Specifications
“Aqua Smart” has been implemented by a rapidly growing number of establishments in the textile sector for its practical economic advantages and the benefits they provide. Economy and efficiency have become more integral in the machine-manufacturing sector with each passing year, as industries focus on more coherent and cost-effective means of production.
So, how do we describe the concept of being economic with regards to a dyeing machine? In short, through energy-saving innovations, reduced usage of available resources and environmentally-conscious construction. Time-saving through optimized processes, cost savings due to low maintenance expense, and minimal environmental pollution are some of the benefits attained due to our practice of experienced and intelligent design.
- Potential to recover your initial investment costs in a maximum of 6 months
- Probability of min. 50% less labor
- Up to 50% space conservation on site or in your existing space
- Opportunity to save 50% on your spare part costs
- Advantage of early delivery of the product to your customer with our Short Process features
Saver Makina has already excelled in regards to technological excellence with "Eco Salvo" and has become the pinnacle of Turkish textile machinery in terms of sustainability as well. Furthermore, it has provided numerous solutions that support the textile industry by prioritizing the concept ofsustainable technology in the machine industry by principle. Dyeing with low flotte ratios has been widely accepted as an essential method of reducing costs and enabling manufacturing. The real difficulty of dyeing with low flotte ratios lies with the person who does the dyeing; therefore, many dyers have chosen to use relatively safer flotte ratios such as 1:7 and 1:8 in order to ensure proper dyeing quality and manufacturing continuity.
The staff and operational expenses required to manufacture fabric has made flotte ratios the less critical issue. In order to counteract the increased legal pressures caused by foreign competitors, the industry has become more interested in water and time-saving processes that lower costs and maximize efficiency.
Technical Informations
- Main Circulation Pump with Belt-Pulley power transfer, operating at (1/1) liquor ratio
- Nozzle System adjusted with a variable-speed Linear Actuator
- J-Box System prevents mixing even on very light fabrics
- Horizontal Type Filter with High Filtration Area
- Vertical type Heat Exchanger with proportional control at the entry, with High Heating Gradient
- 100% Hot Water Preparation Tank (flotte: 1 /4 )
- Elliptic Fabric Tube expanding fabric at the outlet of Nozzle
- Minimum Fabric Tension with the Long Tower Transfer system
- Continuous Fabric Flow due to Teflon Film lining the floor of the J-Box
- Large Diameter Front Lid and Combined Safety System
- Seamless fabric transfer due to heavy-duty structure.
- Dye and Chemical tanks with Mixers and Direct and Indirect Heating
- Dosing Pump can transfer products under pressure as a result of superior engineering
- Batch Transfer with minimal loss
Technical Specifications
- Aqua Smart is a high-temperature (135°C) fabric dyeing machine.
- It can be used for the pre-treatment, dyeing and washing of sensitive and technological fabrics, as well as offering special settings for lightweight, upholstery and towel fabrics.
- 1:4 - 1:5 liquor ratio. (icluding washing process).
- Vertical type reserve tank for liquid preparation purposes. (with setting controls).
- Ability to use the main pump with an inverter control at different speeds.
- Touchscreen industrial PLC.
- Perimeter-located dyeing and chemical tanks with level probes and mixers.
- Fabric speed control with end-finding sensor.
- Level measurement with the analogue level control system.
- Inner washing system.
- Bottom collector positioned on the pump suction line and internal filtration system.
- Power Drain with a main pump.
- Exterior Shell and Tube type heat exchanger.
- First-rate fabric stacking and fabric circulation with a Plaiter, if desired.
- Adjustable nozzle system with a linear Actuator.
Product Catalog and Documents
- Seam Detector system detects fabric seams during sampling and fabric unloading,
- Pump inverter mounted in the electrical panel, which adjusts the motor speed and thus the bath flow,Proportional valve controlled by an IP converter for Heating and Cooling
- The reserve tank system, which is used to save time, energy and labor, is used to prepare the hot water required for the following step of the dyeing process and delivers it to the machine automatically as needed. Chemical storage is another advantage of the reserve tank.
- At the end of each process, such as preliminary bleaching, dyeing, rinsing and washing, the liquid bath can be quickly emptied via pump.
- A highly efficient in-machine washing system for your fabric dyeing machines; it cleans the inner surface from residues and fibers after dyeing. The fabric washing water can be pre-heated by transferring it to the hot machine surface and thus the lost energy is regained. With automatic internal washing, your costs and processing times are reduced, and manual cleaning time is eliminated.
- An extra additional container is included, equipped with an automatic valve and indirect heating system, in which dyestuffs are added to the system.
While the water drawn in the machine by the pump is passed through the heat exchanger to the nozzles, steam and cooling water are passed through the heat exchanger in the flow opposite to the water flow direction, thus cooling or heating the flotte with the highest efficiency. The values read in ohms with a PT100 are transmitted to the PLC and the temperature change is controlled to the desired SET temperature value. With PLC Control, the valves can be opened proportionally and heating and cooling can be done in degrees/minute.
The pump is capable of taking water from the reserve tank and pumping it to the nozzle. Simultaneously, in order to maintain the maximum water level, the machine discharge valve is opened periodically and overflow washing is performed. If desired, the heat exchanger is activated at this time, enabling the water coming from the reserve tank to be heated more. If the water in the reserve tank runs out during this process, the PLC takes water directly from the line and continues the process.
Water is supplied to the suction line of the machine from the main line and an effective washing is done with clean water by passing through the heat exchanger and filters. The increasing water level of the machine is kept constant via the overflow valve. This process is done by controlling the amount of water, time and level. Overflow washing in liters is controlled by the flowmeter in the water inlet line, providing a continuous repeatable washing effect.
It is controlled by converting the resistance formed on the analog level control bar located outside the device to 4-20 mA with a Magnetic Floating Buoy. The only disadvantage is that when the machine overflows equal to the volume of fabric in it, the overflowing water level cannot be calculated. The advantage is that the machine receives the required amount of water by calculating the amount of water in the fabric in the new water intake process after the water discharge process. This happens automatically via PLC min. and max. adjusted by the control level. The common point of all water intake procedures is that the pump does not operate until the proper safety level is reached. The water intake procedure begins and when it reaches the set level, the water intake valve closes and the towers start to operated.
While the pre-dyeing program is in progress, water is received according to the amount of fabric. While the PT100 is heated to the required temperature for the dye bath, water is transferred from the reserve tank to the indirectly heated chemical tank until reaching the maximum level and the mixer is activated automatically. At the same time, the additional container is heated up to the set temperature and the water inside is pumped into the reserve tank, thus a water cycle begins between the reserve tank and the additional container. During this cycle, salt is dissolved in the additional container. The salt water is added to the correct proportion from the additional container and waits ready for use for the dye bath.
Fabric amount and max. water level is adjusted via settings from PLC or Flowmeter. The main pump does not function during water intake. With the flowmeter installed on the line after the water inlet lines, the amount can only be measured during water intake. A change in the amount during the process cannot be determined. When used together with the analog dipstick, both the amount of water intake and the amount of water remaining in the fabric during the process are determined by the analog level and the required additional amount is supplemented with the flowmeter. The amount of water consumed in the overflow procedure is controlled by a flowmeter.
