Compactor Machine

Prepared By : Mazadul Hasan sheshirID: 201000040000813th Batch (session 2009-2013)Department : Wet Processing Technology Email: mazadulhasan@yahoo.comBlog : www. Textilelab.blogspot.com (visit)

Southeast University Department Of Textile

EngineeringI/A 251,252 Tejgaon Dhaka Bangladesh

Prepared By :

The compactor machine is a tubular fabric shrinkage control

machine which can compact the fabric in length wise direction,

to provide over feed to the fabric while processing in presence of

steam, and able to control the shrinkage. In other words, this is a

process of compacting the fabric in length ways direction.

Compactor Machine:

Upgrade the fabric hand feel and import a smooth, silky touch to

the fabric.

Compress the fabric and reduce its thickness.

Improve the opacity of the fabric.

Import different degree of luster to the fabric.

Reduce the yarn slippage.

Objective of Compacting:

Function:

1. Shrinkage control

2. GSM control

3. Width control

4. Ironing the fabrics

5. To compact the fabric

6. To control the shrinkage

7. To maintain proper width and G.S.M

Machine Operating Rules & Regulation for Compacting

Machine: • Machine should be kept always clean.

• Knot & very much course stitch containing fabrics should not be feed to

the machine.

• Machine should not be stopped until the temperature decrease at 65ºC

• Teflon should be cleaned minimum two times in a day.

• Load value of load cell should be check.

• Machine inlet steam should be between 4 – 6 bars.

• Electric component should be safe from water during machine cleaning.

• If any problem is observed in dyeing machine, the information should be

sent to maintenance department as soon as possible. Operator must not be

accessed electric control panel in any condition.

Shrinkage Tolerance of Different Fabric:

Fabric Type Length (%) Width (%)

S/J -5.50 -5.50

Lycra S/J -6.00 -6.00

Single Lacoste -7.00 -7.00

Lycra Single Lacoste -7.00 -7.00

1X1 Rib -7.00 -7.00

Lycra 1X1 Rib -7.00 -7.00

2X2 Rib -8.00 -8.00

Lycra 2X2 Rib -8.00 -8.00

Interlock -7.00 -7.00

Terry Fleece -5.00 -5.00

Mechanism of Blanket Type Compactor

Fabric Path of Tube Compactor

FUNCTION ONAL SELECTION LEGEND 1 – Fabric Brake 13 – Felt Centering Rollers 2 – Fabric Feeding roller 14 – Felt Tensioning Rollers 3 – Beater 15 – Heated Roller 4 – Safety Photocell indicating Lack of

Fabric 16 – Felt Drawing Rollers Covered with Rubber

5 – Fabric Conveyor Belt 17 – Rollers with Loading Cell for automatic Fabric Tension Control

6 – Photocell Loop Control 18 – Exit Belt Drawing Roller 7 – Operator Platform 19 – Fabric Conveyor Belt 8 – Re – directing Roller 20 – Movable Arms 9 – Automatic Spreader Mod. AL-BATROS 21 – Fabric Conveyance Hopper

10 – Steaming Chamber 22 – Plaiting Roller

11 – Motorized Adjustable Rollers 23 – Fold Pressing Device 12 – Felt Re – directing Adjustable Rollers 24 – Plaiting Platform

OPTION: A – Ring Spreader for Tubular

Fabric C – Cardboard Positioning Device

B – Cooling Chamber at Exit D – Cutting Device

Machine Parameter Set Up Value

Steam Pressure 2 bar.

Air Pressure 4 bar.

Temperature 100-120 C.

Machine Speed 15-50 m/min

Over Feed 35 m/min

Brand name : Fabcon Manufacturing country : U.S.A Year of manufacturing : 2006Maximum speed : 60 m/min Minimum speed

: 10 m/min Production/day : 8 tons/day Maximum Temperature : 70˚C

Fabcon Tube compactor Machine

OPEN COMPACTOR

Machine specification: Brand name: HELIOT International Type/model no: HC2000GLCompany: FranceNo of motor: 08Over feed = m/minMachine speed range: 13-22m/minTermperature(0C) range: 100-1400CMaximum width 86Minimum width 36Applied for: Open fabric

Left over feed: -20% +20%

Right over feed: -20% +60%

High production: -20% +60%

Front over feeding cylinder: -20% +60%

Middle belt: -20% +60%

HELIOT CompactorOpen fabric Compactor

Check point:

I)Check steam & air line pressure

II)adjust felt temperature

III)Blanket pressure:3.5-4.0-4.5

Some instructions for optimum performance:

1. Center the felt blankets on the cylinder. Ensure that all cylinders are running

parallel relative to each other. Adjust the limit switch against the edge of the felt.

2. Place the felt under tension. Upper felts tension-2 bar, Lower felt tension-1 bar.

3. raise the heated drum working temperature to 200 f| & set the speed to 11-22

yd/min(10-20 m/min)

4. Open the humidification ramp in order that felts are in a steam atmosphere.

5. As soon as these conditions are reached, let the felt run for 2.5 m

Check point:

Machine specification:Brand name: FERRARO Type/model no: COMPTEX-RE 2800.Company: ITALY.No of motor: 17Over feed = Max + 35%, Min -35%.Machine speed = Max 32m/min, Min 4m/min.Termperature range: 100-2000CMaximum width =240cmMinimum width =100cmApplied for: Open fabric

Left over feed: -20%+20% Right over feed: -20%+60%High production: -20%+60%Front over feeding cylinder: -20%+60%Middle belt: -20%+60%

FERRARO Compactor Open compactor

Heating system: Steam

Main parts of the machine: 1. Heating chamber2. Blower (2, one at the entry chain zone for uncurling and another

at the entry of compacting zone)3. Synthetic blanket as a conveyor,4. Folder5. Exhaust fan6. Unpinning cylinder (-40%+40%)7. Belt cylinder (-40%+40%)8. Uncurling device at entry of compacting zone.9. sensor 10. brush roller

FERRARO Compactor

Additional attachment:

• Selvedge cutting

• Selvedge safety

• Pinning safety

• Selvedge unrolling

• Selvedge drying

• Steam zone heating

Controlling points:

•Water pressure 2.5 lb

•Air pressure 4 lb

•Steam pressure 6 lb

Manpower Required: Worker: 06

Production: Capacity: 5 tones/shif

Actual production: 4 tones/shif

Utility: Steam Electricity, Compressed air.

Controlling points:

Overfeed % Up Setup for Lafer compacting Machine:

Overfeed % Up for Lycra Single Jersey : 60

Overfeed % Up for Single Jersey : 35/40.

Overfeed % Up for Lacost fabric : 35/40

Overfeed % Up for Rib fabric : 20/22

Overfeed % Up for CVC fabric : 45

Main Parts: (Lafer Compacting Machine) Heat Padder: Control Motor Speed. Heat Chamber: Three.1. Lower Padder2. Stenter3. Compactor Main Power Blanket: For finishing Cloth. Guide Roller Clip: Straighten the fabric Wheel raising Steam Box: soften the fabric Load Cell: Keep the delivery Roller for perfect tension. Temperature: 1500C (Highest) Speed: 50 M/Min Overfeed % Up: More the Overfeed % Up More the GSM. Steam Pressure: Up to 10 Kg

Lafer Compacting Machine

In Tube-tex compactor m/c fabric spread range:

Fabric dia (inch) Maximum spreading (inch)14” 17”16” 19”17” 20”19” 25”

22.25” 28.25”

26” 36.38”34.75” 47”

45” 57”48.25” 60”

Maximum spreading

For different type of fabric speed and compaction (TUBE TEX):

Fabric Type Speed ( r.p.m ) Compaction

S/J 20 8-9 %

Lycra S/J 25 7-10 %

1*1 Rib 30 8 -11 %

Single lacoste 30 10 -14 %

2×2 Rib 30 -35 6-7 %

Double lacost 30 -35 12 %

Pk. Fabric 30 10 -12 %

Interlock 30-35 9 – 12%

Technical description of the basic compacting machine:

Support Structure: It consists of sturdy body sides made of painted steel, supporting the cylinders, the mechanical part and the plant system; they are connected by means of longitudinal and transversal cross-section. The body sides are provided with special safety locks.

Inlet Tightener: The inlet tightner is designed to drag the fabric to the machine with an adequate tension. Its effect can be varied by turning the hand wheel provided.

Fabric Draw Roller: The draw rollers receive their movement from a variable speed motor. They deter-mine the speed of fabric.

1. The rollers are normally covered with rubber and it is most important that the surface of the covering is always in good condition so ass to avoid slipping of the fabric. Should this not be so then it is necessary to replace the covering.

2. The processing of fabrics treated with chemical against might involve a rapid deterioration of the drag rolls coating.

Idle Cylinders:

The idle cylinders are designed to change the route of the fabric to

convey it in the right position for subsequent working.

Dancing Roller Synchronizer:

The dancing roller is constituted by a cylinder mounted

on oscillating arm, connected to a rheostat for the synchronization of the various group.

Inlet fabric Guide:

It consists of shoulders supporting a couple of adjustable spreader

rollers operated by an independent motor, and a pneumatically operated fabric centering

unit with move-able staves, controlled by border guard photocells.

Steaming Tank :

It consist of no. 1 steam delivery chamber on the fabric, made of inox

steel and complete with metering valve and on-off solenoid valve.

•Compacting units:

They are the real compacting units. Each unit consists of:

1. A steam heated cylinder, diameter 500 mm., made of chromium plated and

ground steel; it is complete with a rotary joint for steam feeding, a thermocouple

feeler to feel the temperature, and an effective system for the condensate

drainage. The cylinder temperature can be adjusted with the utmost (+/-2˚C)

directly from the keyboard placed on the control board, and is shown on the

display.

2. A thick Nomex – Polyester compacting felt. The double action felt centering de-

vice ensures perfect felt alignment during running. The computer controlled felt

control mechanisms automatically releases felt tension after a machine stop.

3. An adjustable position counter-roller for the fabric shrinkage control during inlet

in the compacting group.

4. An inlet element in a special non-adherent fibre (shoe) equipped with a device

for adjusting both angle of incidence and insertion length.

Spreader Roller It is a spreader roller, for the selvedge unwinding and the inlet of the fabric perfectly spread in the machine.

Scroll Roll Unit

The adjustable spreading scrolls at entry are used for open width knits and for all fabrics that have lengthwise creases. Consists of two adjustable spiral scroll roll driven by an independent motor.

Device for Fabric Tension Check

It consists of a cylinder combined with a special load cell sensor. It allows synchronizing the speed between the upper and lower compacting unit, and adjusting the fabric tension between them with the utmost precision. The adjustment is performed directly from the keyboard placed on the control board and is shown on the display.

Cooling Unit

It consists of a steel structure including a conveyer belt, the drag and tension

cylinders Of the latter, a suction chamber with a net plane for a perfect distribution of

the cooling air. The chamber is connected to a high-efficiency centrifugal electric fan.

Checking Table:

The inspection table is composed by a steel structure that supports a table that

accompanies the fabric falling from the cooling band. In this phase the operator placed

in the rolling up unit zone can carry out a check on the quality of the worked fabric

and notice possible defects.

Fabric Storage Chute for the System Non-Stop:

It consists of a j-plate for the fabric storage during the phase of roll change. It

allows removing the finished roll, and starting a new roll without stopping the system.

Rolling Unit It consists of a bearing structure and a moveable trolley which supports the rolling cylinders. The trolley sides on two rails in order to allow the perfect alignment of a selvedge on the roll of fabric. The movement is automatically controlled and is operated by an electromechanical actuator. The reading of the selvedge border is performed by two photocells, whose position can be adjusted by means of a hand wheel. The rolling cylinders are covered with vulcanized rubber for a perfect adhesion. The roll compactedness can be adjusted by a pneumatically operated device. The rolling unit is complete with a spreader roller, operated by an independent motor, placed immediately before the rolling cylinders. Steam System It is installed in the machine. It includes a filter, an on-off valve, a pressure gauge for displaying the line pressure and a condensate separator. It is provided with a series of servo-operated solenoid valves to feed the different elements of the machine and wit automatic steam traps complete with by-pass for manual drainage. Controls The main controls are located on the left side at the machine entry; they include a “Touch Screen” interface and a set of buttons. The auxiliary controls are placed on the panel at the machine exit. The emergency stop buttons are located on the sides of the machine.

S) Electric Board:

The electric board is installed in the machine. It includes the electromechanical instal-

lation, electronic cards, a set of inverters and the PLC controlling the machine. It is

also equipped with protection devices, and cooling devices. All operation func-tion is

shown in the “Touch Screen” on the main control board. The machine is equipped

with a direct grounding of all the electric components and of the metal frame. The

preventive measures to ensure immunity in the presence of electromagnetic dis-

turbances have been adopted, and have been taken the necessary precautions to atte-

nuate the disturbances of an electromagnetic nature produced by the electric/

electronic system of the machine

T) Pneumatic System

It includes an on-off valve, a filter-lubrication unit, a pressure regulator and a series of

solenoid valves for the operation of the pneumatic actuators.

Monforts Compactor Machine:

Maximum Speed : 40 m/min

Minimum Speed : 7 m/min

Steam Pressure : 4 - 4.5

Maximum Over feed (%) : 22%

Minimum Over feed (%) : 18%

Pressure Type : Cylinder + Rubber Belt

Monforts Compactor Machine:

Navis Compactor Machine:

Type: Blade Compactor Machine

Types of Roller: 4 (Anti Roll, Expander Roll, Retard Roll, Pad Roll)

Compaction depends on Retard Roller.

Shade depends on Shoe Depth.

Feed Roll Temperature is automatically set by the machine.

Shoe Pressure: 2.5 - 3

Maximum Fabric Passing Speed: 40 m/min

Minimum Fabric Passing Speed: 20 m/min

Maximum Over feed (Bilateral Slat) %: 98%

Minimum Over feed (Bilateral Slat) %: 90%

Maximum Temperature: 80oC

Navis Compactor ( Blade Types Compactor Machine )

Ferraro Compactor Machine:

Type: Blanket Compactor Machine

No. of Steam Chamber: 2

Steam Temperature: 100oC

Maximum Fabric Dia Capacity: 225-228 cm

Minimum Fabric Dia Capacity: 100 cm

GSM Control: 7-8

Maximum Fabric Passing Speed: 20 m/min

Minimum Fabric Passing Speed: 10 m/min

Maximum Over feed (%): 35%

Minimum Over feed (%): 0%

Ferraro Compactor ( Blanket type Compactor Machine )

Santex Compactor Machine (Tubular Knitted Fabric Compactor):

Type: Blanket Compactor Machine

Minimum Fabric Dia Capacity: 126 cm

Maximum Fabric Dia Capacity: 28 cm

Steam Temperature: 120oC

Maximum Overfeed (%): 40%

Minimum Overfeed (%): -10%

No. of Cylinder: 2

Padder Pressure: 6-7

Santex(Tubular Knitted Fabric Compactor)

Fabric type Colour Speed(m/min)

Over Feed(%)

Temperature(degree C)

Blanket Pressure

Teflon

Pressure

Stretch(%)

Single jersey

White Colour

15-18 15-18

25-30 25-

30

90-110 110-

120

1.5-2bar 36psi As required

Pique (s/j,d/j)

White Colour

15-18 15-18

30-35 30-

35

100 110-120

1.5-2bar 36psi As required

Lycra s/j White Colour

12-16 12-16

Full over feed

100-110 100-120

1.5-2bar 36psi As required

1x1 Rib White Colour

15-20 15-20

20-30 20-

30

100 110-120

1.5-2bar 36psi As required

2x2 Rib White Colour

12-15 12-15

25-30 25-30

100 110-120

1.5-2bar 36psi As required

Interlock White Colour

12-16 12-16

Full over feed

100 110-120

1.5-2bar 36psi As required

Teflon speed (+) – More compaction

Teflon speed (-) – Less compaction, G.S.M because overfeed is less.

Utilities used:•Electricity•Steam•Compressed air

Control Point :- Water pressure- Air pressure- Steam pressure

1. Shade Check: In delivery side operator checks the shade of fabric with

customer approved swatch.

2. With Check: Operator measures fabric width by using measuring tape

and compared with required width.

3. Wight Check: Operator checks the weight by using GSM cutter and

electronic bal-ance& compares with the required finished width.

4. Fault Check: As mentioned before

5. Design & Slanting: Operator checks design and slanting at delivery side.

6. Edge line checking: check two edges of fabric at delivery side.

Checking Parameter:

Belt Principle for Imparting Mechanical Shrinkage for Knits

1. Yarn Manufacturing TechnologyLink:http://www.facebook.com/pages/Yarn-Manufacturing-Technology/485014954866808

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