Monforts stands firmly behind “Blue Competence”
Klaus A. Heinrichs from Monforts gives three example of the achievements reached with the German Initiative “Blue Competence” by VDMA the German Engineering Federation
First of all he confirms: “We had no hesitation in participating in the VDMA’s “Blue Competence” initiative. Energy management has been one of our primary goals for many years, driving us to develop energy efficient and resource conserving solutions. For many years textile finishing has operated with chemical and thermal processes, which, by present day standards, can have a very severe impact on the environment”. Then he adds: “The energy costs are high, and the use of chemicals is absolutely essential. But with innovative ranges and intelligent ancillaries, Monfortrs has succeeded in optimizing these processes, and the savings benefits we have achieved in recent years are in some cases, quite considerable”.
The first example “Econtrol”: As we all know, during textile dyeing, chemicals are used to fix the dyestuffs on the textiles. Classic processes for the dyeing of cotton textiles are as follows, e.g. it includes 250 grams of salt per litre of treatment fluid. When calculated for three-shift operation, up to 500 t of salt is required annually.
For the dyeing and cleaning process with subsequent washing, a total of around 1545 kg of chemicals are required for dyeing processes and also an immense amount of energy is also required for the subsequent drying process.
Together with DyStar, one of the leading dyestuff producers, Monforts has developed the Econtrol process for pure cotton textiles. In the process the dyestuff is fixed during and not after drying, using a controlled chamber climate with 25 % v/v steam thus eliminating a complete steaming process. Now, only 20 grams of salt are required per litre. Furthermore, the dyeing result is available after just two minutes and not only after 12 to 24 hours.
For fibre blends (polyester/cotton), Monforts has developed the Econtrol TCA process also jointly with DyStar and it allows polyester and cotton to be dyed simultaneously thus eliminating the commonly used two process steps. The dye is alkaline resistant and can be applied at the same time as reactive dyestuff. When dyeing mixed fabrics, the use of chemicals can be reduced by around 86 %, water by 63 % and energy consumption by around 50 %.
The second example is the ECO Applicator reducing significantly the initial moisture content before the drying process. Generally, the fabric is transported through a trough containing the finishing and dyeing liquor (aqueous liquid to wash, bleach, dye and impregnate textiles). Afterward the “wet” fabric has to be dried by a stenter. The drying energy is a decisive cost factor.
In the ECO Applicator, the liquor is applied thinly by steel rollers resulting in a maximum energy yield, because moisture not being applied to the textile fabric does not have to be dried later. The savings of heating and electrical energy are up to 65 %, if the initial moisture content in the textile is reduced from 70 % to 40 %.
The third example are the Energy Tower and ECO Booster, the Energy Tower is a stand-alone air/air heat exchanger for heat recovery and thanks to its design it becomes a versatile and flexible retrofit module that enables even older ranges to benefit from the principle of heat recovery. The module draws i9n the exhaust air from the drying process and returns it via heat exchangers to the range so that the air is preheated to around 90°C and has to be heated up to 150 °C and this temperature can be reached quicker, therefore lower energy costs result.
The ECO Booster (fully automated) is also designed to minimise energy costs when using stenters. The new module cleans the stenter during operation and eliminates standstill times for maintenance. For the cleaning only 100 litres of water are necessary. The product permits a computer-controlled adaptation of the heat exchanger performance to the prevailing waste are stream, adding efficiency, and at the same reducing process costs.
Of course it is a fact that efficient technology may cost more, but the procurement cost account for less than 20 % of the life-cycle costs if you take the total costs for energy into consideration. The paypack period for the Monforts technology is around 18 months to two years.
Heinrichs is stressing: “The trendsetting Monforts technology continues to prove itself and left a long lasting impression at ITMA Asia”. TextileFuture has also reported on the continued success of Monforts Eco-Products in recent months.