MANTEX TECHNOLOGIES FOR TEXTILES
ECO CENTRES DYEING WITH DIGNITY PLASTIC DYETUBES ONE STEP FORWARD, TWO STEPS BACKWARD
DYE PACKAGE CENTRES FROM THE INCEPTION OF YARN DYEING HAS MOVED FROM FIRST GENERATION CONES
SECOND GENERATION DYETUBES
THIRD GENERATION DYESPRINGS
FOURTH GENERATION PLASTIC DYETUBES
SPOT THE DIFFERENCE BETWEEN THE SECOND GENERATION AND FOURTH GENERATION BOBBIN
THE ONLY DIFFERENCE BETWEEN THE TWO BOBBINS IS THE MATERIAL THINK AGAIN IF SECOND GENERATION BOBBINS WERE TECHNICALLY FIT, THESE WOULD HAVE NEVER GOT CHANGED TO DYESPRINGS AT THE FIRST PLACE. IT WAS NOT THE MATERIAL, WHICH WAS THE PROBLEM IN DYEING, BUT IT WAS THE SHAPE OF THE PACKAGE, WHICH DID NOT CONFIRM TO THE TECHNOLOGY OF DYEING MOVING TO PLASTIC DYETUBES IS ONE STEP FORWARD, TWO STEPS BACKWARD
WHY DID DYETUBES GOT OVERTAKEN BY DYESPRINGS AS PER ALL THE RESEARCH WHICH WAS DONE ON THE PACKAGE CENTRE , IT WAS FOUND THAT IN ORDER TO GET LEVEL DYEING
PACKAGES NEED TO BE COMPRESSED FOR DENSITY EQUALISATION
PACKAGE COMPRESSION BREAKS THE SHOULDERS, WHICH ARE THE HARDEST PART OF THE PACKAGES
THE FLOW OF LIQUOR SHOULD BE LEAST RESTRICTIVE INTERESTINGLY, THE DESIGN OF THE NEW DYE CENTRE ADDRESSED DENSITY EQUALISATION BREAKING OF HARD SHOULDERS FREE FLOW OF DYE LIQUOR AND THE DYESPRING WAS BORN
THE ADDITIONAL INCENTIVE WHICH CAME WITH DYESPRING WAS INCREASE IN PRODUCTIVITY REDUCTION IN MATERIAL TO LIQUOR RATIO SUPER SAVING IN COST ENHANCED QUALITY
TAKEN FROM “Thies” PRESENTATION
WHICH MEANS, COMPRESSION IS NON OPTIONAL IT IS PART OF DYEING TECHNOLOGY SO, EVEN IF ONE CHOOSES, PLASTIC DYE CENTRES, THEN THE ONE TIME COMPRESSIBLE DYETUBES ARE STILL TECHNOLOGY COMPLIANT
HOWEVER, NON COMPRESSIBLE DYETUBES ARE NON COMPLIANT FOR DYEING TECHNOLOGY
BUT WITH ONE TIME USE DYETUBES
ONE SHOULD HAVE A SUPPLY CHAIN OF ENDLESS SUPPLIES DELIVERING PER DAY TO THE PLANT THE COST OF ONE DYETUBE IS AROUND 2O TO 25 CENTS ( Rs 10 PER PIECE) THIS BECOMES THE ADDITIONAL COST FOR DYEING ANY BREAKAGE ( RECYCLED MATERIAL USAGE IN MAKING OF DYETUBE) OF ONE DYETUBE DURING PRESSING SPOILS THE FULL LOT ON ACCOUNT OF PRESSURE DROP AND CONSEQUENT LIQUOR LEAKAGE STUDY THE PICTURE ABOVE AND SEE THE COMPRESSED PACKAGE FORMS A GRID ACROSS THE PACKAGE AND THIS GRID DROPS THE PRESSURE, HENCE EFFECTIVE PRESSURE DROP ACROSS THE PACKAGE IS NON LINEAR WITH HIGH DROP ON THE INITIAL PHASE OF PACKAGE AND LESS DROP IN THE MIDDLE AND OUTER PHASE . WHERE AS FOR LEVEL DYEING LINEAR PRESSURE DROP IS A MUST FOR LEVEL DYEING
VERY HIGH CARBON FOOT PRINT AS DETAILED BELOW
PP DYETUBES ARE ONLY 75% RECYCLABLE , 25% HAS TO BE DISPOSED INTO MOTHER NATURE AS WASTE FOREVER FOR 10 TPD YARN DYEING PLANT WITH 1.2 KGS DYE PACKAGES NOS OF DYETUBES USED OF 40 GMS PER DAY = 8333 GMS OF NON RECYCLABLE POLYMER WASTER PER DAY = 40 GMS X 25% X 8333 = 83.330 KGS PER DAY NON RECYCLABLE PLASTIC WASTE ADDED TO NATURE PER YEAR 3000 KGS 0R 30 T0NS IN 10 YEARS YOUR CHILDREN AND GRANDCHILDREN WILL HAVE TO LIVE WITH MOUNTAIN OF CARBON DUST AROUND THEM FOR THIS SHORT TERM OUTLOOK ON DYEING, WHERE OTHER PROVEN ECO FRIENDLY SOLUTIONS ALREADY EXIST FOR DECADES WHY IS PLASTIC PREFERRED CROWD FOLLOWING RECOMMENDED BY MACHINE MAKERS, WHO THEMSELVES HAVE NEVER WOUND OR DYED ONE KG OF YARN IN LIFE LOOKS NICE AND COLORFUL
WELL BUTTERFLIES ALSO LOOK NICE AND COLORFUL, BUT WHEN IT COMES TO DOING HARD WORK, ONE NEEDS HORSE POWER AND NOT BUTTERFLY POWER
WHY DYERS STILL GET LEVEL DYEING WITH PLASTIC NON COMPRESSIBLE DYETUBES IT IS LIKE DRIVING A CAR WITH THE BRAKE HANDLE . CAR STILL DRIVES, BUT RETARDS AT THE SAME TIME DYEING STILL TAKES PLACE , BUT WILL COST MORE WATER, MORE CHEMICALS, MORE POWER, MORE STEAM, MORE LABOR AND ABOVE ALL ONE IS NEVER SURE, IF THE DYEING WILL BE LEVEL THE LEVELLING AGENTS DO THE TRICK BUT IS ALL THIS REALLY WORTH WITH SUCH HUGE COST, WHEN THERE IS A PROVEN SOLUTION THAT HAS WORKED FOR DECADES
WHY SOME DYESPRING USERS SWITCHED TO PLASTIC DYETUBES IN MANY PARTS OF THE WORLD POOR QUALITY OF DYESPRINGS, WHERE THE PREMATURE FAILURE OF DYESPRING WITHIN 6 MONTHS WAS ALWAYS BOTHERING THE USER. THE CONSUMER ALSO DOES NOT WANT TO PAY FOR HIGH QUALITY DYESPRINGS, AND LATER SUFFERS WITH PREMATURE FAILURES HIGH WASTE ON DYESPRINGS: AS THE CUSTOMERS WERE NEVER GUIDED BY THE SPRING MAKERS ON THE RIGHT WAY OF USAGE. NOR IS THE INDUSTRY USE TO GAINING FROM OTHERS EXPERIECE. EVERYONE BELIEVES HE KNOWS THE BEST THERE ARE USERS OF DYESPRINGS, WHO EFFECTIVELY USE DYESPRINGS FOR 5 YEARS AND HAVE ZERO WASTE AND THERE ARE USERS, WHO DAMAGE THE DYESPRINGS WITHIN 1 YEAR AND HAVE WASTE AND OTHER COMPLEX PROBLEMS.
BUT THE LIMITING ISSUES OF DYESPRINGS CAN STILL BE ADDRESSED. HOWEVER THE UNLIMITED DAMAGE WITH PLASTIC DYETUBES IS USD HALF A MILLION (RS 3.25 Cr) LOSS TO COMPANY AND A NON TECHNOLOGY COMPLIANT PACKAGE DYEING
WITH COMPRESSIBLE PLASTIC DYETUBES, ONE HAS TO BE REALLY INSENSITIVE TO THE ENVIRONMENT TO IGNORE
3000 KGS PER YEAR OR 30 TONS IN 10 YEARS AND 300 TONS FOR 10 SUCH PLANTS IN ONE SMALL DYEING CITY ( TIRUPUR OR LUDHIANA OR DHAKA OR PANIPAT) ADDING NON RECYCLABLE PLASTICS TO NATURE
DYEING IS A PHYSIO CHEMICAL PROCESS PHYSICAL PART OF THE DYEPACKAGE IS AS IMPORTANT AS THE CHEMISTRY OF DYEING. DYESPRING IS PART OF DYEING TECHNOLOGY IT IS NOT A REPLACEABLE PRODUCT UNTIL ANOTHER COMPRESSIVE SHAPE MEMORY MATERIAL IS INVENTED WHICH GIVES THE SAME DELIVERABLES AS THAT OF DYESPRINGS WITH ONE HUNDRED EVILS OF DYESPRINGS, IT IS STILL A MILLION TIMES BETTER THEN ANY OTHER CURRENT KNOWN PACKAGE CENTRE FOR DYEING
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