Vario Line

7/28/2019 Vario Line

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Bank Details: Stadtsparkasse Solingen Account No.: 528 083 (Bank Code: 342 500 000), SWIFT-ADRESS SOLS DE 33Competent court of jurisdiction and place of performance is Solingen.The company is based in Solingen. Register Court: Local Court (Amtsgericht) Solingen HRA 23144

Vario Line Jigger

Wichelhaus GmbH & Co KG Feuerbachstr. 12 D-42719 [email protected]


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Vario Line Jigger Texti le Machinery Engineering of the Future

Dear ladies and gentlemen,

thank you very much for your inquiry and your interest in our textile machinery products.

Wichelhaus GmbH & Co KG has always been engaged in developing, designing, and manufacturingspecial production plants for different purposes. Recently we got involved in a project for developing anew kind of textile jigger machine, which led to today's division 'Textile Machinery' as new portfolio ofWichelhaus GmbH & Co. KG in Solingen in April 2011. For further information on our company pleasevisit our website www.wichelhaus-co.de.

Tradition:Processes such as pre-treating, scouring or dyeing of textile fabrics have been carried out on jiggersfrom the beginning of the textile industry. Textile finishing highly benefits from this simple but efficienttechnology. The jigger is especially suitable for the treatment of crease-sensitive, non-permeable, veryfine as well as very heavy textiles mostly made of natural fibres.However, a traditional jigger machine does neither comply with the requirements of modern textilecompany's regarding its energy management nor with the quality requirements for high-class, mostlytechnical textiles.

Our Vision:Our vision is to combine environment, energy and engineering matters with the existing procedureproviding highest production efficiency while keeping energy and water consumption at its minimumand following ecological and economical aspects as guiding principles. A very critical environment-related factor was to ensure energy resource savings already during design and development of newmachines. That means a significant energy-saving manufacturing of the plants and usage of recycla-ble materials, wherever possible. However, the most important aim was to achieve the reduction ofcurrent energy consumption during production process.

We were aware of turning things upside down:


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Current Situation:The Vario Line Jigger brings together the benefits of traditional finishing technologies and high-techmechanical engineering developments while complying with both economical and ecological de-mands. The usual treatment of natural fibres is added by the possibility of the optimum pretreatmentand dyeing of polyamide fabrics, as well as blends with a high percentage of elastane.

Test Centre:Effectiveness in the future requires on-going development and optimization. The installation of aready-for-action Vario Line Jigger allows test operation and trial runs under production conditions,whenever required. We look forward to offering you both a demonstration of the machine's functional-ity and trials using your own materials.

Benefits:Consistent temperature, fabric tension and fabric speed, processing time, dyestuff/ chemicals up-takeand liquor ratio are some of the most important parameters to deliver best qualities. Reliable control ofthe whole process provides optimum safety. The Vario Line Jigger meets all these requirements: It iseconomical, user-friendly, eco-friendly and Made in Germany Consistent fabric tension Consistent fabric speed Optimum and consistent liquor ratio (for large & small batch sizes) Special expander construction Perfect monitoring due to large inspection windows Friction-free guide rollers bearing Insulated stainless steel liquor trough and economic dye trough Vario Master Roll reduces passages Automatic traversing

Circulation pump for an even dispersion Filter station High-performance heat exchanger Add tank with mixer and rinsing tubes Programmable dosing system

Range:The Vario Line Jigger has been designed for fabric widths from 1600 up to 4000 mm and for batchingroller diameters of 1000, 1200, and 1400 mm. The liquor quantity can be set from 110 up to 2850 l.The machine provides an optimum use of space due to the arched design of its protection windows tobe opened and closed overlapping in the roof area.


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Technical Design:

Basic Frame:The side walls are built of two solid tripods made of a special polymeric cast, providing best mechani-cal properties. Low thermal conductivity and effective heat capacity of this polymer material provide ahigh thermal stability. In comparison to steel constructions, polymeric casts neutralize vibrations ten

times faster, the material is highly isotope and homogeneous, preventing tripods from getting de-formed through loading. The machine-specific connecting parts (e.g. roller bearing, diagonal mem-bers, etc.) are made of stainless steel and integrally cast in the base frame.

The large inspection windows are electrically driven and suit best for the operator to visually monitorthe whole process. The hermetic sealing of the inspection windows ensures a consistent inside tem-perature. Both inspection windows are made of 14 mm safety glass providing excellent insulation val-ues, too. The two fluorescent light tubes inside support process monitoring.

Liquor Trough:The special design provides an optimum and consistent liquor ratio. The trough design allows an eco-nomic dyeing of small-sized batches. As a result, you are flexible to immediately respond to any re-quirement. Two large pneumatically controlled outlet valves enable quick liquor discharge. The unique

Vario Master Roll (VMR), equipped with a third convex guide roller in the trough, increases the liquorexchange, reduces the number of passages by approx. 35%, resulting in a decreased liquid consump-tion. The system may be applied as required for large and small fabric batches and for difficult textiles.

Vario Master Roll (VMR) as schematic illustration

Material ExpanderThe construction of the two material expanders enables an improved dyeing and scouring result. Thetwo expanders are adjustable within and allow very smooth material transport. The design of the ex-pander lips protects even very sensitive textiles.

Drive System Main Rollers:Two AC three-phase motors are responsible for the direct drive of the main support rollers. The brak-ing energy is transformed into driving energy. The two main support rollers, featuring special bearings

at the roller ends, are driven frequency-controlled. A high-quality stainless steel casing protects theroller core against aggressive agents.

Guide Roller BearingsLike other components, the bearings are made of high-quality materials. The Vario Line Jigger fea-tures special two-rowed self-aligning ball bearings, made of ceramics with concave outer ring racewayto absorb radial and axial forces even more easily. The use of ceramic instead of carbon/ steel rollerbearings allows an extremely smooth running of the machine's main rollers. This protects the textilesagainst suffering from standard high tension that may result in strong deformation and loss of elastic-ity. The rather large angle adjustability of the bearing units compensates small misalignments andshaft deflection without any problems, even at high temperatures. Ceramic roller bearings are non-magnetic, non-conductive, and resistant to abrasion and corrosion. They do not require any oil or


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grease lubrication, independent from work temperature, which leads to much less maintenance ofceramic bearings.

Automatic TraversingAutomatic traversing enables the main roll to get shifted in the longitudinal direction resulting in a sig-nificant benefit for edge treatment.

Control Panel:The control panel can be swivelled freely around for optimum operation of the machine. The controlunit designed as a cabinet is located directly next the plant to ensure all conduits to be as short aspossible. Alternatively, the control unit may be integrated into one of the side walls of the basic frame.The plant controller features a fully automatic process control DDC (Drive Dyeing Control) includingintegrated PLC and software, emergency system, touch screen monitor, stable operating system, ma-chine visualization, Ethernet TCP/IP, possible network connection, Internet technology and USB inter-face.

Temperature Measurement:The temperature within the hood and the trough area is measured by temperature sensors.

Liquor Level Monitoring:A level sensor is a transmitter to reliably monitor the level of liquor in the bath.

Circulation System:The liquor circulation pump equipped with rinsing tubes ensures a consistent temperature and a ho-mogeneous dye concentration in the bath. The filter unit is integrated into the cycle of the liquor circu-lation, collecting any accumulation of fluffs from the liquor. The filter drag has to be cleared by hand.

Heat Exchanger:The use of a state-of-the-art high-performance plate heat exchanger ensures the utmost heating-up orcooling-down of the liquor. The large surface enables a high energy transfer. The plate design allowsan easy maintenance and a low risk of blocking through fluffs. These two factors considerably in-crease working efficiency. The working temperature is achieved very fast and continuously maintained

due to perfect sealing of the Vario Line Jigger, resulting in considerably shorter processing times.

Add tank:The stainless steel add tank has a capacity of 150 litres. Jigger-sided (liquor tubes and outlet) andoutlet-sided, the add tank features automatic valves. The dosing device allows an exact dosage ofdyes and chemical agents right from the add tank.

Specification:Drive engines: 2x 5,5 KW; Pump: 1x 2,0 KW; Hoods: 4x 0,25 KW, Traversing: 1x 0,25 KWHeat exchanger: Liquor: 17,6 l; Pressure: 0-16 barPneumatics: Consumption approx. 16 l/min.

Documentation:

Design documentation: Assembly drawings including stock list, operating instructions and mainte-nance guide; CE-documentation including declaration of conformity documentation on the electricequipment. The documentation is completely available in digital forming any number of your choice.Additionally, it is available on our website via online access with your password-protected customerlogin. In German language.


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Spare Parts:During the time of project realisation, wear parts will be defined, and then separately highlighted in thestock list. The scope of our delivery does not include a spare parts kit. Generally, the mounting posi-tions of the replaceable wear parts are designed to provide easy access for replacement.

Inspection and Acceptance :

The operating and functioning inspection and acceptance of the machine will be carried out at theWichelhaus company. The machine is considered to be inspected and accepted, when all featuresand motion sequences are fully delivered and the plant is complete and in good order after inspectioncarried out by the customer. The plant will be run in full operation mode but without production due tothe lack of periphery.Initial start-up and final acceptance of the machine will be carried out on your production site. Yourstaff will be instructed how to operate the machine on the day of final acceptance. The machine isconsidered to be inspected and accepted, when all features and motion sequences are fully deliveredand the plant runs trouble-free during a period of 5 hours. The acceptance report documents are pre-pared in advance, and will be provided. The customer supplies a sufficient amount of material for freeto allow us running the complete initial start-up and acceptance procedures.

Options:

The following options present a range of variation and additional features to be selected according tocustomer's demands. Depending on the kind of application, we provide a number of further specialdesigns, as our strength is the development of constructions suitable for practical applications meetingtailor-made our customer's demands, considering his manufacturing structure, and his individual busi-ness concept. => You feel there are lacking options - please feel free to contact us!

Automatic TraversingAutomatic traversing enables the main roll to get shifted in the longitudinal direction resulting in a sig-nificant benefit for edge treatment.Motor traversing: 1x 0,25 KW

External Expander for Manual Loading and Offloading An expander is used to load or offload the batches, serving as additional support device to expand the

textile between the main roller and the external batch.

Central Lubr icationThe machine will feature an automatic central lubrication at the relevant points. The lubrication systemis mounted on the machine.

Trough InsulationThe stainless steel trough features an additional GFR insulation to reduce the heat dissipation throughthe surface, resulting in heat loss to be minimized.

Lock RollerLock rollers serve as water deflector for sensitive, thin textiles with poor water permeability, and theyare float mounted on the main rollers.

Addi tional Equipment for Add Tank - MixerTo prepare solutions of granulated or powder chemical agents, the add tank will be additionallyequipped with a mixer.Motor for mixer: 1x 0,25 KW

Addi tional Equipment for Add Tank - Automatic Fil lingFilling the add tank with water will be automatically controlled through an additional valve. As usual,chemical agents feeding has to be carried out manually.


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Dosing SystemIn the finishing industry, the dosing system means to be a comprehensive subject that we are able tohandle in accordance with your individual production processes. Please find the information on therelevant design for your individual application in the commercial documents attached.

Putting into Operation On-site

To be carried out on-site by a service technician in your production plant

Putting into operation comprises the following works:- Vernier adjustment of the machine frame- Control of the supply lines- Function test of the drive units- Testing all features- Checking filters (if available) prior to and after one dyeing run- Dyeing process acc. to programme- General visual inspection for any machine damages (transport losses)- Drafting the acceptance report- Handing over the machine to the customer

Within the customer's responsibility:- Main connections for the supply lines- Bringing in and positioning of the machine- All supply lines for current, water, steam and pneumatics have to be connected by the customer- The customer delivers a qualified fitter and electrician to be available on demand for putting the ma-chine into operation.- Internet connection with Ethernet cable to run initial start-up and remote maintenance.

Within the responsibility of Wichelhaus GmbH & Co. KG:- Control and calibration- Electrical and mechanical testing of all features- Test run with sample material delivered by the customer

DeliveryIn compliance with your wishes we offer delivery free or EXW, unloading and bringing the plant intoyour production hall excluded. Due to our price proposed, we assume the installation of the supplylines (current and air) and the connection to the machine to be carried out by the customer.

Price:Information on the relevant design concept meeting your individual application are available in thecommercial documents attached.

We hope the concept, as described above, meets your demands and fully attracts your interest.Should you have any questions about the concept or should there be any uncertainty, please do nothesitate to call us. We will be glad to help you with further information, or try to find other technical

design concepts together with you. We are looking forward to receiving your feedback.

Kind regards from SolingenWichelhaus GmbH & Co. KG

Jrg Demtrder


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Documents

Vario Line