My 3rd Patent : Eco centres for Yarn Dyeing

Frome Cones To Eco Centres . From 19th Century to Digitial Age.

Plastic Out, 

Eco Centres

 15 to 25% Less Water Usage in Dyeing

Eco Centres For High Temperature Dyeing

Eco Centres In Action 

If you care for Enviroment, you will choose Eco Centres For Dyeing.

70,00 Kilo litres of Water Saved Per Year in 10 TPD yarn Dyeing Plant with Eco Centres

The mindless usage of water in the Yarn Dyeing Industry is more on account of incompetence in the Industry rather then the need of the Industry. Like I have written earlier in my blog on " Yarn Dyeing Machines : Fraud of the Century ". Where most dyers refused to use their knowledge of technology and simply follow the practices of 19th century.

Let us see, how a simple product, where in the potential energy changes to kinetic energy on compression brings about 15 to 25% reduction in water and hence all the related savings of power, chemicals, labor, space etc etc.

The compression of the Eco Centres provides room for additional loading of yarn onto the same spindle. Thereby using the same water, chemicals, energy, labor, you are now dyeing additional 25%. This translates to profit of USD1 Million per year for 10 TPD yarn dyeing plant.

The New Patented Eco centre licks away all the issues of the old metal dyesprings.

1. It provides covers to the ends, so no yarn slippage on the ends and hence no wastage.
2. It protects the ends of the dyesprings, so longer life of a dyespring.
3. It gives room for the dye centre on the winding machine so the drum and the dyecentre do not foul with one another.
4. It provides uniformity of compression.
5. The slip clips on the dye centre ensures that the initial winding of the yarn is perfect.
6. The Unwinding Caps ensure that the yarn unwinds till the last layer.
7. The Life of the eco centre is 5 years with the right kind of hydro.
8. The open space provides the free flow of liquor. So , no poor dyeing in the initial layers
9. The compression provides the uniformity of dyeing by equalization of density.
10. For coarser counts less then 20s, there is no other way, but to use mantex eco centres for dyeing. Even after precision winding.

My 2nd Patent: Physics of Yarn Dyeing/ Density Measurement And Sorting of Soft Packages.

Because Yarn Dyeing is a Physio-Chemical Process. The Physics of Dyeing is as important as Chemistry of Dyeing.

The Physics of Dyeing Comes by managing the Uniformity of Density achieved by:

1. Angle of Wind, which ensures the same number of layers from top to the bottom of the package.
2. The Shape of the package, which has to be cylindrical and compressible. Compression is the only phenomenon which ensures that the unevenness of the soft packages from precision winder is neutralized.

However, there is still no such practical system, which measures and sorts out the density range of the soft packages as required for good dyeing.

Herein my Solution

Co-ordinates For Volume

The imaging technology captures the volume if the soft package via a camera.

The Soft Package is placed in position and the machine started. The Pusher arm pushes it under the DMS, where the camera captures the volume and the weighing machine under, captures the weight.

The Density is then worked out by the computer and the sorting program pushes the soft packages into bins.

The Off Density packages , viz above are pushed into one bin, the below in another bin and those within the range come straight to the end bin.

This way the dyer can then dye, the above range soft packages together and the below in another lot, without the need of rewinding. Also, the RFT percentage improves on account of the correct physics of yarn dyeing.

DMS In Action At Sewing Thread Plant.

The production rate is around 6 nos per minute or say around 10 tons per day.

Currently under Beta Testing and should be available to market in another 3 months time. Expression of Interest is welcome.

My 3 Patents This Year : Carbon Spinning Tubes; Spinning will never be the same Again.

This year, I took 3 patents, two in area of dyeing and one in spinning. Let me start first with the Mother of all the 3 patents viz : "Carbon Spinning Tubes "

What happened to Light Bulbs in the last decade will be the same model, which will take place for Ring Tubes with my invention. Ten years from now, there will be only my tubes for ring spinning and no other tubes. This will be my legacy, the world will remember for a very long time to come. InshaAllah!

For the last 3 years, I had been struggling to make carbon composite spinning tubes and then with the help of a Japanese company ( Which does not want to be identified at this stage ) the product was Prototyped.

Patented Carbon Composite Spinning Tubes

What is the difference between the Normal Ring Tube and Carbon Spinning Tubes

Carbon Ring Tubes in Action

There are 4 very Significant changes that take place in the spinning industry with my this patent.

1. The weight of the tube comes down from 42 gms to only 8 gms on a 7 inches tube giving major power saving upto 9%
2. The wall thickness of the tube is only 0.5mm against the wall thickness of 2.5 mm of current tubes. Which means, practically you take 40 to  55% higher content per tube and therefore higher efficiency on the Ring Frames and and higher efficiency on the Auto Coner.
3. The wall thickness allows a yarn spinning on 42mm ring dia to change to 38 mm ring dia and take 11.5% minimum higher productivity.
4. Which also means, that, if the machine is now with 38mm ring dia, the pitch of the spindles reduces and hence in the same space, one gets more number of spindles and hence higher productivity per ring frame and lower utility cost of suction and blower fans and humidity fans. A gain in 10% spindles per ring frame means for each 10 machines, one machine is already less .

The tubes are now under Beta Testing in 3 countries and the first results are  very encouraging. I got my patent in Feb 2014 and the PCT has been filed for the Global Patent.

This would mark the first ever carbon composite product to be brought into Textile Industry by someone. 

The next product being tested by me is the tube for TFO, wherein the 38 x43x 170mm Tube is being changed to only 37.5mm OD. Giving a room of 5 mm for the extra yarn. This will change the whole concept of TFO and the spindle size of 100 mm and 120 mm will become the universal pot size with contents as same , which now goes into 135 mm and 145 mm pot dia. Look for my next post on these trials.

Spinning and Twisting will never be the same. One small step for Atul, one big leap for Spinning.