Del iver ing High Per formanceSince 1959

INNOSINGEPRODUCT RANGE FOR CONTINUOUS SINGING

Chopra-Dhall Group deploys the latest trends in manufacturing technology(in-clude CNC lathes, Trumpf laser sheet-cutting, HACO CNC bending) to build our machines at our engineering complex in Ahmedabad, Gujarat. Backed by strong after-sales service and a customer-oriented perspective, Chopra-Dhall Group is looking to deliver exceptional value and strong Return on Invest-ment(ROI) for our target customers. In order to develop world-class capabili-ties in textile finishing and processing machines, DHALL GROUP has formed stratagic partnerships with several key industry leaders, such as REISKY MAQUINAS/BRA (former subsidiary of KÜSTERS/GER), ZIMMER/US & DOLFUSS MÜLLER/F.

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Established in 1959, Chopra-Dhall Group is one of the world’s leading manu-factures of finishing and processing machines and still a family owned compa-ny. Chopra-Dhall Group has proven track record of over 50 years in delivering world-class products to more than 2000 satisfied customers in India and over 30 countries world-wide including Japan, Australia, United Kingdom, Bangla-desh and Thailand. Chopra-Dhall Group’s list of international customers includes well-know premium textile industry leaders such as Arvind, Raymond, Alok Industries, Bombay Dyeing, Pradeep Overseas and Nahar Group in India, and Sunflag Industries (Nigeria), Ha-meem, Rahim Group(Bangladesh), Toray Group(Japan) and Bradmill (Australia) in interna-tional textile market. Chopra-Dhall’s product portfolio contains the following machine range : Continuous Bleaching, Washing and Mercerizing, Pad Dry and Pad Steam Ranges, Cold Pad-Batch Dyeing ranges with S-ROLL padder, S-ROLL dye & finishing padders, Jigger, Drying Ranges, Stenter & Relax dryers, Shrinking Ranges and Vacuum Foam Finishing Ranges. Chopra-Dhall Group also offers Zimmer(US)-Chopra-Dhall rotary nickel screens developed using the latest technology from Zimmer(US) and highest quality standards to deliver a world-class product of unmatched performance & quality.

THE PROCESS OF SINGEING

The word ‘singe’ literally means ‘to burn superficially’. Technically, singeing refers to the burning off of loose fibres not firmly bound to the yarn and/or fabric structure. Singeing is an important part of pre-treatment consisting of burning off of protruding fiber ends from the surface of the fabric. If not done properly, unclear print patterns, mottled fabric surfaces, and pilling results forming small fluff balls on the surface of the fabric. Textiles materials are most commonly singed in woven or knitted fabric form or in yarn form.

THE PROCESS OF SINGEING

Singeing of a fabric is done in order to obtain a clean fabric surface which allows the structure of the fabric to be clearly seen. Fabrics, which have been singed, soil less easily than un-singed fabrics. The risk of pilling, especially with synthetics and their blends, is reduced in case of singed fabrics. Singed fabrics allow printing of fine intricate patterns with high clarity and detail. The risk of uneven dyeing with singed articles dyed in dark shades is considerably reduced, as randomly protruding fibres are removed in singeing which could cause diffused reflection of light.

OBJECTIVES OF SINGEING

Before Singeing

After Singeing

Cotton materials are valued for their smooth appearance. After the formation of fabric it has a fuzzy or hairy appearance due to project-ing fibers, thus affecting the lustre and smoothness cotton is known for. Unsigned fabrics are soiled easily and the protruding fibers obstruct the subsequent dyeing and printing process. Similarly, goods which are to be mercerized are singed to maximize the lustre on the fabric. In fabrics of polyester and cellulosic fiber blends singeing is the best method to control pilling, sometimes double singeing is done to minimize the pilling.

SIGNIFICANCE OF SINGEING

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THE PROCESS OF SINGEINGThere are 3 main types of Singeing Lines

In Plate-Type Singeing Range, the cloth passes over and in contact with one or two heated curved copper plates. The thickness of the plates ranges from 1 to 2 inches. The heating of the plates is done by a suitable burning arrangement of gas mixed with air. The plates are heated to bright redness and the cloth passes over and in contact with these plates at a speed ranging from 150 to 250 yards per minute.

The passage of the cloth can be arranged in such a manner that one or both sides of the fabric may pass over and in contact with the heated plate(s), in order to accomplish singeing of one or both sides of the fabric in a single passage. However, it may not be possible to maintain the plates at uniform temperature, which leads to non-uni-form singeing effect on the fabric.

PLATE TYPE SINGEING RANGE

Fabric passes over and in contact with a heated rotary cylinder made of copper or cast iron. The rotary cylinder has an internal firing arrangement and revolves slowly so that constantly a fresh surface of the roller comes in contact with the fabric. The direction of rotation of the cylinder is opposite to the direction of the fabric so that the protruding fibres or nap of the fabric is raised. This type of machine is particularly suitable for the singeing of velvets and other pile fabrics. But uneven singeing results are commonly found due to difficulty in maintaining uniform temperature and fresh contact surface at all times.

CYLINDER TYPE SINGEING MACHINE

In this type of singeing machine, the fabric passes over a direct, intensive singeing flame at such a speed that only the protruding fibres are burnt off and the main body of the fabric is not damaged by the flame. Due to its effectiveness, this is the most common type of machine used for singeing fabrics as well yarns and forms the foundation of Chopra-Dhall’s INNOSINGE range

GAS TYPE SINGEING MACHINE

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INNOSINGE

It is extremely critical to ensure the fabric is pre-cleaned thoroughly of external impurities such as fluff, lint and dust particles to ensure the most effective singeing results on the fabric. Special grade carbon brushes are arranged over the full width of the fabric to ensure optimal cleaning results without undue stress on the fabric. The cleaning rollers are inverter controlled with complete flexibility for clockwise and counter-clockwise operation – thereby maximizing the potential for uplifting the residual hairs on the fabric for effective singeing. All residual dust and impurities separated during the cleaning process is collected in filter bags for efficient extraction.

CARBON BRUSH CLEANING ROLLERS

The heart of the INNOSINGE Singeing unit is the effective burner system for ensuring equal distribution of the air and gas mixture through a series of expansion and compression chambers. To ensure even and effective singeing results, it is critical to maintain an even, uninterrupted flame across the desired fabric width – a phenomenon guaranteed by the singeing burner design on the INNOSINGE. We have taken special care to ensure generation of high-intensity, homogeneous flame that is critical for superior singeing results on different fabric profiles, from wovens to denims to knit fabrics.

BURNER DESIGN

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DESIGN CONFIGURATIONS

INNOSINGE-1: Singeing range for yarn dyed shirting and bottom-weight fabrics INNOSINGE-2: Singeing range for denim fabrics

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INNOSINGE-4: Singeing range with in-line bleaching range

INNOSINGE-5: Singeing range with in-line desizing and bleaching range

INNOSINGE-3: Singeing range with cold-pad batch bleaching

BURNER ADJUSTMENTS

INNOSINGE affords a variety of singeing positions to ensure optimal singeing results on the input fabric. The choice of burner adjustment depends on the underlying fabric construction and desired singeing effect on the fabric.

The singeing flame hits the fabric at right angle as the fabric travers-es between the guide rollers. This position is recommended for 100% cotton and blend fabrics that have the need to be thoroughly beaten since the impact of singeing flame on fabric is highest in this position.

SINGEING AT RIGHT ANGLES

The singeing flame hits the fabric just as it transitions off the guide roller. This position is recommended for temperature sensitive qualities that require delicate application of singeing flame on the fabric.

SINGEING AT SOURCE

The singeing flame can be configured to hit the fabric at an angle of up to 45 degrees. This position is recommended for fabric profiles that require indirect exposure to the flame.

SINGEING AT TANGENT

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SALIENT FEATURES

To ensure efficient transmission of high intensity homogeneous flame from source to fabric, the high-quality ceramic brick structure is tapered at the lower edges. This design enhancement guarantees the best singeing results while ensuring sufficient manoeuvrability of the unit to maintain different burner adjustments as desired.

TAPERED BRICK STRUCTURE FOR EFFICIENT SINGEING

In order to minimize energy wastage and ensure optimal singeing results on fabrics of different working widths, Dhall provides an automatic flame width adjustment mechanism on the INNOSINGE range. The appropriate width of the flame can be set using simple controls provided on the control panel of the machine

AUTOMATIC FLAME WIDTH ADJUSTMENT

Ability to simply manage optimal distance between fabric run and singeing flame is critical to deliver the best singeing results on different fabric profiles. Since the input fabric may vary in construc-tion, quality and cleanliness – Dhall provides the ability to rese this distance up to 8 to 10 mm depending on the requirement.

OPTIMAL DISTANCE MANAGEMENT BETWEEN FABRIC AND FLAME

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INNOSINGE

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THE DRIVE SYSTEM

Large diameters for all guiding rollers of 203mm prevent a formation of wrinkles and lateral displacement of the fabric. This is supported by computer controlled fabric tension, easy running external bearings with low frictional resistance; frequency controlled spiral spreader rollers as well as short dis-tances between the guiding rollers. Load cells with a very sensitive tension range as well as pendulum and turning compensators guarantee a passage free from creases and wrinkles.

All DHALL ranges are characterised by particularly comfortable plant control and drive technology. All main drives are imple-mented as frequency controlled A/C-gear motors. As far as mechanical conditions permit they work as direct drives without mechanical intermediate drives. The air-conditioned switch cabinet accommodates the electrical control units for all drives of the complete range. Likewise, the central control panel is equipped with an air-conditioning system. The central operating interface of the control panel can either be operated as a touch-screen or via mouse. Imported attributes such as presetting of fabric tension, quantity of water, chemical quantity defaults etc., can be made. A modem for remote service and maintenance of the range is certainly a standard feature.Frequency controllers can be offered standard from LENZE, ABB & SIEMENS and other systems.

FREE FROM WRINKLES & CREASES

RANGE LAYOUT

The classical plant examples specified here are to give a short overview of the application range of the INNOSINGE range. The intelligent modular unit assembly system permits most differential range combination

EXAMPLES OF INSTALLATION

INNOSINGE-1: Singeing range for yarn dyed shirting and bottom-weight fabrics

INNOSINGE-2: Singeing range for denim fabrics

INNOSINGE-4: Singeing range with in-line bleaching range

INNOSINGE-5: Singeing range with in-line desizing and bleaching range

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INNOSINGE-3: Singeing range with cold-pad batch bleaching

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Dhall Enterprises & Eng.Pvt. Ltd.P.O. Saijpur Bogha,Naroda Road,Ahmedabad - 382345 Gujarat, IndiaTel.: +91-79-2282 0383Fax +91-79-2282 0225E-Mail: dhall@dhallgroup.comwww.dhallgroup.com

Sales Offices : Ahmedabad, Delhi, Mumbai, Calcutta, Dhaka, Istanbul.

Del iver ing High Per formanceSince 1959