Master Indigo Dyeing Line

Year: Installed: 2004 (Dye vats and padders manufactured in 1994 and reconditioned by Master when the line was extended and installed in 2004)
Roller Width: 1800mm
Purpose: Continuous dyeing and treatment for modern denims, including mercerising, bottoming, topping, sulphur dyeing, and classic indigo blue, designed for maximum flexibility.

Components:
Beam Creels (2 units):
Maximum 14 beams of 1400mm diameter
One creel can be prepared while the other is running for maximum efficiency
Automatic yarn tension adjuster
Yarn pulling and feeding element
Mercerising/Wetting Process:
Soda process or pre-dyeing vat with padder
6 steam heated, PTFE-coated timing cans (800mm dia.) for mercerising
Fixing or 2nd wetting or washing vat with stainless steel tank and mangle.

Dyeing Section:
Neutralising or washing vat
Washing vat with stainless steel tank and padder
6 dyeing vats with stainless steel tank, intermediate padders, and overhead oxidising roller arrangement with finned stainless steel rollers and dancing roller
Counter current dye circulation system with filters, dosing, and pumps
Circulation tank for indigo
Overhead-mounted steamer for colour denim/oxidiser for indigo.

Post-Dyeing Treatment:
3 washing or post-dyeing treatment vats with intermediate padders
Accumulator for automatic storage of dyed yarn during beam changes (150m capacity, 5 minutes at 30m/min)
Drying cylinder pre-dryer range with 10 PTFE-coated drying cylinders

Sizing Section (Karl Mayer-Rotal, 2002):
Sizing box with prewetting (double dip, double nip)
Drying cylinder range with 14 PTFE-coated drying cylinders

Warp beaming head:
Roller width 2840mm
Maximum beam width 240cm between flanges
Maximum weaving beam diameter 1600mm

Size Preparation Kitchen:
Indigo dye & chemicals storage system:
2 tanks for chemical bath pretreatment
5 indigo tanks
1 sulphur black tank
3 stocking tanks for indigo
1 tank for softened water

Other Features:
Canopies
Electrical control panels