To further boost the weatherproofing specialist’s highly flexible operations, Monforts has installed and commissioned a new Montex finishing range at the Baltic Works of Halley Stevensons. The range, with a working width of 2 m, was built at the Montex assembly plant in Austria and consists of a MontexCoat coating unit in knife execution for paste and foam coating and a Montex 8500 6F stenter.
Over the years, Halley Stevensons Ltd. Dundee/UK, has amassed technical know-how and manufacturing experience in waxed cotton for weatherproofed fabrics. The new range draws on the latest advances and technical expertise of A. Monforts Textilmaschinen GmbH & Co. KG, Mönchengladbach/Germany, allowing Halley Stevensons to pigment dye, direct coat and pad apply finishes and offering more scope for R&D.
The precise process control functions of the line give the technicians confidence to make new products as well as finely tuning the energy requirements of existing products. The energy used on each production batch can be recorded and used for continual improvements and efficiency savings. The touchscreen software is visual and easy to use, moving from one screen to another to check the various parameters of processing.
The range has replaced one of the company’s older stenter/coating lines and has already enabled the company to recreate various products with lower coating applications at higher speeds than before. The MontexCoat has a higher coating accuracy and higher quality of the treated fabrics. The completely integrated coating lines from a single source and the coating machine is tailored to the subsequent Montex drying technology with all the benefits resulting from fully integrated plc control.
The machine is very robust – especially the chains, which need very little lubrication and will last long. Changes can be made from e.g. a 100 g/m² fabric to a 600 g/m² fabric with no requirement to adjust tensions.
Waxed cotton was originally developed by sailors in the early 15th century when Scottish North Sea herring fleets began treating flax sailcloth with fish oils and grease in an attempt to waterproof their sails. Remnants of these sails were used by the sailors as capes to withstand the high winds and sea spray.
While traditional waxes are petroleum or paraffin based, Halley Stevensons uses a waste product from industry and reuses it to make products that last a lifetime. One of the most popular finishes is the hybrid aero – an emulsified blend of waxes. This fabric is water repellent but has little wax in the mixture, so the handle is much drier to touch than the traditional wet waxes.
The company has also recently launched a new 100% plant-based wax – Ever Wax Olive – consisting of a blend of olive oil, rape seed and castor bean with comparable water repellence to petroleum and a far better rating than other natural waxes which have come before it.
The dyeing methods use very low levels of water and the waxes are simply heated up for application and cooled down to store when not in use, meaning no waste discharges. Now, with the new Monforts line, the company is also achieving running speeds 2-3 times faster than with the older stenter, combined with less gas usage.
Montex = registered trademark