Prepared By :

Prepared By : Mazadul Hasan sheshir

ID: 2010000400008
13th Batch (session 2009-2013)
Department :Wet Processing Technology
Email/Facebook: mazadulhasan@yahoo.com
Blog : www. Textilelab.blogspot.com (visit)

Southeast University
Department Of Textile Engineering
I/A 251,252 Tejgaon Dhaka Bangladesh
 Aerodynamic technology
The fact that the limits of the aerodynamic Airflow system first presented by Wil- helm
Christ in 1984 are far from being reached and that great potential remains is indicated
by the High-Speed Leveling (HSL) process (patent registered). System- atic further
development aimed at the ex- ploitation of the innumerable advantages of the
aerodynamic system has led to shorter dyeing processes and massive resource savings.
However, a mastery of aerodynamic technology is a prerequisite for the safe use of this
process.
The basic principle underlying the aero- dynamic system is that the fabric passes
through an air-steam mixture emitted from a blower. This means that contrary to a
hydraulic dyeing machine, neither a dye bath nor an aqueous medium is needed

for fabric transport. In other words, the fabric passage is possible without liquor. The
material is in constant motion from feeding to the end of the process, as well as during
drainage and filling procedures. Fig. 1 shows the air suction pipe, which has been
designed as a filter, in the center of the dyestuff vessel. The blower and the airline, which
leads to the transport nozzle, can be seen in the background. The fabric skein is drawn off
from the dyestuff vessel by the winder, fed to the nozzle line and then returned to
the storage chamber via the cuttler. The storage chamber is fitted with PTFE rods
(Fig. 2). PTFE, which is familiar under the brand name Teflon, offers very good non-adher-
ence characteristics with the result that the surface of the fabric is well protected. There
is no dyeing liquor in the dyestuff
 Airflow Dyeing Machine

This is another development of the very popular jet dyeing machines. The
main difference between the Air Flow Machine and Jet Dyeing machine is
that the airflow machine utilizes an air jet instead of the water jet for
keeping the fabric in circulation. Typically the fabric is allowed to pass into
the storage area that has a very small amount of free liquor. This results in
a reduction in consumption of water, energy and chemicals. The figure
below shows how in an Airflow Machine the bath level is always under the
level of the processed textile. Here the fabric does not remain in touch
with the liquor (the bath used is below the basket that holds the fabric in
circulation). This invariably means that the bath conditions can be altered
without having any impact on the process phase of the substrate.
Discontinuous processing of textile substrates require more water and energy
compared to continuous processes. However, for a long time efforts are undertaken
to optimise discontinuous processes with respect to productivity, efficiency and also
to minimise energy and water consumption respectively. This lead to dyeing jets.
Thereby liquor ratios have been reduced step by step. The latest developments have
LR of 1:3 (for woven PES fabric) and 1:4.5 (for woven CO fabric). To achieve such low
LR, within the machine (jet), the fabric is moved by moisturised air or a mixture of
steam and air only (no liquid) along with a winch. The prepared solutions of
dyestuffs, auxiliaries and basic chemicals are injected into the gas stream. The bath
level is always below the level of processed textiles in order to maintain low LR. The
principle of such an airflow dyeing machine is illustrated. Rinsing is carried in a
continuous manner. During the whole rinsing process, the bottom valve is open and
rinsing water is discharged without additional contact with the fabric (which is
the case in conventional machines) This also allows the discharge of hot bath liquors,
also after high-temperature dyeing at 130°C. Thus, in addition to time saving,
optimum heat recovery can be performed. The fabric itself is processed with low
tension and crease formation is minimised.
 Advantages of Airflow Machine

1. Completely Separated circuit for liquor circulation without getting in touch

with the textile
2. Bath less Dyeing operation
3. Rinsing process offers all the added benefits of continuous processing as it
is no longer a batch operation
4. Extremely low liquor ratio
5. Virtually nonstop process
6. Comparatively lesser energy requirement due to faster heating/cooling and
optimum heat recovery from the hot exhausted dye liquors
7. Reduction in consumption of the chemicals (e.g. salt) dosage of which is
based on the amount of dye bath
8. Lesser water consumption savings up to 50% from the conventional Jet
dyeing machines
9. Sensitivity towards ecology
10. Economical operation
11. More safety while dyeing.
XDWG 225, 450, 675, 900, 1350
 Main technical data:

For cotton: (XDWG 450)

Liquor ratio: 1: 4
No of fabric container: 2
Load capacity: 400-450 kg
Fan Power: 45 kw
Main pump: 7.5 kw
Cloth lift: 4.4 m
Total power: 56.9 kw
Operating power: 18.8 kw
Capacity of preparation tank (L): 2000 L
Transmission speed: 100-700 m/min
Rate of temperature rise (Average): Steam pressure more than 5 kg/ m2
Rate of temperature drop (Average): Steam pressure more than 2 kg/ m2
 Shorter processing time and higher efficiency

 Extreme low total water consumption

 Obvious reduction of dyestuffs and additives

 Flexible load and stable liquor ratio( bath ratio )

 Dyeing stability

 Applicable for high quality and high demand fabrics

 Full automatic control or reduce personal error

Specification s 1 2 3 4 6 Remarks
(Numbersof tubes
)
Load 225 450 675 900 1350
Capacity (kg )
Liquor ratio Cotton 1:4 1:4 1:4 1:4 1:4 Put dry
cloth in
Polyester 1:5 1:5 1:5 1:5 1:5
the water
Power Fan 25 45 75 90 120 Equipped
Main Pump 5．5 7．5 11 11 15
Cloth lift 2．2 4．4 6．6 8．8 13．2

Total Power(kw ) 32．7 56.9 92.6 109.8 148.2

Operating Power(kw) 10.8 18.8 30.6 36.2 51.9 Measured
Capacity of preparation tank(L) 1000 2000 3000 4000 6000 Optional
Delivery Speed 100-700 m/min
Rate of temperature rise (Average ) 6 ℃/MIN Steam Pressure ＞ 5kg/m2
Rate of temperature drop(Average ) 6 ℃/MIN Steam Pressure ＞ 2kg/m2
 It adopts air dynamic theory ,making high speed airflow generated from high
pressure fan ( blower ) enter into nozzle from air entrance . And at the same time,
injecting atomized dyeing liquor to nozzle from water entrance . Atomized dyeing
liquor merges with high speed airflow in the nozzle and after further atomizing
process it will make the fabric move accordingly .
 Airflow making fabric circulate to lower bath ratio to minimum
 Dye liquor after being atomized is fed to provide better even dyeing effect .
 The atomized airflow blow to the fabric to make it change the rope status
constantly .So that it can make the change to crease for sensitive textile be the
lowest .
 The nozzle adopts special design , supplying more comfortable handling
environmental for fabrics , which can make the fabric more smoothness .
Figure : Schematic diagram of Then Airflow technology; the air
suction pipe, which is designed as a filter, is located in the middle
of the dyestuff vessel (Then)
Figure : Storage chamber of the Airflow dyeing machine is fitted with PTFE
rods; the PTFE rods have non-adherence characteristics, which protect the
surface of the textile
THEN Air Flow dyeing Machine

THEN Airflow Made

by Fongs – China

THEN-AIRFLOW® SYNERGY G2
THEN-AIRFLOW® SYNERGY G2
Ongoing further development forms a major element in our corporate
philosophy. Therefore, we are proud to be able to present the SYNERGY G2
dyeing machine which apart from a high load per strand also provides further
sizeable reductions in water and energy consumption. In other words, the
SYNERGY G2 is a top product from both a cost-efficiency and ecological point of
view. “Our SYNERGY G2 is based on the tried and tested technology of the
successful THEN-AIRFLOW® system. Accordingly, the use of proven advantages
and the creation of additional innovative features has resulted in our best ever
piece dyeing machine.”

THEN-AIRFLOW® SYNERGY G2
Increased loads —
A number of decisive changes to the design of the fabric storage chamber have led
to an increase in load to a maximum of 300 kg per chamber.
Process time reduction —
The G2 slashes the process time, which is seen as a cost-efficiency benchmark to
record-breaking low values.
Lower energy and water costs —
The G2 further reduces water consumption by 20% and at the same time provides
corresponding energy savings.
Shorter liquor ratio —
In tandem with an unaltered basic design, the increased payload of the SYNERGY
G2 results in another marked reduction in the nominal liquor ratio.
Exact reproducibility —
The SYNERGY G2 furnishes unsurpassed reproducibility and “right first time”
dyeing rates of up to 98%.
Immense fabric range—
No other piece dyeing machine on the market can successfully and economically
dye such a wide range of fabrics.
1. Main tank made of supreme stainless steel SUS . ( SS 316L )
2. The bottom of main tank is covered with fine Teflon Pipes .
3. Special stainless steel fan with inverter control .
4. Cloth lift and laying up synchronous adjustment with inverter control.
5. Air dust filter of fabric cuttings and fluffs .
6. Filter of fabric cuttings and fluffs before pump .
7. Full automatic program , computer control .
8. Proportional temperature control .
9. Feed pump of dosing tank .
10.Liquor atomizing and jetting device .
11.Proportional dozing device .
12.High efficient steam heat exchanger .
13.Analog water level control system .
14.High temperature discharge system .
15.Delivery device .
16.Double-inlet drain-select system .
17.Cloth end detection device .
 Spray dye Liquor Air Blowing

Blower Pipe

Nozzle

Steam valve

Unloading Blower
Motor

Heat Exchanger

Main Pump

Flow Diagram
Dyeing Flow Chart :
 Air Blowing

Nozzle

Blower

Dinmenler Jumbo Type Air flow dyeing Machine - 6 Nozzle

Dinmenler Air flow dyeing Machine - 3 Nozzle
DMS 03 DIL-AIR1
Operational data
The airflow dyeing machine offer combination of high
productivity and reproducibility and reduction of water, chemicals
and energy consumption.

Economics
Investment cost for airflow dyeing machines, compared to
conventional dyeing jets are around one third higher but due to
high savings a short payment period can be achieved.

Driving force for implementation

High productivity and reproducibility and minimisation of water,
chemicals and energy consumption have been and still are the
main driving forces for the application of this technique.
Main achieved environmental performance
Textile processing at low LR and practically continuous rinsing, water
saving of about 50% are achieved compared to machines having a
hydraulic system (the fabric is moved by injection of process liquor and a
winch) at LR of 1:8 up to 1:12. The same is for heating energy. There are
also savings of auxiliaries and basic chemicals of about 40%. The savings
are compiled in Table 4.16 for exhaust dyeing with reactive dyestuffs
The application of this technique needs investment in new dyeing
machines Existing machines can not be retrofitted. The machines can
be used both for knit and woven fabric and for nearly kinds of textile
substrates. Fabrics consisting of wool or wool blends with a percentage
of wool of more than 50% can not be dyed because of felting. It can not
be recommended to dye linen fabric with the described system because
of scaling of the machines with linen fluffs. For silk, the system has been
approved but is still rarely applied for it.

Concerning dyeing with vat and sulphur dyestuffs, a process has been
developed to minimise the oxidation of dyestuffs by oxygen from
injected air (minimisation of oxidation by heating up to steam
atmosphere).
Elastic fabrics containing polyurethan fibres (lycra) are always
difficult to dye with respect to dimension stability but they can be
dyed in the airflow system. Also other substrates, such as PES or
PES/WO blends are difficult or impossible to process in case of low
dimension stability of the fabric.
However, the Airflow dyeing machine had one disadvantage: dyeing of
extremely delicate fabrics didn't give a perfect result. Current and future
trends pointing toward more and more lightweight fabrics with high
contents of elastane in finest yarn counts and gauges prompted the next
stage of Airflow machinery design.
To meet the required voluminous hand as well as top-grade quality
standards, the world's first long-tube Airflow machine, the Airflow Lotus
200, was developed. The new dyeing machine incorporates the latest
advances in Then's Airflow technology and operates according to the
original aerodynamic principle. The dye liquor passes the self-cleaning filter
and is then evenly applied and finely 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.
 High temperature high pressure airflow dyeing machine

M7202 High temperature

high pressure airflow
dyeing machine

Technical parameters :
Tube number : 1, 2, 3, 4, 6 tubes.
Fabric volume: for one tube machine, 225 kg, for six -tube machine,1350
kg (for 170～300g/m 2 medium thick fabrics)
Bath ratio: Chemical Fiber Fabrics ≤1:2 , Cotton and wool fabrics ≤ 1:4.
Max Operating Temperature: 140℃.
Max Operating pressure: 0.4Mpa
Normal temperature normal pressure airflow dyeing

SME2701 Normal
temperature normal
pressure airflow dyeing
machine

Technical parameters:
Tube number : 1, 2, 3, 4, 6 tubes.
Fabric volume: for one tube machine 225 kg, for six-tube machine,1350 kg
(for 170～300g/m2 medium thick fabrics)
Bath ratio:1 : 4.
Max Operating Temperature: 98℃.
Fig. 3: THEN-AIRFLOW® SYNERGY G2.
 THEN-AIRFLOW® Dyeing Machine
The researchers at THEN had already predicted the situation of increasing
scarcity of usable water as far back as the 1970s, when they began developing a jet
dyeing system that would dramatically save water. The basic idea was to use dye
liquor for the sole purpose of dyeing the fabric, and not to waste copious amounts of
it, to simply move the fabric through the kier. They achieved this by harnessing the air
inside the dyeing vessel and use it as a jet stream to propel the fabric through
the dyeing nozzle. Thus, the chemicals and, in reactive dyeing, particularly of
Glauber’s salt. Dyeing of most synthetic fabrics can be effected without the use
of anti-foaming agents. Over and above this, the lower liquor ratio also offers
a higher efficiency of dyestuffs. In THEN- AIRFLOW® technology, the dyeing
point is in the nozzle. By injecting the dyeing liquor into the airstream trans-
porting the fabric through the nozzle, an aerosol mist is created that offers
dyestuff penetration far beyond the reach of any dye bath. In reactive dyeing,
customers achieve annual savings of around 5% on their dyestuffs bill. The low liquor
ratio and low overall water consumption also mean that total cycle times are
greatly reduced. For a 100% cotton fabric in a dark red (maroon) shade, the
total process time including loading, pre- bleaching, reactive dyeing, washing-off,
rinsing and unloading is 278 min. This means a theoretical batch rate of 5.2 per day
and thus a massive improvement in productivity over old technology. The overall
water consumption for this fabric from loading to unloading is 39 l per kg. In pure
bleaching operations, THEN-
 Water consumption figures of 8 litre per kg for RFD (ready-for-dyeing) and 9
litre per kg for optical white. THEN-AIRFLOW® machines are available as
high-temperature models or as atmospheric machines. There are presently
more than 2,500 units of late design in operation worldwide, offering their
respective owners economic and ecological superiority on both woven as
well as knitted fabrics across all natural and man-made fibre contents.
AIRFLOW® machines achieve water con- THEN-AIRFLOW® concept was
born, and it became an immediate success initially in Europe and America in
the 80s and 90s of the last century. Today, the global success story of the
THEN-AIR- FLOW® continues, and it has become the most popular brand of
exhaust dyeing machines even in China. As air is used to move the fabric
through the machine, the liquor ratio required in THEN-AIRFLOW®
machines (Fig) is typically 30% to 50% lower than in hydraulic round vessel
dyeing machines.
For 100% cotton fabrics, it is typically 1:3.75 at full loading, and even at half
loading, 1:4.6 is achievable, as the THEN-AIRFLOW machine works without a
liquor bath in the bottom of the kier. The significantly lower amount of
water in circulation also means consider- ably lower requirements of
auxiliary
 THEN-AIRFLOW technology is unrivaled as the most economical exhaust
dyeing technology and the most ecologically sound solution in the industry: it
offers the smallest water footprint of any exhaust technology available today.
The recent new factory is for one of our subsidiary company- KC
Print. The new factory has installed THEN Airflow dyeing machine.
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