YARN DYEING INDUSTRY
ARE YOU THROWING AWAY PROFIT OF RS 5 CRORES PER YEAR
CASE STUDY BY
DYECENTRES .
PLASTIC RIGID AND COMPRESSIBLE DYETUBES. CURRENT CHOICE OF YARN DYERS RECOMMENDED BY PRECISION WINDING MACHINE MAKERS RECOMMENDED BY DYEING MACHINE MAKERS EASE OF WINDING LOWER RESIDUAL WASTAGE RF FRIENDLY COLORFUL
LOSS FOR THE DYEHOUSE
PLASTIC DYECENTRES PENNY WISE POUND FOOLISH
PENNY WISE FOLLOWING BLINDLY OTHER DYERS RUNS FASTER ON PRECISION WINDERS RECOMMENDED BY MACHINE MAKERS
POUND FOOLISH PRODUCTIVITY LOSS ON ACCOUNT OF LOWER LOADING PER CHARGE INTO THE DYEING MACHINE HIGHER VOLUME OF WATER USED PER KG OF DYEING MORE POWER CONSUMPTION PER KG OF DYEING MORE CHEMICAL AND AUXILARY COST PER KG OF DYEING MORE STEAM COST PER KG OF DYEING INHERENT DENSITY VARIATION WITHIN PACKAGE GIVING LOW RFT ECO DISASTER DO YOU RUN THE PLANT FOR THE PROFIT OF MACHINE MAKER OR ON THE WHIMS OF A FANCY MANAGER OR FOR THE PROFIT OF SHAREHOLDERS
IS YOUR DYEHOUSE COLOR BLIND TO LOSSES
Dyeing cost/Kg Lower Loading with Precision wound Plastic Dyecentres Opportunity Cost with better loading ( Dyg Cost x 85%) Loss Per Kg of Dyeing Loss Per 10 TPD of dyeing Loss Per Month Loss Per Year
Rs. Rs. Rs. Rs. Rs. Rs.
60,00 15% 51,00 9,00 90.000 2.700.000 27 Lacs 32.400.000 3.25 Crores
DYEING LOSS ON PRECISION WINDER WITH DYETUBES
Dyeing cost/Kg Lower Loading with Drum winders and Plastic Dyetubes Opportunity Cost with better loading ( Dyg Cost x 85%) Loss Per Kg of Dyeing Loss Per 10 TPD of dyeing Loss Per Month Loss Per Year
Rs. Rs. Rs. Rs. Rs. Rs.
60,00 25% 45,00 15,00 150.000 4.500.000 45 Lacs 54.000.000 5.4 Crores
DYEING LOSS ON DRUM WINDERS WITH DYETUBES
THROWING AWAY PROFIT OF RS 3.25 CRORES WITH PRECISION WINDERS AND RS 5.50 CRORES WITH DRUM WINDERS
THE GAME CHANGER
SMALL CHANGE FROM PLASTIC DYETUBES TO MANTEX DYESPRINGS BALANCE SHEET NET PROFIT UP BY RS 3.5 CRORES.
PRESENTATIONS OF MACHINE MAKERS LIKE THIES AND SSM
CAPTURED FROM THIES PRESENTATION
COMPARISON OF TIME AND WATER WITH DYETUBES AGAINST DYESPRINGS
CAPTURED FROM THIES PRESENTATION LOSSES WITH DYETUBES FOR 10 TPD 20,000 LITRES OF EXTRA WATER USED = EXTRA CHEMCIALS + EXTRA POWER + EXTRA STEAM +EXTRA EFFLUENT TREATMENT= ADDL COST OF RS 9 PER KG LOSS OF RS 3.25 CRORES PER YEAR 14MINS X 10,000KGS = 97.22 HRS OF EXTRA DYEING TIME MEANING 97.22 HRS OF LOST CAPACITY PER DAY = 4 DAYS OF PRODUCTION COST
MYTHS AND FACTS ON MANTEX DYESPRINGS DYESPRINGS DON’T RUN ON HIGH SPEED WINDERS FACT AS BELOW
SSM MACHINES AT COATS INDIA
SSM MACHINES RUNNING WITH MANTEX DYESPRINGS
MODERN WINDERS LIKE SSM HAVE PROGRAMS TO SLOW START AND THEN GRADUALLY ADD SPEED GIVING AS HIGH AS 1400 MPM. CALL SSM GENERAL MANAGER MR NARAYANAN AT AND CONFIRM THIS FACT AND LEARN THE SEETING FROM SSM
MYTH DYESPRINGS GET HARD PRESSED ON TOP AND BOTTOM PACKAGES IN A COLOUMN FACT
SOME DYERS PRESS MORE THEN 25% TO GET ADDITIONAL PROFITS AND THIS LEADS TO HARD PRESSING ON TOP AND BOTTOM PACKAGES.
MYTH PRECISION WINDING SHAPE IS LOST IN PRESSING FACT
CAPTURED FROM ‘Thies’ PRESENTATION PRECISION WOUND PKGS HAVE DENSITY RANGE OF +/- 10 GMS = 20 GMS. WHICH IS 5% BETWEEN PACKAGE DENSITY VARIATION. UNLESS THIS DENSITY IS EQUALIZED, LIQUOR WILL ALWAYS TAKE THE PATH OF LEAST RESISTANCE AND MOVE MORE OUT OF LOWER DENSITY PKGS. GIVING UNLEVELLED DYEING THIS DENSITY VARIATION WITHIN PACKAGE CAN ONLY BE EQUALIZED BY PRESSING ON DYESPRINGS. THERE IS NO OTHER TECHNOLOGY IN THE WORLD TO MANAGE THIS WITHIN PACKAGE AND BETWEEN PACKAGE DENSITY VARIATION.
MYTH HIGHER RESIDUAL WASTE FACT RESISUAL WASTE ON PRECISION WINDERS IS NILL. AS RESIDUAL WASTE COMES ONLY OUT OF INITAL LAYERS WINDING AND IN CASE OF PRECISION WINDERS, INITIAL SLOW SPEED SETTINGS GIVES UNIFORM LAYERS. THIS WAS TRUE IN CASE OF OLD DRUM WINDERS WHERE INITAL SPEEDS COULD NOT BE AJUSTED.
MYTH DIFFICULT TO HANDLE
FACT ANY WORK HORSE, WHICH SAVES THE COMPANY RS 3.25 CRORES IS WORTH HANDLING
MYTH DAMAGES IN HYDRO
FACT MANTEX DYESPRINGS ARE DESIGNED BY TEXTILE ENGINEERS FOR THE TEXTILE INDUSTRY. THE UNIQUE DESIGN DOES NOT GET DAMAGED ON HYDRO
TOP INDIAN COMPANIES USING DYESPRINGS WITH PRECISION WINDERS
ARVIND ASHIMA ABHISHEK RAYMONDS MORARJEE SIYARAM WELSPUN MAFATLAL COATS NAHAR RELIANCE PREMIER S.KUMAR GARUDA COTEX THREADS INDIA MANY MANY MORE
ARE YOU THROWING AWAY PROFIT BY USING PLASTIC DYETUBES IN YARN DYEING
FREQUENTLY ANSWERED QUESTIONS
WHY MACHINE MAKERS LIKE SSM AND FADIS RECOMMEND PLASTIC DYETUBES FOR WINDING ON THEIR MACHINES. DEPENDS ON Technical Capability of the Sales Manager. ( There are Competant Sales Managers Like Mr AT Narayanan GM SSM INDIA and Mr MM Chaudhary Sr Manager Peass Schlafhorst , who have spend their lives in winding and dyeing and guide the clients correctly and there are others who have no clue of the Industry ) And Technical Capability Of Yarn Dyer
The one and only argument favoring Plastic Dyetubes is that it run at higher speeds on winding and hence the recommended centres. But Ruins the Profitability of a Dyehouse. The winnning combination is to Run the Winder at High Speed and use MANTEX DYESPRINGS.
DYESPRINGS DON’T RUN AT HIGH SPEEDS: Not True Anymore
Thanks to freely programmable speeds of SSM , the Dyesprings can be made to run at 1300 mpm +. How : Call up GM SSM India : Mr Narayanan +9787635505 OR Call Up Sr Manager Peass : Mr Chaudhary +9324615110 OR Write to us at mantex@rad.net.id Precision and Modern Drum Winders start at low speeds and can be programmed to then deliver final speeds as per machine capability.
SSM PW2 RUNNING FOR EMBROIDERY THREADS AT COATS INDIA
VALUE OF WINDING SPEED ABOVE 1000 MPM TO THE DYER Higher Speeds Sound Sexy , but everything has to be an optimum. Beyond which the system frequently crashes. One has to Deeply understand the Yarn Dyers Requirments
\
Captured from’ SSM’ Presentation. Geometry comes from Dyespring Usage Density comes From Winding With Pressing. Optimum Package Centre And Optimum Winding Speed Gives Optimum Density of Package
HIGHER SPEEDS RESULT INTO PACKAGE DEGENERATION
CAPTURED FROM ‘Thies’PRESENTATION Every single time, the yarn reverses on the package, it hardens the shoulder. Higher the speeds, stoner the shoulder. Angle of Wind Changes continously in Precision winders to give a higher weight to the package. This means, within package, some areas have larger angle of wind and some areas have lower angle of wind. As the Package builds up the Angle of wind reduces. It is a known fact that only and only an OPEN WOUND package gives the best dyeing result. This is also the reason that most cases the outer layers have lower penetration as the liquour flow in NON COMPRESSIBLE DYETUBES is inhibited by the Lower Angle Of Wind. But in compressible packages, the angle widens on compression and opens the package uniformly across the surface. Only 8% dyeliqour flows out of shoulders and 25% out from the sides. Ask yourself this question, how then Precision winder justifies Plastic Dyetubes, when this inherent density defect is not corrected. PRESSING OF PACKAGES IS THE ONLY KNOWN WAY OF CORRECTING THIS PACKAGE ANAMOLY
OUR DYEHOUSE IS ALREADY SET NOW WITH PLASTIC DYETUBES; WHY DISTURB Well, if Shareholders Value Rs 3.25 Cr for their biz, then whatenver needs to be done has to be done. There is no room for complacency in competing biz environment. Lazy thinkers will always get penalized.
WHY EUROPE AND US DYERS USE PLASTIC DYETUBES Most of them regularly declare Bankruptcy and there is hardly any left across Europe. It is this lazy thinking and arrogance that “ I know all and I don’t want to listen to you “ that has bought today Europe to a state of Bankruptcy and the Third world is funding the IMF in bailing out European States. If you want to lead your biz to Bankruptcy Ignore this presenation Or Think Again. Is Blind Following Worth Or Using Own Conviction Worth. Warrn Buffett said, Savings is Profits , Spending Wastefully is Total Loss. Smart Guys take a Leading Position with well diffirentiated products in markets with the lowest investments and lowest operational cost. Dull Guys copy paste biz models. SONY AND NOKIA ALSO BELIEVED THAT THEY WERE SUPERIOR AND DID NOT WANT TO ADDRESS INEFFICIENCES . TODAY YOU CAN BE A MARKET LEADER AND TOMORROW YOU ARE INTO RED FOR YOUR OWN COMPLACENT ATTITUDE Good market time, everyone gets a pie . Bad Markets , even the smallest pie needs the lowest comepting price. Today for Rs 1 the orders are lost, inspite of the best machines, best yarns and best infrastructure. Have your Proofed Your Biz For Competition ? Or you Have Black Holes eating into profits.
DYEING MACHINE MAKERS RECOMMEND PLASTIC DYETUBES Not Really with “Thies” . As you can already see the Part of this Presentation is actually from “Thies”
Certain Italian Dyeing Machine makers do recommend Plastic Fact is that they have no arguments, whatsover against Dyesprings, but fear Dyesprings, because with Dyesprings, the capacity of the machine enlarges and hence the number of vessel sold by them reduces. Technically, for a 10 TPD plant, you buy machines only for 7.5 TPD as Dyesprings gives the extra 2.5 TPD free to the Dyer. Captial Cost Saving of 25% for Dyer, Loss for the Italian Dyg Machine Maker. However, with Germans, no such issues. ( Some white are more whiter then others in dyeing ) FONGS RECOMMENDS PLASTIC DYETUBES Same Reason as Italians. Use Dyesprings and you Buy less Number of Vessels, Use Plastic Dyetubes and Invest 25% extra number of Vessels.At prices lower then even Dalal, somewhere Poor Fongs has to make money.
QUALITY OF DYEING IS BETTER WITH PLASTIC DYETUBES AND PRECISION WINDERS. If Quality was Better, High Value Yarn Dyed shiring Makers like Arvind, Morarjee, Raymonds, Mafatlal will not get a Delta E value of less then 0.2 in yarn dyeing with Dyesprings. Has your dyeing plant ever reached a Delta E value of less then 0.2 with any plastic centre.? Second, See The Pic Below. One does not need Great Brains to see, which will give better flow to passage of liquor in yarn dyeing.
DYESPRINGS DON’T GO WELL WITH HYDRO Time to kiss good bye to Hydro and RF Dryers : Like Rapid Dryers! Nothing goes well with Hydro. Plastic Dyetubes damage and shape distorts. There is a Design Issue with the Modern Machine. Unless packages are managed internally and externally, damage to package Centres will be part of the dyeing cycle
Lab Pro Hydro : The Ultimate Design in Hydro
“ Thies “ Rapid Dryers Knock out Hydro And RF Dryers and Operational cost same as RF Dryers. ZERO HANDLING AFTER DYEING TO DRYING. VERY LONG LIFE OF DYESPRINGS AND NO MORE SHAPE AND LAYER DISTORTION. PLUS FASTER DRYING WITH DYESPRINGS.
NEW DYEHOUSE WINDING -DYEING -
DRYER - REWINDING.
ELIMINATED HYDRO +RF DRYER+PLASTIC DYETUBES
ECO COMMITTMENT
DYESPRINGS ECO KISS
ENVIRIONMENT POLICY OF A COMPANY IS NOT A STATEMENT MADE ON WEBSITE, BUT ACTUAL IMPLEMENATION OF ECO SAVINGS
7.5 MILLION LITRES OF WATER PER YEAR CHEMICALS AND AUXILARIES FOR 7.5M LTR WATER EFFLUENT TREATMENT OF 7.5 MIL LITRES PER YEAR NO MORE DISPOSAL OF PLASTIC DYETUBES AUSTRALIA IS THE FIRST COUNTRY TO INTRODUCE CARBON TAX. MORE COUNTRIES WILL FOLLOW MAKE YOUR ECO COMMITTMENTS WITH MANTEX DYESPRINGS
YOUR TECHNOLOGY PARTNER FOR YARN DYEING
SALES COUNSELLING TEAM
BANGALORE :
MR K V Shanker : 9743877863 ( GM ) MS Jayashree
: 080 22427863
CHANNEL PARTNERS COIMBATORE ;
Mr S Sriram Visveswar 94875 - 45184
DELHI
Mr Amitabh Ghosh : 9810150391
LUDHIANA
Mr A P Singh
SURAT
Mr Vijay Pathak
MUMABI
Mr MM Chaudhary : 9324615110
AHMEDABAD
Mr Dinesh Dhagat : 93270-14844
CALCUTTA
Mr Anil Saria
: 93276-10930
: 9831047494
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