Yarn Dyeing Industry
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Transcript of Yarn Dyeing Industry
YARN DYEING INDUSTRY
ARE YOU THROWING AWAY PROFIT
OF
RS 5 CRORES PER YEAR
CASE STUDY BY
DYECENTRES
.
PLASTIC RIGID AND COMPRESSIBLE DYETUBES.
CURRENT CHOICE OF YARN DYERSRECOMMENDED BY PRECISION WINDING MACHINE MAKERS
RECOMMENDED BY DYEING MACHINE MAKERS EASE OF WINDING
LOWER RESIDUAL WASTAGERF FRIENDLYCOLORFUL
LOSS FOR THE DYEHOUSE
PLASTIC DYECENTRESPENNY WISE POUND FOOLISH
PENNY WISE
FOLLOWING BLINDLY OTHER DYERSRUNS FASTER ON PRECISION WINDERSRECOMMENDED BY MACHINE MAKERS
POUND FOOLISH
PRODUCTIVITY LOSS ON ACCOUNT OF LOWER LOADING PER
CHARGE INTO THE DYEING MACHINE
HIGHER VOLUME OF WATER USED PER KG OF DYEING
MORE POWER CONSUMPTION PER KG OF DYEING
MORE CHEMICAL AND AUXILARY COST PER KG OF DYEING
MORE STEAM COST PER KG OF DYEING
INHERENT DENSITY VARIATION WITHIN PACKAGE GIVING
LOW RFT
ECO DISASTER
DO YOU RUN THE PLANT FOR THE PROFIT OF MACHINE MAKER OR ON THE WHIMS OF A
FANCY MANAGER OR FOR THE PROFIT OF SHAREHOLDERS
IS YOUR DYEHOUSE COLOR BLIND TO
LOSSES
DYEING LOSS ON PRECISION WINDER WITH DYETUBES
DYEING LOSS ON DRUM WINDERS WITH DYETUBES
THROWING AWAY PROFIT OF
RS 3.25 CRORES WITH PRECISION WINDERSAND
RS 5.50 CRORES WITH DRUM WINDERS
Dyeing cost/Kg 60,00Rs. Lower Loading with Precision wound Plastic Dyecentres 15%Opportunity Cost with better loading ( Dyg Cost x 85%) 51,00Rs. Loss Per Kg of Dyeing 9,00Rs. Loss Per 10 TPD of dyeing 90.000Rs. Loss Per Month 2.700.000Rs. 27 LacsLoss Per Year 32.400.000Rs. 3.25 Crores
Dyeing cost/Kg 60,00Rs. Lower Loading with Drum winders and Plastic Dyetubes 25%Opportunity Cost with better loading ( Dyg Cost x 85%) 45,00Rs. Loss Per Kg of Dyeing 15,00Rs. Loss Per 10 TPD of dyeing 150.000Rs. Loss Per Month 4.500.000Rs. 45 LacsLoss Per Year 54.000.000Rs. 5.4 Crores
THE GAME CHANGER
SMALL CHANGE FROM PLASTIC
DYETUBES TO MANTEX DYESPRINGS
BALANCE SHEET
NET PROFIT UP BY RS 3.5 CRORES.
PRESENTATIONS OF MACHINE
MAKERS LIKE THIES AND SSM
CAPTURED FROM THIES PRESENTATION
COMPARISON OF TIME AND WATER WITH
DYETUBES AGAINST DYESPRINGS
CAPTURED FROM THIES PRESENTATION
LOSSES WITH DYETUBES FOR 10 TPD
20,000 LITRES OF EXTRA WATER USED = EXTRACHEMCIALS + EXTRA POWER + EXTRA STEAM +EXTRAEFFLUENT TREATMENT= ADDL COST OF RS 9 PER KG
LOSS OF RS 3.25 CRORES PER YEAR
14MINS X 10,000KGS = 97.22 HRS OF EXTRA DYEINGTIME
MEANING 97.22 HRS OF LOST CAPACITY PER DAY = 4 DAYS OF
PRODUCTION COST
MYTHS AND FACTS ON MANTEX DYESPRINGS
DYESPRINGS DON’T RUN ON HIGH SPEED WINDERSFACT AS BELOW
SSM MACHINES AT
COATS INDIA
SSM MACHINES RUNNING WITH MANTEX DYESPRINGS
MODERN WINDERS LIKE SSM HAVE PROGRAMS TOSLOW START AND THEN GRADUALLY ADD SPEED GIVING
AS HIGH AS 1400 MPM.CALL SSM GENERAL MANAGER MR NARAYANAN AT AND CONFIRM THIS FACT AND LEARN THE SEETING
FROM SSM
MYTHDYESPRINGS GET HARD PRESSED ON TOP AND BOTTOM
PACKAGES IN A COLOUMN
FACT
SOME DYERS PRESS MORE THEN 25% TO GETADDITIONAL PROFITS AND THIS LEADS TO HARD
PRESSING ON TOP AND BOTTOM PACKAGES.
MYTH
PRECISION WINDING SHAPE IS LOST IN PRESSING
FACT
CAPTURED FROM ‘Thies’ PRESENTATION
PRECISION WOUND PKGS HAVE DENSITY RANGE OF +/- 10 GMS = 20 GMS.
WHICH IS 5% BETWEEN PACKAGE DENSITY VARIATION.
UNLESS THIS DENSITY IS EQUALIZED, LIQUOR WILL ALWAYS
TAKE THE PATH OF LEAST RESISTANCE AND MOVE MORE OUT OF
LOWER DENSITY PKGS. GIVING UNLEVELLED DYEING
THIS DENSITY VARIATION WITHIN PACKAGE CAN ONLY BE
EQUALIZED BY PRESSING ON DYESPRINGS.
THERE IS NO OTHER TECHNOLOGY IN THE WORLD TO MANAGETHIS WITHIN PACKAGE AND BETWEEN PACKAGE DENSITY
VARIATION.
MYTH
HIGHER RESIDUAL WASTE
FACT
RESISUAL WASTE ON PRECISION WINDERS IS NILL.
AS RESIDUAL WASTE COMES ONLY OUT OF INITAL LAYERS
WINDING AND IN CASE OF PRECISION WINDERS, INITIAL SLOW
SPEED SETTINGS GIVES UNIFORM LAYERS.
THIS WAS TRUE IN CASE OF OLD DRUM WINDERS WHERE INITAL
SPEEDS COULD NOT BE AJUSTED.
MYTH
DIFFICULT TO HANDLE
FACT
ANY WORK HORSE, WHICH SAVES THE COMPANY RS 3.25 CRORES
IS WORTH HANDLING
MYTHDAMAGES IN HYDRO
FACT
MANTEX DYESPRINGS ARE DESIGNED BY TEXTILE ENGINEERS
FOR THE TEXTILE INDUSTRY. THE UNIQUE DESIGN DOES NOT GET
DAMAGED ON HYDRO
TOP INDIAN COMPANIES USING DYESPRINGS WITHPRECISION WINDERS
ARVINDASHIMA
ABHISHEKRAYMONDSMORARJEESIYARAMWELSPUNMAFATLAL
COATSNAHAR
RELIANCEPREMIERS.KUMAR
GARUDA COTEXTHREADS INDIA
MANY MANY MORE
ARE YOU THROWING AWAY PROFIT BY USING PLASTICDYETUBES IN YARN DYEING
FREQUENTLY ANSWERED QUESTIONS
WHY MACHINE MAKERS LIKE SSM AND FADIS RECOMMENDPLASTIC DYETUBES FOR WINDING ON THEIR MACHINES.
DEPENDS ON
Technical Capability of the Sales Manager.
( There are Competant Sales Managers Like Mr AT Narayanan GM SSMINDIA and Mr MM Chaudhary Sr Manager Peass Schlafhorst , who have
spend their lives in winding and dyeing and guide the clients correctly andthere are others who have no clue of the Industry )
And
Technical Capability Of Yarn Dyer
The one and only argument favoring Plastic Dyetubes is that it run at
higher speeds on winding and hence the recommended centres.
But Ruins the Profitability of a Dyehouse.
The winnning combination is to Run the Winder at High Speed and useMANTEX DYESPRINGS.
DYESPRINGS DON’T RUN AT HIGH SPEEDS: Not True Anymore
Thanks to freely programmable speeds of SSM , the Dyesprings can be
made to run at 1300 mpm +. How : Call up GM SSM India : Mr Narayanan +9787635505
OR
Call Up Sr Manager Peass : Mr Chaudhary +9324615110
OR
Write to us at [email protected]
Precision and Modern Drum Winders start at low speeds and can be
programmed to then deliver final speeds as per machine capability.
SSM PW2 RUNNING FOR EMBROIDERY THREADS ATCOATS INDIA
VALUE OF WINDING SPEED ABOVE 1000 MPM TO THEDYER
Higher Speeds Sound Sexy , but everything has to be an optimum.
Beyond which the system frequently crashes.
One has to Deeply understand the Yarn Dyers Requirments
\
Captured from’ SSM’ Presentation.
Geometry comes from Dyespring Usage
Density comes From Winding With Pressing.
Optimum Package Centre
And
Optimum Winding Speed
Gives Optimum Density of Package
HIGHER SPEEDS RESULT INTO PACKAGE DEGENERATION
CAPTURED FROM ‘Thies’PRESENTATION
Every single time, the yarn reverses on the package, it hardens theshoulder. Higher the speeds, stoner the shoulder.
Angle of Wind Changes continously in Precision winders to give a higherweight to the package. This means, within package, some areas have
larger angle of wind and some areas have lower angle of wind.
As the Package builds up the Angle of wind reduces.
It is a known fact that only and only an OPEN WOUND package gives thebest dyeing result. This is also the reason that most cases the outer layers
have lower penetration as the liquour flow in NON COMPRESSIBLEDYETUBES is inhibited by the Lower Angle Of Wind. But in compressiblepackages, the angle widens on compression and opens the package
uniformly across the surface.
Only 8% dyeliqour flows out of shoulders and 25% out from the sides.
Ask yourself this question, how then Precision winder justifies Plastic
Dyetubes, when this inherent density defect is not corrected.
PRESSING OF PACKAGES IS THE ONLY KNOWN WAY OF
CORRECTING THIS PACKAGE ANAMOLY
OUR DYEHOUSE IS ALREADY SET NOW WITH PLASTIC DYETUBES;
WHY DISTURB
Well, if Shareholders Value Rs 3.25 Cr for their biz, then whatenver needs
to be done has to be done. There is no room for complacency incompeting biz environment.
Lazy thinkers will always get penalized.
WHY EUROPE AND US DYERS USE PLASTIC DYETUBES
Most of them regularly declare Bankruptcy and there is hardly any left
across Europe. It is this lazy thinking and arrogance that “ I know all and I
don’t want to listen to you “ that has bought today Europe to a state ofBankruptcy and the Third world is funding the IMF in bailing out European
States.
If you want to lead your biz to Bankruptcy Ignore this presenation Or
Think Again.
Is Blind Following Worth
Or Using Own Conviction Worth.
Warrn Buffett said, Savings is Profits , Spending Wastefully is
Total Loss.
Smart Guys take a Leading Position with well diffirentiated products inmarkets with the lowest investments and lowest operational cost.
Dull Guys copy paste biz models.
SONY AND NOKIA ALSO BELIEVED THAT THEY WERE SUPERIORAND DID NOT WANT TO ADDRESS INEFFICIENCES .
TODAY YOU CAN BE A MARKET LEADER AND TOMORROW YOU AREINTO RED FOR YOUR OWN COMPLACENT ATTITUDE
Good market time, everyone gets a pie . Bad Markets , even the smallestpie needs the lowest comepting price. Today for Rs 1 the orders are lost,
inspite of the best machines, best yarns and best infrastructure.
Have your Proofed Your Biz For Competition ? Or you Have Black
Holes eating into profits.
DYEING MACHINE MAKERS RECOMMEND PLASTIC DYETUBES
Not Really with “Thies” . As you can already see the Part of this
Presentation is actually from “Thies”
Certain Italian Dyeing Machine makers do recommend Plastic
Fact is that they have no arguments, whatsover against Dyesprings, but
fear Dyesprings, because with Dyesprings, the capacity of the machine
enlarges and hence the number of vessel sold by them reduces.
Technically, for a 10 TPD plant, you buy machines only for 7.5 TPD as
Dyesprings gives the extra 2.5 TPD free to the Dyer.
Captial Cost Saving of 25% for Dyer, Loss for the Italian Dyg MachineMaker. However, with Germans, no such issues.
( Some white are more whiter then others in dyeing )
FONGS RECOMMENDS PLASTIC DYETUBES
Same Reason as Italians. Use Dyesprings and you Buy less Number ofVessels, Use Plastic Dyetubes and Invest 25% extra number of Vessels.Atprices lower then even Dalal, somewhere Poor Fongs has to make money.
QUALITY OF DYEING IS BETTER WITH PLASTIC DYETUBES AND
PRECISION WINDERS.
If Quality was Better, High Value Yarn Dyed shiring Makers like Arvind,
Morarjee, Raymonds, Mafatlal will not get a Delta E value of less then 0.2
in yarn dyeing with Dyesprings.
Has your dyeing plant ever reached a Delta E value of less then 0.2 withany plastic centre.?
Second, See The Pic Below. One does not need Great Brains to see, which
will give better flow to passage of liquor in yarn dyeing.
DYESPRINGS DON’T GO WELL WITH HYDRO
Time to kiss good bye to Hydro and RF Dryers : Like Rapid Dryers!
Nothing goes well with Hydro. Plastic Dyetubes damage and shapedistorts. There is a Design Issue with the Modern Machine.
Unless packages are managed internally and externally, damage to
package Centres will be part
of the dyeing cycle
Lab Pro Hydro : The Ultimate Design in Hydro
“ Thies “ Rapid Dryers Knock out Hydro
And RF Dryers and Operational cost
same as RF Dryers.
ZERO HANDLING AFTER DYEING TO DRYING. VERY LONG LIFE OFDYESPRINGS AND NO MORE SHAPE AND LAYER DISTORTION.
PLUS FASTER DRYING WITH DYESPRINGS.
NEW DYEHOUSE
WINDING -DYEING - DRYER - REWINDING.
ELIMINATED
HYDRO +RF DRYER+PLASTIC DYETUBES
ECO COMMITTMENT
DYESPRINGS ECO KISS
ENVIRIONMENT POLICY OF A COMPANY IS NOT A STATEMENT MADE ONWEBSITE, BUT ACTUAL IMPLEMENATION OF
ECO SAVINGS
7.5 MILLION LITRES OF WATER PER YEARCHEMICALS AND AUXILARIES FOR 7.5M LTR WATEREFFLUENT TREATMENT OF 7.5 MIL LITRES PER YEAR
NO MORE DISPOSAL OF PLASTIC DYETUBES
AUSTRALIA IS THE FIRST COUNTRY TO INTRODUCE CARBON TAX.MORE COUNTRIES WILL FOLLOW
MAKE YOUR ECO COMMITTMENTS
WITH
MANTEX DYESPRINGS
YOUR TECHNOLOGY PARTNER
FOR
YARN DYEING
SALES COUNSELLING TEAM
BANGALORE : MR K V Shanker : 9743877863 ( GM )
MS Jayashree : 080 22427863
CHANNEL PARTNERS
COIMBATORE ; Mr S Sriram Visveswar 94875 - 45184
DELHI Mr Amitabh Ghosh : 9810150391
LUDHIANA Mr A P Singh
SURAT Mr Vijay Pathak : 93276-10930
MUMABI Mr MM Chaudhary : 9324615110
AHMEDABAD Mr Dinesh Dhagat : 93270-14844
CALCUTTA Mr Anil Saria : 9831047494
www.dyespring.net
DYESPRINGS, DYEING MACHINES, DRYERS, WINDING MACHINESAND ACCESSORIES
TECHNOLOGIES FOR TEXTILES
Coming Soon
Automation and RoboticsWireless TechnologiesNano Technology
Bioengineered TextilesTechnical Textiles Engineered YarnsComposites
Clean Renewable Energy Education, Training and Management Entropy and Thermodyanamics Water and Air Management
Machine Designing and Technology Scaling.Material Handling
Testing, Endorsements and Accredition.Super Critical Carbon Dyeing.
Speciality Chemicals
STOP VISCOSE SAVE FOREST
Global Production Capacity of Viscose = 2.5 million tonnes
1 kg of Viscose = 4 kgs of Tree Wood
2.5 million tonnes of Viscose = 10 Million Kgs of Tree Wood
1 Tree of 20 years age = 500 kgs of Tree Wood
Viscose Deforestation per year = 20 Million Trees