Impressive cost savings at Colombia’s Permoda thanks to a Montex 6500 stenter
The leading Colombian garments producer Permoda Ltda has installed a Montex 6500 stenter in its Bogota plant to ensure maximum competitiveness in the quality of its own brand products
Permoda manufactures for Latin American markets, with brand names such as Armi, Pronto, B-Kul, Koaj and Love, serving mainly the young fashion sector.
The six chamber Monforts Montex was supplied by Monforts’ Colombian distributor Servimtexa in late 2011. The plant was put in operation seven years ago, and up to its installation the company has been using conventional stretching frames for its fabrics.
William Garzon Alarcon stated: “This is a completely new addition to our production line and is following our strategy to improve the quality of our output, and to become more competitive, and at the same time to increase our production. We believe that quality drives sales and hence production. This is why we have installed the Montex 6500. The Monforts technology enables us to achieve these goals.”
The new stenter is handling a wide range of knitted fabrics, including 100 percent cotton, combines polyester and cotton, and Lycra. Garzon adds: “We can now process any kind of knitted fabric, and the stenter is helping us to increase our fabrics mix.” The stenter handles material to a width of 2.60 m. The average weight of the material is 180 g/m2, with a maximum weight of 350 g/m2. The company handles between 5 to 6 t/day, and the factory works 25 days per month, thus an output by the stenter will reach more than 125 t a month.
The stener is equipped with a heat exchanger, helping Permoda to closely control costs.
When discussing the specifications of Permoda’s requirements before installation, we were told by Servimtexa that our projected output would probably use 90 m3 of gas per hour. In reality the operation is using 40 to 45 m3 or about half of what the customer expected. Garzon continues: “At the same time, we were told to expect to use about 200 kW of electrical power, but so far we have been using only about 95 kW. We are very happy with our consumptions rates. We are saving on our costs and are easily meeting the local environmental rules”.
We all know that energy can account for more than half the costs of operating a thermal system, and the Monforts heat transfer system is designed to reduce these to the minimum amount possible. The heat exchanger is integrated into the roof construction of the stenter and uses exhaust air heat to heat the fresh combustion air. Heated fresh air enters at the inlets of the stenter via integrated fresh air ducts. Up to 60 % of the fresh air required by the stenter can be preheated in the described manner, providing a conservatively estimated energy saving of between 10 to 30 %, depending on the production process.
Permoda is monitoring costs very closely, and it seems likely that the large percentage of actual savings as against estimated savings is due to a combination of relatively long production runs, well trained operators, and regular and thorough maintenance. Garzon affirms: “We believe that we are running the stenter at its optimum range, and consequently are enjoying the full benefits”.