Better fabric quality, faster throughputand significant energy savings are the triple benefits from using Roctex rollsin knitting finishing. Calculations based on industrial installations in theBrazilian textile industry have proved that a typical knitted fabric wetprocessing plant can apply the Roctex’s unique liquid expression properties toleave 25% less water in the material at the stenter.
This energy cost saving potential isachieved while also creating a softer handle in the fabric, according to aleading finishing plant in Brazil.
RHLCZ is convinced that there is great scope for notable improvements inproduct quality, productivity and profitability in wet-on-wet end userpadderlines, where chemical softeners are applied, and is able to provide detailedtechnical and economic guidance to assist companies in incorporating the Roctexinto these processes.
Says RHLCZ sales director James : “We have found that Roctex worksvery well in the knitted industry. For example, when our agent in Brazilinstalls a Roctex in knitted lines he is able to demonstrate the savings thatcan be made by the customer, which is subsequently borne out over time underproduction conditions. We are sure that this experience can be successfullyapplied by finishers in other areas.”
Typically,the Roctex is used in wet on wet knitted fabric applications, in which thefirst bath contains only water, to immerse the fabric and then squeeze evenly,so that finishing chemicals in the next bath are applied as efficiently anduniformly as possible across the entire width of the material.
In thissequence, changing the first mangle to a Roctex roll means that the secondmangle can exert increased pressure, to squeeze more water out retain the samechemical penetration into the fabric.
Says James: “If the first squeeze can achieve only 80%pick up, and 20% of softener (finishing chemical) needs to be applied, then thepressure on the second squeeze needs to be below maximum to achieve 100% pickup before the stenter. However, using a Roctex at the first squeeze can achieve60% or less pick-up, and this means that the second squeeze can be pushed tomaximum pressure to achieve the same 80% level as the conventional rubber roll.
“The resultis that the material going to the stenter is 25% drier, yet contains the sameamount of softener. The customer then has the option to increase the linespeed, or to save costs through the use of less drying energy in the stenter.”
Feedbackfrom a leading Brazilian customer also underlines the quality advantage arisingfrom using a Roctex roll at the first squeeze. The customer reports that itsproducts are now being produced with a softer feel, which it attributes to themore delicate squeezing effect of the Roctex compared to rubber rolls. The effectis said to create a much better finish in the fibres and the knit fabricconstruction.
RHLCZ adds thatstill further benefits would result from using two Roctex rolls at the firstsqueeze, which is calculated to give about 5% additional expression, as well asan even softer feel to the fabric.
