSIZE sizing machine operates with the new VSB Size Box, and the sizing result guarantees first-rate efficiency during weaving. Its advantages include compact yarn feed, short yarn paths, accurate process control, and a high level of reproducibility.
