Compared to a new machine, upgrades are a low-cost investment that deliver clearly defined benefits, with enhanced production, sustainable operation and energy savings. One major benefit of the dyeing, finishing and coating machines designed and engineered by A. Monforts Textilmaschinen GmbH & Co. KG, Mönchengladbach/Germany, is that they can be upgraded. The retrofitting of specific modules with new control and drive technology can have a significant impact on the performance of an existing line. A major modification project has recently been undertaken for Grupo Kaltex, Mexico City/Mexico, on a Montex stenter that was first commissioned in 1995.
Grupo Kaltex is a fully vertically integrated textile company with divisions manufacturing synthetic fibers, yarns and fabrics. It also has garment and home textiles divisions exporting internationally.
The modifications carried out at the Kaltex finishing plant consisted of the exchange of the complete switch cabinet and the replacement of all control panels to the latest technical specifications, with new frequency converters, transport drives and a gearbox, along with modifications of the circulation fans. In addition, the Montex stenter has been equipped with full PLC control, 24-inch touchscreen PC control and the latest Monforts visualization software.
The machine now runs very well on the electrical side and unplanned stops have been eliminated. In addition, significant energy savings are being achieved.
Monforts has further new options for energy optimization available to customers. The universal Energy Tower is a flexible, free-standing air/air heat exchanger for recovering the heat from the exhaust air flow of thermal processes. This can result in a 30% reduction in the energy consumed by a line, depending on the exhaust air volume and operating temperature.
A Eco Booster, completely integrated into the chamber design of the Montex stenter, is another retrofitting option. As a single state-of-the-art heat recovery system with automatic cleaning, it can be added to existing ranges. For ranges of up to 8 chambers only one module is necessary to achieve significant energy savings. In addition, the Eco Booster consumes only minimal amounts of water during the cleaning cycle and the entire process is controlled and monitored automatically.
The Matex Eco Applicator is an alternative to the conventional padding process for energy-conscious finishing and achieving considerable savings in the drying of treated fabrics. The precise amount of chemical can be applied to the fabric so that less drying capacity is required in the stenter.