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BEN-WASH Solubilizing. Diffusion. Dilution.
2
Minimal fresh water consumption leads to saving in water, effluent andenergy costsCapital investment and operating costs
determine the economy of washing
machines. The water consumption for a
defined washing effect is depending on
the type and number of washing
compartments. Our palette of compart-
ment types permits a machine configura-
tion that is as flexible as it is economical.
The right machine combination for every requirementThe diversity of washing compartments
available and the modular design provide
the means for every industrial textile
washing need. By correct selection of
type and number of washing compart -
ments, the plant layout is adapted to any
customer requirement.
The EXTRACTA principle divides the
washing process into stages that can be
repeated with accuracy. Besides making
the whole process easier to follow it also
makes it amenable to calculation. In each
of the sepa rate washing chambers the
dirt or chemical liquor present in the cloth
is exchanged 50 to 80% for wash liquor,
which is loaded commensurately with dirt
and chemicals. Entrainment of the conta-
m inated liquor with this cloth is prevented
by the EXTRACTA roller. In the next
chamber the liquor ex change is repeated
but with much lower dirt concentration in
the wash liquor. Together with the known
freshwater throughput, this predictable
action provides the basis for calculating a
washing oper ation in advance.
The EXTRACTA principle:High washing efficiency with low water usage
BEN-WASH
3
A crease-free fabric run is guaranteed■ Large guide roll diameters and adapted
roll spacing that prevent the fabric from
skewing and guarantee crease-free
treatment from entry to exit of the range
■ Computer controlled tension force
from 100–500 N with press rolls or,
200–600 N without press rolls
■ Screw expanders with separate drive
■ Free running outer bearings with mini-
mal friction
■ on bath rollsSelf-aligning ball-bearings, life-time
lubricated, with carbon sliding ring
seals;
■ on upper rollsSelf-aligning ball-bearings; life-time
lubricated, with PTFE labyrinth seals;
■ on press rollsSelf-aligning roller-bearings; life-time
lubricated, with PTFE labyrinth seals.
Drive control via swivelingcompensators and load cellsIntermediate squeezers (pulling/squeez -
ing device) are controlled via swiveling
compensator and frequency converter
in the next compartment. The upper roll
single drive is controlled with a separate
frequency converter; in compartments
followed by a pulling/squeezing device
via a measuring roll with a load cell;
in compartments without subsequent
pulling/squeezing device via the swive -
ling compensator of the following com-
partment.
With Benninger, crease-free operation is a matter of fact
Angle detector of Swiveling compensator for drive
control
Load cell
4
Energy saving starts in the washing compartments
These high-performance, double loop
washing compartments with rubber coa -
ted press rolls, especially recommended
for medium to heavy fabric, achieve a
max imum washing effect.
In each washing chamber, the fabric is
immersed twice in the washing liquor
which is then pressed through the fabric
in the nip pools between roll and fabric.
The intensive liquor exchange in the fab-
ric is supported by the cross flow in the
chambers.
The single driven upper rolls with press
rolls (EXTRACTA squeezers) are a fully
fledged drive. Thus no other additional
drive in the form of an intermediate
squeezer is needed, as is the case with
sliding clutch and relax drives.
No steam escapes from the steamtightEXTRACTA washing compartmentseven at high temperature. The steamsealing of the entire washing range leads to a better washing effect, andenergy consumption is distinctly reduced.
DA 3 Fabric content 13 m
DA 7Fabric content 32 m
DA 3C Fabric content 15 m
DA 5Fabric content 23 m
DA 5C Fabric content 25 m
DA 7CFabric content 34 m
High-efficiency washing compartments DA C without intermediate squeezer
High-efficiency washing compartments DA with intermediate squeezer
Good accessibility to the washing
compartments, covers can be lifted easily
BEN-WASH
5
The variety of compartments gives you flexibility
The EA high-performance washing com-
partments use the same principle as the
DA compartments, with press rolls
(EXTRACTA squeezer) and individually
driven upper rolls.
Washing compartments with 3-, 5 or 7
chambers with single loop, upper roll drive
and press rolls for best liquor separation.
Single loop provides better accessibility
to the cloth and easier handling. As only
one immersion per chamber is possible,
the washing effect with the same amount
of water (per cloth weight) is lower than
with double loop. This effect is compen-
sated for by the greater number of wash-
ing chambers per compartment. The
residence time in the EA washing
compartments is, however, lower than
with double loop.
High-efficiency washing compartments EA with intermediate squeezer
High-efficiency washing compartments EA C without intermediate squeezer
EA 5Fabric content 15 m
EA 3Fabric content 9 m
EA 5CFabric content 15 m
EA 7CFabric content 9 m
EA 7C Fabric content 20 m
EA 7Fabric content 20 m
6
No rubber coated press rolls The advantage of this model lies in the
low maintenance costs, as these com -
partments have no rubber coated press
rolls (EXTRACTA squeezers).
Optional single drivesFor tension sensitive styles, upper roll
single drives are available as an option,
whereby the number of drives is freely
selectable.
The plain wash compartments with strip-
per roll for liquor separation are used with
individual drive for open and lightweight
cloths with single liquor separation.
Liquor exchange and washing efficiency
are much lower for reduction washing
than with the EXTRACTA roll system.
Washing compartments E C without intermediate squeezer
Washing compartments E with intermediate squeezer
E 3 Fabric content 9 m
E 5Fabric content 15 m
E 7Fabric content 20 m
E 3C Fabric content 9 m
E 5C Fabric content 15 m
E 7C Fabric content 20 m
The plain wash compartments with stripper roll
EXTRACTA
7
EXTRACTA compartments enable most economical washing
Reaction compartments D with intermediate squeezer
Reaction compartments D C without intermediate squeezer
This disadvantage can be compensated
only by making the machine longer or
using more water.
The high-performance ‘D’ wash compart-
ments follow the principle of the ‘E’ com-
partments.
‘D’ compartments are used mainly for
post-dye washing, where good diffusion
and long reaction time are demanded.
D 3Fabric content 13 m
D 5 Fabric content 23 m
D 7Fabric content 32 m
D 3C Fabric content 15 m
D 5C Fabric content 25 m
D 7CFabric content 34 m
Profit from these advantages■ Flexible machine layout due to the
variety of models and the modular
design
■ Operationally reliable and functional
design
■ Calculable washing effect
■ Controlled reproducible results
■ Closed steamtight machine
■ Best possible washing effect
■ Compartments with two separate
sections
■ Low water and power consumption
■ Only single drives applied
■ Constant fabric tension
■ Crease-free operation
10
High-performance washer for surface contamination
The FORTRACTA prewasher is a further
development of the proven Benninger gap
technique for washing-out contamination.
The cloth web is led upwards in two ducts.
The wash liquor flows down by gravity
simi lar to a waterfall. A strong washing
action is obtained by this counterflow prin-
ciple in the duct. Liquor separation is
effected by stripper rolls and flat jet nozzles
at the exit from the FORTRACTA compart-
ment.
Since the fabric carries large amounts of
chemicals especially at the beginning of
the wash, rubberized rolls are not provi -
ded in this compartment. The short dis-
tances be tween rollers and the large roll
diameters assure creaseless cloth
running.
FORTRACTA
11
With the classical roller vat washingprocess where the fabric is movedthrough stationary liquor with only shortreaction times, costs can hardly bereduced. In this process high mo lecularweight substances are fully swelled andas con sequence lead to an increase inviscosity, conglutination and therefore ahigh water con sumption.
The Benninger patented concept on the
other hand, is based on a significantly
lower water and steam consumption and
minimum use of chemicals. As opposed
to conven tional methods, comparable
results are better and achieved substan-
tially quicker.
A quite natural washing processThe fabric passes through a narrow cas-
ing divided into two shafts. Steam and
water are directed onto both sides of the
fabric, either individually or in any desired
combi nation. Due to the slot and shaft
geometry high flow speeds are caused
which create a high kinetic energy.
According to the process used, operation
can be with counter-flow water only from
the following washing compartment and a
liquor circulation system. The INJECTA
offers numerous process variations and
thus a high degree of flexibility in styles.
Through the shock heating of the wet
fabric to 100°C in the INJECTA the high
molecular weight substances swell up
im mediately, with a simultaneous reduc-
tion in viscosity through the effect of the
high kinetic energy. This means that they
are removed with a significantly smaller
quantity of water.
BEN-CONTROL Speak with data
Economics determine the washing procedure
12
Rationalized removal of high molecular weight substances
To facilitate infeeding the fabric the shafts can
be opened
The INJECTA makes the single-stage BEN-BLEACH concept feasible: In one single step! – from greige to finished, dry fabric.
Optimized desizingThe size is removed to the extent that sub-
sequent processes can be carried out in
the best possible manner and without diffi-
culty. Water-soluble sizes such as PVA,
PAC, PES and CMC, and also unmodified,
water-inso l uble starch sizes are removed
with a very high removal rate and low
water application of 3–5 l/kg. 100% syn -
thetic fabrics can also be successfully
desized in this manner. Airbag fabrics are
cleaned to the required residual content
of < 0.5% by the INJECTA.
Do you wish to wash out conventional size
and printing thickeners, that is, high mole -
c ular weight and adhesive substances with
a high swelling capability? Or must PVA,
PES sizes, spinning or spooling oils be
removed from synthetic fabrics? You can
solve all your critical tasks with the new
INJECTA washing system.
INJECTA
13
Clean washing is a matter of superior technology
Profit from INJECTA advantages■ Significantly lower water and steam
consumption
■ Highly concentrated effluents provide
ideal conditions for partial flow dis -
posal or size recycling
■ The washing effect of a single
INJECTA compares to that of a
multi-chamber high-performance
full-width washing machine
■ Printing after treatment is no problem
with no danger of staining the ground
■ Continuous desizing of
water-insoluble starch sizes
14
Low-tension open-width treatment
Benninger, the leading manufacturer ofroller vat washing machines, is alsoyour best advisor for drum washingmachines.
The TRIKOFLEX system, ensuring low
tension treatment of knitted, pile and
woven fabrics, has set new standards in
textile finishing.
Incorporating a range of system improve-
ments, Benninger has found the best way
to meet increased market requirements.
The TRIKOFLEX LT-DB in a few words
■ Flexibility due to modular concept
■ Box design with excellent torsion and
floor stability
■ No transmission drives nor friction
clutches; only single motor drives
■ Separate intermediate squeezer
■ Connectable with EXTRACTA
compartments
■ Excellent accessibility to the squeezers
and compartments for cleaning/
maintenance
■ The entire machine is steamtight
■ Optimum shrinking results ensured by
single motor drives
■ Two side washing, specially important
for dense fabric
■ Large guide roll diameter and proper
spacing ensure crease-free operation
■ Liquor separation due to two circulating
systems
■ Counter-flow by gravity possible over
the whole washing range
■ Spray pipes adjustable from the outside
■ Functional, modern design
■ Level of automation as required
TRIKOFLEX
15
For mono- and bi-elastic woven goods
Result:The new Benninger TRIKOFLEX genera-
tion enables the finisher to treat the entire
range from mono- and bielastic, as well
as crease sensitive woven fabrics without
problems and at low tension. This con -
cept also offers savings on water and
energy.
16
with reaction zone
1 liquor circulation
Cloth content 12 m
with reaction zone for neutralisation
2 liquor circulations
Cloth content 12 m
Flexibility in the structure
with intermediate squeezer
1 liquor circulation
Cloth content 8 m
with intermediate squeezer
2 liquor circulations
Cloth content 8 m
without intermediate squeezer
2 liquor circulation
Cloth content 7 m
without intermediate squeezer
1 liquor circulation
Cloth content 7 m
Taylor made conceptsDepending on the fabric and the process,
the modular build system TRIKOFLEX
can be delivered in various versions.
■ LT-DB with one liquor circulation
with 60 m3/h
■ LT-DB 2 with two liquor circulations
with 2 x 30 m3/h
■ LT-DB with intermediate squeezer
■ LT-DB C without intermediate squeezer
■ Direct steam heating, or indirect hea-
ting with heat exchanger
■ Mechanical, or automatic self-cleaning
filters
■ Various drive systems
TRIKOFLEX
TRIKOFLEX LT-DB 2 TRIKOFLEX LT-DB C2 TRIKOFLEX LT-DB 2/2-R
TRIKOFLEX LT-DB TRIKOFLEX LT-DB C TRIKOFLEX LT-DB C-R
17
Grooved drum
The heart of the TRIKOFLEX washing
system is the grooved drum with a com -
bination of grooved profile and mesh
covering.
It serves as a supporting element for the
fabric. The large surface of the drum
ensures smooth and low-tension fabric
passage over a long contact path. The
enclosed design prevents impurities from
entering the drum.
Further features:
■ Minimum deflection points
■ Short fabric path in the area of the
drum, trough and compensating roll
■ Large roll diameter
■ Low tension fabric transport through
controlled single motor drives
4 spray pipes are arranged around the
grooved drum and integrated into the cir-
culating system. These ensure the ex -
tremely high washing efficiency at great
circulating capacities.
The drum surface forms the groove pro-
file with a mesh covering. As the fabric
passes through the spray section, it is
supported by the drum surface and is
thus unable to avoid the hydrodynamic
water pressure.
The result:The washing liquor penetrates the fabric
and forms a liquor film on the front and
back side. In this way, impurities on both
sides are quickly removed. At the same
time a cleaning effect within the mesh is
created. The washing effect, compared
to standard mesh and screen drum sys -
tems, is considerably increased.
Drawing of the active washing principle with grooved drum1 Closed drum body
2 Groove profile
3 Mesh belt
4 Fabric
5 Outer liquor film
6 Spray pipe
Spray batteryThe spray battery with adjustable spray
angle is decisive for the optimum wash-
ing effect, in addition to the grooved
drum. The washing liquor is constantly
circulated through the spray pipes within
the compartment by means of a pump.
This produces a cross-flow and a heavy-
flowing liquor film on both sides of the
fabric. This ensures optimum mass trans -
fer and re moval of the substances being
washed off.
18
Maximum washing efficiency through circulation and counter-flow
A meandering liquor guidance principle,
similar to that found in vertical washing
machines, has been used for the first
time in the TRIKOFLEX drum washing
machine. The liquor guidance, in con -
junction with the spray line mecha nism,
results in the high washing effect of the
basic LT-DB model.
Compared to the LT-DB, the washing
effect of the TRIKOFLEX LT-DB 2 is in -
creased by the addition of a second,
independent circulation flow and bath
separation.
This bath separation allows the tempe -
ra ture of the liquor to be varied within
the drum washing compartment. This
is espe cially important for even fabric
shrinkage.
The washing effect of the TRIKOFLEX
washing machine has been tested under
production conditions. Results show a
40% increase in the washing effect at -
tributable to bath separation and second
circulation flow.
TRIKOFLEX LT-DB 2 with two liquor
circulations and bath separation
TRIKOFLEX drum washing machine comparison, one (LT-DB), two circulation system (LT-DB 2) and EXTRACTA (DA 4)
Number of chambers
Co/LY 97/3%
Twill 2/1 - 240 g/m2
V = 40 m/min
T = 95°C
Water: 4 l/kg
TRIKOFLEX
19
Shrinking with lowest fabric tension
Continuous shrinking, desizing and washing of Filaments (PA 6.6, PET, PTT, PBT, PP)
Multi-flexible pre-treatment and washing range for tension-sensitive fabrics
Use of the TRIKOFLEX drum washingmachine is called for when fibre mate-rials show a high shrinking potential orif an increased risk of creasing existsin a roller vat.
Shrinkage occurs at the first contact with
hot water. The rate and degree of shrink-
ing is dependent on the temperature.
Dimensional changes (length/width) in the
fabric must not be inhibited during this
stage of processing.
The TRIKOFLEX makes processing at
different temperatures possible within a
washing compartment. The advantage
is that a slow and even shrinking can be
attained across the entire width of the
fabric.
The drive technology plays an equally
important role in achieving an optimal
result. TRIKOFLEX drums are controlled
by rotary magnet motors, or tension
control (load cells).
Should longer washing and dwelling
times be necessary the TRIKOFLEX can
be complemented with the EXTRACTA
roller vat washing compartments. Larger
fabric contents lead to longer diffusion
times. A high degree of washing efficien-
cy is guaranteed by separating the liquor
in different chambers.
Washing after
Vat-printing
Rinsing Oxidation Soaping Washing, Neutralizing, Rinsing
Washing, Neutralizing, Rinsing
Washing, Neutralizing, Rinsing
Washing, Neutralizing, Rinsing
Washing, Neutralizing, Rinsing
Washing, Neutralizing, Rinsing
Reductive cleaning
Impregnation, Caustification
Impregnation, Bleaching
Rinsing
Rinsing
Rinsing
Rinsing
Washing after
Disperse-printing
Washing after
Reactive CPB, Dyeing
Cold/Hot, Caustification
Of Viscose
Washing after, CPB-
Bleach + Shock-bleaching
Washing after
CPB-Bleach
20
Diffusion washing processesWashing in spray and reaction aggregates
Efficient washing is of centralimportance during textile finishing andis defined by the factors mechanicalaction, time, temperature and water.
Depending on the washing task the
weighting of the individual factors varies.
Often the term washing is only associa -
ted with dilution washing whose success
essentially depends on the water tempe -
rature and mechanical washing action.
On the other hand, reaction processes
require a specific amount of time for the
chemical reactions to take place. The
fastness wash for obtain ing wear-, wash-,
or water fastness falls under the term
diffusion wash. Objective of this washing
process is to bring the unfixed residual
dye in the core of the fibres to the fabric
surface and to remove it. Here time and
temperature are key factors.
REACTA
21
Dilution wash
caustic soda, salts, H2O2,
emulsified oils
Fastness wash (diffusion
wash) reactive dye, etc.
Reaction processes
demineralisation, oxidation,
neutralisation, emulsification
Time
Mechanical washing action
Fresh water
Weighting of the factors that affect textile washing processes
Machinery-related requirements andequipment for the diffusion wash
Diffusion washing processes cannot be
undertaken satisfactorily using common
washing systems; the investment
required is also excessive.
The fabric content is not sufficient, to
perform a soaping process for 2-8 mi -
nutes. Time-consuming washing pro -
cesses can be performed significantly
better in dwelling compartments.
For diffusion washing and reaction
processes Benninger relies on roller bed
dwelling compartments with additional
spraying areas. The washing principle
applied by Benninger is based on the
principle of seeping wash, where liquor
is applied to the textile substrate and
slowly seeps through the fabric.
Unlike storage racks, accumulator belts
or chains, the roller bed used by
Benninger has the major advantage that
the pile of fabric is continuously in motion
and is passed from roller to roller. The re -
lative motion within the individual fibres
and threads improves the penetration of
the capillary spaces by the seeping water.
Temperature
22
5
4
3
2
1
1 2 3 4 5
Economic water removal with Vacuum Systems
The Hydrovac vacuum technologyis applied in situations where an efficient
bath separation is required. Simultaneous
to the extraction of water, lint, emulsified
and dispersed contaminants, hydrolysed
dyestuff and sizing agents are removed.
At the same time, the possibility exists to
separate this polluted liquor from the
process water. The fresh water consump-
tion is considerably reduced due to the
increased degree of concentration that
develops during the ensuing washing
processes. Partial disposal of this highly
polluted liquor can reduce waste water
contamination (COD) considerably.
SeparatorThe cyclone separator with pre-separa-
tor and the newly developed air flow
system guarantee optimum separation.
HYDROVAC
Suction tubePre-separatorWater separatorDiaphragm pumpRotary pump
23
The advantages at a glance:
■ Partial flow recycling is achieved
by separating the concentrated
polluted liquor
■ Removal of contaminated liquor
from the process water enables
increased washing efficiency
■ Emulsified and dispersed
contaminants are removed
■ Especially suited to remove
printing thickener and size
■ High dewatering values particularly
for synthetic fabrics
■ Possibility for size recovery
Increased washing efficiency and simultaneously reduced impact on the environment
Suction tubeThe conical construction prevents the
accumulation of contaminant residues.
The fabric is exposed to practically no
friction at all as it passes over the slot
opening, which is adjustable and easily
accessible from above.
Rotary pump blowerThe so-called ‘Roots’ pump is the most
economic and efficient vacuum system
available.
Air controlA secondary air adjustment valve is
utilised to control the system (a frequen-
cy converter is used in some cases).
Blower aggregateThe noise reduction hood offers easy
access to the blower aggregate and its
various components, e.g. the suction
silencer.
Acetate
Acetate Filament
Cotton
Lyocel/Tencell
Polyacryl
Polyamide Filament
Polyamide Staplefibre
Polyester Filament
Polyester Staplefibre
Polyester/Cotton
Polyester/Viscose 65/35
Polyester/Wool 55/45
Viscose Filament
Viscose Staplefibre
Wool
The efficiency of a vacuum system is contingent
upon the type of fibre and construction.
The table below shows average rates of residual
moisture achievable.
You can feel it’s Benninger
The Swiss company Benninger has been the textile industrys leading partner across the globe for one hundred and fifty years with global branches and service representatives. Benninger develops and manufactures textile finishingand cord production ranges as well as providing complete system solutions. As the market leader Benninger will continue to rely on its comprehensive process know-how in order to be able to offer high-quality installations withexcellent customer service.
Benninger AG9240 Uzwil, Switzerland
T +41 71 955 85 85
F +41 71 955 87 47
www.benningergroup.com
Benninger Zell GmbHSchopfheimerstrasse 89
79669 Zell i.W., Germany
T +49 7625 131 0
F +49 7625 131 298
Benninger ZittauKüsters Textile GmbH
Gerhart-Hauptmann-Strasse 15
02763 Zittau, Germany
T +49 3583 83 0
F +49 3583 83 303
Benninger AGMoscow Office
Leningradsky pr-t 72
Bld. 4, Office 802
125315 Moscow, Russia
T +7 495 721 18 99
F +7 495 721 30 84
Benninger India Ltd.415/416 & 417
Sunshine Plaza
Dadar (East)
Mumbai 400 014, India
T +91 22 4322 7600
F +91 22 4322 7601
Benninger Textile Machinery Co. Ltd.Room 904, Tower A
City Center of Shanghai
100 Zun Yi Road
Shanghai 200051, P.R. China
T +86 21 6237 1908
F +86 21 6237 1909
Locations
Head officeUzwil, Switzerland
SubsidiariesMumbai, India
Shanghai, China
Zell, Germany
Zittau, Germany
Representative officeMoscow, Russia