Product category:
Flowmeters and Flow Sensors
News Release from: Burkert Fluid Control Systems
Edited by the Engineeringtalk Editorial
Team on 08 November 2002
Double savings for dyeing specialist
The installation of simple but effective process control systems has solved a QA problem, improved quality and reduced costs for a customer in the textile industry.
By installing simple but effective process control systems Burkert Fluid Control Systems' distributor J Ll Leach has solved a QA problem, improved quality and reduced costs for a customer in the textile industry Worthington Manufacturing, a specialist dyer of fabrics and fittings for the lingerie trade, has enjoyed a close working relationship with Burkert Fluid Control Systems' distributor J Ll Leach
This article was originally published on Engineeringtalk on 25 Jun 2008 at 8.00am (UK)
Related stories
Solenoid valves handle diverse environments
The Type 6027 is a direct-acting (2/2 and 3/2 NO and NC) range of solenoid valves for shut-off, dosing, filling and ventilating tasks as well as vacuum applications.
Ph measuring system simplifies installation
The Burkert 8201 pH measuring system's enamelled stainless steel finish provides nonstick performance for maximised hygiene while pH values are measured.
Following a major factory fire in May 2000 the two companies began a programme to update and improve the efficiency of Worthington's Macclesfield textile dyeing plant.
The project included the automation of batch control and heating systems for water used in the dyeing process, and new temperature control and heat transfer systems for the dyeing tanks.
Design and installation of the process systems was carried out by J Ll Leach and included steam, hot water, temperature control panels, pneumatics and compressed air.
Further reading
Valves cut energy waste
Burkert's type 1066 valve control heads provide a decentralised method of opening and closing of process valves automatically, eliminating the need for the wasteful venting of control air.
System cuts costs of decentralised automation
The FreeLine system integrates fieldbus, I/O and pilot valves for use in the most demanding process environments.
Burkert supplied a variety of components including flow sensors, batch controllers, water and steam solenoid valves and steam angle seat valves.
A spokesman for J Ll Leach explains: "Dyes were being added to the dyeing vats using measuring jugs but there was no accurate measurement of the water used, which meant there could be a difference of 30 to 40 litres between vats, leading to inconsistencies in material colours and shades".
"To solve the problem, each vat was fitted with a Burkert flow meter and batch controller to control the on/off flow of the water; and a small paddlewheel sensor to measure how much water was going in.
The flow sensor was linked to the batch meter and a solenoid valve." The installation solved Worthington's QA problem by providing consistent batch dyeing and process repeatability.
Accurate dispensing of dye liquors is now matched by accurate, automatic filling of the tanks to ensure more consistent dyeing of fabrics and significantly reducing material wastage and labour costs.
Burkert also supplied steam valves for the bespoke on/off temperature controls in a new heat recovery system that uses heated wastewater to raise the temperature of the incoming mains water.
The system provides a double saving for Worthington.
First it reduces wastewater temperatures, which can be as high as 90C, to the 42C required for main drains disposal.
It then raises the incoming mains water from 12 to 31.5C.
Burkert steam valves are also fitted to the system that raises the water temperature in the vats to 40C before the dye is added and on up to 90C for the process itself.
The water is recirculated through a plate heat exchanger to ensure that it doesn't contaminate the dye liquor.
Commenting for Burkert, a spokesman says the Worthington installation demonstrates how much can be done at a relatively low cost to improve the quality and consistency of manufacturing processes, adding that even basic process improvements can reduce cost of ownership and increase the competitiveness of a business. Request free introductory details about products from Burkert Fluid Control Systems ...
• Burkert Fluid Control Systems: contact details and other news
• Email this article to a colleague
• Register for the free Engineeringtalk email newsletter
• Engineeringtalk Home Page
Search the Pro-Talk network of sites
