During a current webinar organised by Germany’s VDMA textile equipment affiliation, specialists from the three corporations offered particulars of the vary of recent energy-saving choices that’s now obtainable to mills.
VDMA’s current webinar highlighted new resource-efficient finishing and dyeing applied sciences from Monforts, Archroma, and BW Converting.
The Baldwin TexCoat G4 system with Archroma formulations and Monforts MONTEX stenters has achieved main water and power financial savings, notably in Pakistan.
The companions now prolong innovation to dyeing with the brand new TexChroma system, debuting at ITMA Asia + CITME 2025.
In specific, BW Converting’s Baldwin TexCoat G4 precision spray expertise – in mixture with superior Archroma finishing formulations and Monforts MONTEX stenters and MONFORTEX shrinking ranges and associated applied sciences – is pushing the envelope in new requirements for sustainable and long-lasting clear productiveness.
Functionality
Michael Schuhmann, Global Marketing Finishing at Archroma Textile Effectsdefined that typical key features offered in textile finishing embody sweat and odor management, water repellence and UV resistance. Softeners are primarily utilized to make materials extra snug whereas different finishes present decreased crease formation for easy-care properties. The conventional padding or exhaust methods for making use of these finishes require big volumes of water and power intensive drying.
Spray software, in contrast, requires a lot much less water attributable to drastically decreased ‘pick up’ – the quantity of liquid {that a} material absorbs and retains, figuring out how a lot finishing agent stays in the material. This additionally allows considerably quicker drying, making course of speeds of as much as 100 metres per minute attainable, relying on the material.
“As the global fashion brands commit to reducing their emissions, the textile processing industry must respond by adopting safer chemistries with resource-saving processes such as spray application,” Schuhmann mentioned.
Precision
Rick Stanford, Vice President Global Business Development for Textiles at BW Convertingdefined that on the core of the Baldwin TexCoat G4 expertise are precision valves that had been initially developed for the offset printing trade and have been refined over the previous 40 years by greater than 40,000 installations globally.
“These enable extremely precise spray flows which are controlled by proprietary software algorithms,” he mentioned.
Over 100 TexCoat G4 items have been put in worldwide and all three corporations are having fun with notable success with mattress sheeting producers in Pakistan.
“Our first TexCoat G4 in Pakistan was installed in Spring of 2024 for a manufacturer using Archroma chemistry and a ten-chamber Monforts MONTEX stenter,” Stanford defined. “When using the padder at this mill, the pickup rate was 65% and with TexCoat G4 we were able to reduce that to 27%. As a result, the customer was able to increase the MONTEX speed from 60 metres a minute to 100 metres a minute, while also reducing the operating temperature in the stenter. We have subsequently sold 30 TexCoat G4 units in Pakistan, driven primarily by the system’s proven productivity and efficiency gains.”
Energy financial savings
“A BW Converting Baldwin TexCoat G4 unit is now installed at the Monforts Advanced Technology Center (ATC) for trials and fully complementing spray finishing operations are our multiple energy saving innovations,” added Saskia Kuhlen, Monforts Engineer for Textile Technologies. “MONTEX stenters are equipped with the TwinAir air volume regulation system as well as the TwinTherm system for temperature control and feature CADstreamE variable nozzles. These features enable full adjustment to a specific fabric width for either higher operational speeds or lower electrical energy. A further benefit is the150-mm wide advanced insulation system inside the stenter frame”.
Further Monforts modules for optimizing processes embody the coaTTex unit for the knife coating of paste and foam software and the EcoApplicator, a kiss-coating expertise for the oblique software of finishes on one or either side of a cloth, with a stenter manufacturing pace as much as 100m/min. Both might be built-in into current strains.
The Monforts Energy Tower and EcoBooster are in the meantime modules for air/air warmth exchanging, for warmth restoration from the exhaust movement of thermal techniques. They will also be retrofitted to current stenter frames, rest dryers, infrared pre-dryers and hotflues.
“We continue to explore the best heating options for every customer, with optimised combinations in order to make our lines as energy efficient as possible,” Kuhlen mentioned. “We have also been deeply investigating the potential of green hydrogen as a further option for the future.”
BW Converting’s Baldwin TexChroma
In response to a giant market demand, the three expertise companions are actually turning their consideration to the dyeing course of.
At ITMA Asia + CITME in Singapore, from October 28-31, they’ll introduce the resource-saving mixture of THERMEX steady dyeing ranges with the brand new BW Converting Baldwin TexChroma spray dyeing system.
“We are excited to introduce the Baldwin TexChroma because spray dyeing is the future,” mentioned Stanford. “We’ve been cautious about providing details on TexChroma too early, but now we’re ready and look forward to outlining its benefits in Singapore with interested customers. We will also be installing a TexChroma unit on a THERMEX line at the Monforts ATC in 2026.”
Monforts is at stand A301 in Hall 3 at ITMA Asia + CITME and BW Converting at stand B201 in Hall 8.
Note: The headline, insights, and picture of this press launch could have been refined by the Fibre2Fashion workers; the remainder of the content material stays unchanged.
Fibre2Fashion News Desk (KD)