Textile processes have become more complex as they develop. This brought about a prolonged process, additional investment and production costs and possible process errors. But digitalization and Industry 4.0 offer new possibilities to reverse this. Monforts demonstrated that simpler and smarter textile processes are possible at the ITMA 2019. Strong brand of textile finishing and dyeing technologies, Monforts had one of the most visited booth amongst the textile manufacturers during the exhibition. The company welcomed industry professionals with new finishing and denim dyeing machines as well as the possibilities of digitalization.
Monforts Sales and Marketing Vice President Klaus Heinrichs said that they met with an intense visitor interest during the fair and announced that they have signed several important projects. Heinrichs answered Textilegence’s questions; “We have reached significant visitor numbers, especially from India, Pakistan and Bangladesh. This region stands out among our target markets, especially in terms of denim production. We also welcomed a large number of visitors from Turkey to our booth”.
Heinrichs informed that India was their largest market in the world, while the largest in Europe was Turkey in 2017 and 2018. Heinrichs; “We have about 17 major projects in Turkey. But this number decreased last year and this year. However, we have a positive expectation that the market will revive again”.
Monforts Digital Twin overcomes the challenges of real production
“We are entering a new digital revolution and we are at the beginning,” said Klaus Heinrich, stressing that this would have a significant impact on productivity increase. Heinrichs stated that Monforts laid the foundation of digitalization by creating the Digital Twin system and continued his words saying;
“By exploiting the latest advanced sensor technology, comprehensive technical machine data can now be virtually mapped in the cloud in real time with Digital Twin. All specifications relating to machine performance and the production process can be mapped, to enable vastly simplified and targeted analysis for controlled planning and production. Insights harnessed from such analysis can be used to optimise the actual production process. At the same time, potential sources of error can be anticipated and eliminated, enabling improved machine availability while considerably minimising downtime”. Heinrichs has announced that the Digital Twin feature is now available to be used across all Monforts machines and systems.
Heinrichs recalled that the data can be easily accessed for an instant overview of the situation using the Monforts Smart Support and Smart Check applications in the next step. Mentioning that the Digital Twin system also provides information on the individual wear parts of a system with Smart Control sensors, Heinrichs noted that customers can order parts directly from their smartphones and tablets. Heinrichs added that Augmented Reality technology is now a good tool for marketing, and in the coming period, it will be developed for service and
A new level in savings with MonforClean
At ITMA 2019, Monforts presented the energy-optimized version of the Montex stenter for the first time. With the introduction of the new MonforClean exhaust air treatment system and other unique process innovations, Monforts has been able to further reduce the energy consumption of Montex stenters by a further 13%. The MonforClean module included in the stenter does not require additional space. Additionally, the cost of secondary installation is eliminated.
Continuing to improve the finishing lines, Monforts used bionic materials to eliminate exposure to ambient air at the machine entrances and exits. This material serves to hermetically seal the stenter frame at the infeed and outfeed. It is constantly adjusting to the profile of the different fabrics being cured and ensuring an absolute minimum of cold air is drawn in and only marginal warmth can escape.
Additional energy can be saved by installing a Monforts Eco Applicator in front of a Montex stenter. It reduces the amount of excess liquor in the finishing process; while a significant reduction in the energy required for subsequent drying. The MonforClean module automates heat recovery and exhaust air treatment, while removing odours. This results in a total energy savings of 40% compared to a conventional stenter.
A revolutionary look at multi-colour yarn dyeing; CYD
Another solution launched at ITMA 2019 was the new CYD multi-colour yarn dyeing system; which is a revolution in yarn dyeing based on the Econtrol® dyeing system. Econtrol® is a pad-dry process employed in Monforts continuous dyeing; in which the reactive dyestuff is fixed to the cellulose fibres during drying; and the CYD multi-colour yarn dyeing system introduces a number of new concepts based on it; including the unique Eco Bleach process.
This latest CYD denim processing technology integrates new functions and processes into the weaving preparatory processes; spinning, direct beaming, warping and assembly beaming, followed by sizing and dyeing; in order to increase quality, flexibility, economic viability and productivity.
Pointing out to the excellent cooperation with Monforts’ Turkey representative Neotek; Klaus Heinrichs said that this cooperation is very effective in their success in this market.