New technology positions Meridian as the Leading Package Dye House in North America
Meridian Specialty Yarn Group (MSYG) announced the investment in a new generation of technology, machines, controls and robotics for package, top and tow dyeing. The new machinery and supporting technologies will be installed later this year in Meridian’s new manufacturing plant in Valdese, NC, US. Construction on that facility began this spring and is expected to be complete by first quarter 2017
Meridian’s multi-million-dollar purchase represents one of the first major investments in state-of-the-art package, top and tow dyeing equipment in North America in decades and positions MSYG as North America’s most modern manufacturing operation with regard to dyeing technology and robotic support equipment. The purchase includes state-of-the-art dye equipment by Galvanin, S.p.A. of Vicenza, Italy; a patented automatic dosing system for dispensing chemicals and auxiliaries from Color Service Dosing Technologies of Dueville VI, Italy; and new monitoring and control systems for all of the new dyeing equipment from Adaptive Controls of Huntersville, NC, US. MSYG is also installing a new Galvanin skein printing machine along with support equipment.
The new machinery and equipment will increase MSYG’s production capabilities to 16 million pounds of yarn per year (based on a five-day week) and expands the markets Meridian can serve.
The package dye machines are vertical, air pad, low liquor machines, which will dye all substrates of yarn and replace all of MSYG’s existing package dye equipment. The new low liquor dye machines will be used to process cotton, rayon, wool, spun and textured polyester and other fibers. The equipment will improve production speeds and all quality aspects of dyeing while at the same time significantly reducing energy, water and chemical consumption.
The new acrylic tow dyeing capabilities will support the raw material needs at MSYG’s plant in Ranlo, NC, US. The skein printed yarns will go into craft yarns, apparel products and some home furnishings. The top dyed wool capability will support worsted spinners supplying high-end apparel, hosiery and home furnishings.
“Our new technology gives us the capability to process every dyeable substrate, which is very unusual in the dyed yarn world,” said Tim Manson, president of MSYG. “Most dye houses specialize in certain products, but we will be in a position to source from all over the world, from every type of textile fibre, supporting a wide array of end uses.”
“We are very pleased to have been chosen as the supplier for all of the package, tow, tops and hank dyeing machinery for this important project and it is a pleasure to work with such an experienced team of professionals as that at Meridian,” said Marcello Galvanin, president of Galvanin S.p.A. “We look forward to seeing this project through and see it as a showcase for next generation yarn dyeing operations.”
Manson added that he and his management team conducted extensive research before making the decision to invest in Galvanin machines and robotics, automatic dosing systems from Color Service Dosing Technologies and monitoring and control systems from Adaptive Controls. “They are all highly respected,” he said. This investment in state-of-the-art technologies opens many possibilities for both Meridian Specialty Yarns Group and the textile industry’s US supply chain,” he added. “This is the dye house technology of the future and we are delighted to be at the forefront of bringing this new technology to North America in such a comprehensive manner.”
Meridian Specialty Yarn Group (MSYG) is installing a new generation of technology, machines and robotics for package, top and tow dyeing. This multi-million-dollar purchase is the first major investment in state-of-the-art package, top and tow dyeing equipment in North America in decades and when installed, will be the first new, full yarn-dyeing facility, globally, in recent years.
The new dyeing machinery is being supplied by Galvanin, S.p.A. of Vicenza, Italy (see Galvanin boilerplate below).
Color Service Dosing Technologies of Dueville, VI, Italy, is installing a new patented Color Service© dosing system for automatic dispensing of chemicals and auxiliaries.
Adaptive Controls of Huntersville, NC, USA, is supplying monitoring and control systems for all of the new dyeing equipment.
Late in 2016 in Meridian’s new manufacturing plant in Valdese, NC, US will be operational.
* The installation includes a full plant of new dye machines, which will replace all of MSYG’s existing package dye machinery.
* The installation also includes robotics and full supporting equipment and technology.
* A new skein printing machine along with supporting equipment is also being installed.
* When installed, the new machinery and supporting technologies will have capacity to process 16 million pounds of yarn per year (based on a five-day work week).
The markets to be served:
*Home furnishings, carpet, upholstery, industrial, hosiery, apparel, craft yarns.
*Acrylic tow dyeing will support major raw materials needs of Meridian’s Ranlo, North Carolina, US plant.
The new machines will increase total plant production capabilities while also reducing water, energy and chemical consumption. Additional information related to this, as well as other sustainability initiatives at the new factory, will be announced later this year.
*MSYG will use the new dyeing technology to process every conceivable dyeable substrate including cotton, rayon, wool, textured polyester and other fibres.
*The equipment also gives MSYG new capabilities to supply demand for dyed acrylic tow for long staple spinning.
Valdese Plant Capabilities:
Package-dyed yarn, three processes of space dyed yarn, top dyed wool, yarn printing and twisting.
MSYG has been in operation in Valdese since 1994. Square footage of existing plant: 152000 Square footage of new plant: 116000; Square footage of completed operation: 265000
Anticipated investment in plant expansion: USD 8 Million; Number of current employees in Valdese: 146, number of new jobs: 26
Meridian Specialty Yarn Group, Inc. (MSYG) is the leading specialty yarn manufacturer in the United States. At the company’s wet processing plant in Valdese, North Carolina, Meridian offers package dyed yarn, space dyed yarn, top dyed wool, yarn printing and twisting. At the novelty spinning operation in Ranlo, North Carolina, Meridian produces coarse count novelty yarn from various substrates using six different yarn formation technologies. The end uses for these yarns include home furnishings, hosiery, industrial, craft and apparel. Meridian Specialty Yarn Group is a Meridian Industries, Inc. company.
Galvanin S.p.A. is the world’s leading manufacturer of yarn dyeing equipment. With headquarters in Vicenza, Italy, the company designs and produces complete automatic systems for top-dyed wool, yarn printing, tow dyeing, stock dyeing and bleaching, as well as complete systems for dyeing and drying package yarn. Galvanin also provides robotic systems for loading and unloading packaged yarn. Galvanin S.p.A. has more than 50 agents around the world serving the global textile industry.