A. Monforts Textilmaschinen GmbH & Co. KG has introduced a range of new Industry 4.0 technologies aimed at simplifying machine operation while providing easy access to all data and instant or remote assistance. At the forthcoming Shanghaitex 2019 textile machinery exhibition, which takes place from November 25-28 in Shanghai, Monforts specialists forward to discussing the company’s latest developments in this area with valued Chinese customers.
Comprehensive Monforts Smart Sensor
They include the latest Qualitex full touch panel control system, with its digital twinning capability and Smart Check and Smart Support apps, reinforced by the comprehensive Monforts Smart Sensor machine monitoring programme.
“On the very latest Monforts machines, our Smart Sensor technologies are controlling selected processing parameter and component, making it possible to access comprehensive technical machine data from any location using the Smart Support and Smart Check apps,” explains Monforts Vice-President Klaus Heinrichs. “The data is virtually mapped in the cloud in real time and provides an instant status overview of a machine’s performance.” This, he adds, allows for vastly simplified and targeted analysis for both controlled planning and production, and insights harnessed from the data can subsequently be used to further optimise the production process.
“At the same time, potential sources of error can be remotely anticipated and eliminated to considerably minimise downtime while the digital twin capability provides information on the individual wear parts of a system,” says Mr Heinrichs. “As a result, operators can now see how long a part will last and when maintenance or replacement is necessary. Direct access to the integrated Monforts webshop then allows users to order spares at the press of the button whenever they are required.”
This full digital control package is being made available for all Monforts machine ranges and makes operation smarter, and at the same time, considerably simpler.
CYD System
Monforts will also be providing full details of its new CYD continuous yarn dyeing system which is based on the Econtrol® technique – the most effective and established dyeing process for denim fabrics that is now being applied for yarn dyeing. *
Econtrol® is a pad-dry process employed in Monforts continuous dyeing in which the reactive dyestuff is fixed to the cellulose fibres during drying.
The fixing medium is a controlled by a steam/air mixture within the Monforts Thermex unit. With sulphur and reactive dyes in particular, the improvement in both quality and fixation is considerable, and with significant savings in energy and time due to the combined bleaching and padder fixation. The use of the Econtrol T-CA technique also allows the dyeing of cotton/polyester and other yarn blends.
Weaving Preparation
The CYD system also integrates new functions and processes into the weaving preparation processes – spinning, direct beaming, warping and assembly beaming, followed by sizing and dyeing – in order to increase quality, flexibility, economic viability and productivity.
Further new concepts include the unique Eco Bleach process. This is the first bleaching system for yarn treatment available on the market and is combined with the washing units, after which the fabric is then dyed immediately, resulting in considerable savings in wastewater and chemicals.
By comparing the usual processing sequences within the denim industry with the new CYD system, the advantages become immediately clear. “We are expecting keen interest in our new CYD continuous yarn dyeing system from valued customers in China who did not have the opportunity to visit ITMA 2019,” says Monforts Head of Denim Hans Wroblowski, “especially from the country’s denim manufacturers. We know from the feedback we’ve already received that the CYD system is something the market has been waiting for.” Trials are currently being carried out with customers on the new CYD yarn dyeing pilot line at the Monforts Advanced Technology Centre in Mönchengladbach, Germany.
VDMA Delegation in Pakistan
Monforts will be part of the VDMA Textile Machinery Association’s forthcoming delegation to Pakistan which will take place from November 11th to 14th. In total, 14 companies covering the entire textile chain are participating in the visit, which will showcase the benefits and technological innovations of German textile machinery at seminars held in both Karachi and Lahore.
“The regions surrounding both of these cities have become major hubs for textile manufacturing, especially in areas such as home textiles and denim, where Monforts enjoys market-leading positions with its finishing systems,” says area sales manager Manfred Havenlith, who in addition to presenting at the seminars, will be holding meetings and networking with existing Monforts customers and potential new ones during the trip. “The Punjab region around Karachi, as Pakistan’s largest city, for example, is now dense with denim manufacturers, many of whom have already expressed keen interest in the new Monforts CYD continuous yarn dyeing system we introduced at ITMA 2019 in Barcelona in June.”
The CYD system integrates new functions and processes into the weaving preparation processes – spinning, direct beaming, warping and assembly beaming, followed by sizing and dyeing – in order to increase quality, flexibility, economic viability and productivity. The unique Eco Bleach process is the first bleaching system for yarn treatment available on the market and is combined with the washing units, after which the fabric is then dyed immediately, resulting in considerable savings in wastewater and chemicals. It is possible to process short batches of yarn in order to produce minimum runs of finished fabrics in a single continuous process and by comparing the usual processing sequences within the denim industry with the new CYD system, the advantages become immediately clear.
Monforts at Techtextil India
Monforts Textilmaschinen GmbH & Co. KG will be providing information on its extensive range of coating and finishing technologies for the production of nonwovens and technical textiles at the forthcoming Techtextil India exhibition.
“India has one of the largest working-age populations in the world and a complete textile value chain for both natural and synthetic fibres.” says Monforts Head of Denim Hans Wroblowski. In addition, he adds, India’s government, through its Ministry of Textiles, has been actively promoting the growth of technical textiles through various programmes based on investment promotion, subsidies, the creation of infrastructure and the stimulation of consumption.
As a result, India’s Ministry of Textiles is forecasting that the growth of technical textiles in the country will be over 18% annually in the next few years, from a value of US$16.6 billion in 2018 to US$28.7 billion in 2021.
