to face international crisis & the competition increase, dye plants have to : reduce theirs...
TRANSCRIPT
To Face
International Crisis & the Competition Increase, Dye plants have to :
Reduce theirs production’s costs (water / times / dyestuff / chemicals) Be Right First Time (to respect delivery time & improve productiveness) Improve the Quality of theirs productions (customer’s satisfaction)
These aims can’t be reach with Universal Process and with Blinds eyes !
« Let’s break again the Dye Limits with Optilab »
Why OPTILAB in Dye plant ?
2
Receipe from Laboratory
STANDARD PROCESS
REDYE & REDYEUnlevellingNo Reproducibility
Lower Quality & Expensive Production Cost No respect of Delivery time
Receipe from Laboratory
Optimized Process OPTILAB
High Efficiency Of Production Dyeing Machines
High Quality & Low Production Cost
Without Possibility to see
?
With Possibility to see
RFT
OPTILAB
Optimization Acrylic processLEACRYL 3,3
OPTILAB
CALLEBAUT DE BLICQUY
31 de la Fonderie – BP 70160 – 59202 Tourcoing cedex (France)
Tel. / Fax. : 0033 3 20 38 89 50 / 0033 3 20 38 89 70
Receipe and actual process Acrylic
Receipe : Actual process :
Yellow OR 200% 0,05 %
Red GRL 200% 0,05 %
Blue GRL 300% 0,05 %
Acetic Acid 1 cc/l
Pérustol AMC (Anti-static) 1 cc/l
Cellolube (softner) 1 cc/l
OPTILAB
Initial Temperature 55°C
Plate 10 Min
Heating 104°C with 1°C/min
Plate 15 Min
Cooling 80°C
Exhaustion curves actual process AcrylicOPTILAB
Receipe and optimized process Acrylic
Receipe : Optimized process :
Yellow OR 200% 0,05 %
Red GRL 200% 0,05 %
Blue GRL 300% 0,05 %
Acetic Acid 1 cc/l
Pérustol AMC (Anti-static) 1 cc/l
Cellolube (Softner) 1 cc/l
OPTILAB
Initial Temperature 55°C
Plate 10 Min
Heating 76°C with 3°C/min
Heating 85°C with 0,2°C/min
Heating 104°C with 2°C/min
Plate 15 Min
Cooling 80°C
Exhaustion curves optimised process AcrylicOPTILAB
B E F O R E
A F T E R
OPTILAB
Before Optimization
After Optimization
Annuals
Saving
Re-dyeing 13% 3%
Water 16,1 L/Kg 14,7 L/Kg 507 m³/an
COD 12,3 Kg/T 9,5 Kg/T 760 Kg/an
+ Time saving : 32 min / process
SAVING
Optimization Cotton processTENCEL
OPTILAB
CALLEBAUT DE BLICQUY
31 de la Fonderie – BP 70160 – 59202 Tourcoing cedex (France)
Tel. / Fax. : 0033 3 20 38 89 50 / 0033 3 20 38 89 70
Receipe and actual process CottonReceipe : Actual process :
Yellow cibacrone F3R 1%
Red cibacrone FNB 1%
Blue cibacrone FR 1%
Croscour WPD (mouillant) 1 cc/l
Rapidoprint XRG (anti-réducteur)1 g/l
Anti-foam 0,3 cc/l
Salt 80 g/l
Soda Solvay 10 g/l
OPTILAB
30’
40°C
60°C
dyestuffs 1/10 3/10 6/10 1/10 3/10 6/10
Soda Solvaysalt
1°C/min
15’ 15’ 30’ 15’ 15’ 15’
Rinsing and SoapingOPTILAB
T°C Time (min)
Rinsing 1 40°C 10
Rinsing 2 80°C 10
Neutralization 50°C 5
Soaping 1 95°C 15
Rinsing 3 80°C 10
Soaping 2 100°C 15
Rinsing 4 40°C 10
Rinsing 5 65°C 10
Softness 50°C 5
Exhaustion curves actual process CottonOPTILAB
Receipe and optimized process Cotton
Receipe : Optimized process:
Yellowcibacrone F3R 1%
Red cibacrone FNB 1%
Blue cibacrone FR 1%
Croscour WPD (mouillant) 0,75 cc/l
Rapidoprint XRG (anti-réducteur)0,75 g/l
Anti-foam 0,3 cc/l
Salt 64 g/l
Soda Solvay 10 g/l
OPTILAB
30’
40°C
60°C
dyestuffs 3/50 10/50 36/50 1/10
3/10
6/10
Soda Solvaysalt
1°C/min
15’ 15’ 15’15’
1/50
Rinsing and SoapingOPTILAB
T°C Temps (min)
Rinsing 1 40°C 10
Rinsing 2 80°C 10
Neutralization 50°C 5
Soaping 1 95°C 15
Rinsing 3 80°C 10
Soaping 2 100°C 15
Rinsing 4 40°C 10
Softness 50°C 5
Exhaustion curves optimized process CottonOPTILAB
B E F O R E
A F T E R
OPTILAB
Before Optimization
After Optimization
Annuals
Saving
Re-dyeing 13% 3%
Water 115 L/Kg 93 L/Kg 367 m³/an
COD 140,2 Kg/T 78,8 Kg/T 1 025,4 Kg/an
+ Saving in Chemicals (Auxiliaries Products)and Time (40 min / process)
SAVING
Optimization Polyester Process
OPTILAB
CALLEBAUT DE BLICQUY
31 de la Fonderie – BP 70160 – 59202 Tourcoing cedex (France)
Tel. / Fax. : 0033 3 20 38 89 50 / 0033 3 20 38 89 70
Receipe and actual process PES
Receipe : Actual Process :
Yellow RD4GRL 0,031 %
Red RD4GFL20 0,007 %
Blue RDGL 0,007 %
Dilatine (carrier) 3,75 ml/l
Eganal EDP (levelling) 1,25 ml/l
102°C
60’
20°C
96°C
1°C/min
OPTILAB
Exhaustion curves actual process PESOPTILAB
Receipe and optimized process PES
Receipe : Optimized process :
Yellow RD4GRL 0,031 %
Red RD4GFL20 0,007 %
Blue RDGL 0,007 %
Dilatine (carrier) 0 ml/l
Eganal EDP (levelling) 0,625 ml/l
130°C
30’
20°C
96°C1°C/min
2°C/min85°C
OPTILAB
Exhaustion curves optimized process PESOPTILAB
BEFORE
AFTER
Auxiliariesproducts
Annualquantity
Unit cost Annual cost
Dilatine 480 Kg 6,49 €/Kg 3 115,20 €
Eganal EDP 180 Kg 4,22 €/Kg 759,60 €
TOTAL 660 Kg 3 874,80 €
Auxiliariesproducts
Annualquantity
Unit cost Annual cost
Dilatine 0 Kg 6,49 €/Kg 0 €
Eganol EDP 90 Kg 4,22 €/Kg 379,80 €
TOTAL 90 Kg 379,80 €
Before Optimization
After Optimization
OPTILAB
Saving Chemicalsproducts
Reduction cost of 90% in Chemicals products
Time saving : 15 min / process
Optimization Polyamid process
OPTILAB
CALLEBAUT DE BLICQUY
31 de la Fonderie – BP 70160 – 59202 Tourcoing cedex (France)
Tel. / Fax. : 0033 3 20 38 89 50 / 0033 3 20 38 89 70
Receipe and actual process PAM
Receipe : Actual process :
BrownCiba JNH 100% 0,03 %
Grey Ciba NH 0,02 %
Yellow Ciba 2GC 0,01 %
Sandacid VS (acid donor) 2,5 ml/l
Felosan R.G.N 0,312 ml/l
OPTILAB
102°C
60’
20°C
96°C
1°C/min
Exhaustion curves actual process PAMOPTILAB
Receipe and optimized process PAM
Receipe : Optimized process :
Brown Ciba JNH 100% 0,03 %
Grey Ciba NH 0,02 %
Yellow Ciba 2GC 0,01 %
Soda Solvay 2,0 g/l
Acetic acid 1,5 ml/l
Felosan R.G.N 0,234 ml/l
OPTILAB
102°C
30’
96°C1°C/min
2°C/min
80°C
Dosing of acetic acid
Exhaustion curves optimized process PAMOPTILAB
BEFORE
AFTER
OPTILAB
Before Optimization
After Optimization
Auxiliariesproducts
Annualquantity
Unit cost Annual cost
Sandacid VS 130 Kg 7,05 €/Kg 916,50 €
Felosan RGN 120 Kg 3,73 €/Kg 447,60 €
TOTAL 250 Kg 1 364,10 €
Auxiliariesproducts
Annualquantity
Unit cost Annual cost
Carbonate 396 Kg 0,43 €/Kg 170,28 €
Acide acétique 78 Kg 0,48 €/Kg 37,44 €
Felosan RGN 90 Kg 3,73 €/Kg 335,70 €
TOTAL 564 Kg 543,42 €
Saving ChemicalsProducts
Reduction cost of 60% Chemicals products
Time saving : 30 min / process