HMCS Max Bernays Pre-Deployment Brief (May 2024).pptx
Compactor
1.
2. Prepared By : Mazadul Hasan sheshir
ID: 2010000400008
13th Batch (session 2009-2013)
Department : Wet Processing Technology
Email: mazadulhasan@yahoo.com
Blog : www. Textilelab.blogspot.com (visit)
Southeast University
Department Of Textile Engineering
I/A 251,252 Tejgaon Dhaka Bangladesh
Prepared By :
3. The compactor machine is a tubular fabric shrinkage control
machine which can compact the fabric in length wise direction,
to provide over feed to the fabric while processing in presence of
steam, and able to control the shrinkage. In other words, this is a
process of compacting the fabric in length ways direction.
4.
5. Upgrade the fabric hand feel and import a smooth, silky touch to
the fabric.
Compress the fabric and reduce its thickness.
Improve the opacity of the fabric.
Import different degree of luster to the fabric.
Reduce the yarn slippage.
6. 1. Shrinkage control
2. GSM control
3. Width control
4. Ironing the fabrics
5. To compact the fabric
6. To control the shrinkage
7. To maintain proper width and G.S.M
7. Machine Operating Rules & Regulation for Compacting
Machine:
• Machine should be kept always clean.
• Knot & very much course stitch containing fabrics should not be feed to
the machine.
• Machine should not be stopped until the temperature decrease at 65ºC
• Teflon should be cleaned minimum two times in a day.
• Load value of load cell should be check.
• Machine inlet steam should be between 4 – 6 bars.
• Electric component should be safe from water during machine cleaning.
• If any problem is observed in dyeing machine, the information should be
sent to maintenance department as soon as possible. Operator must not be
accessed electric control panel in any condition.
8.
9. Shrinkage Tolerance of Different Fabric:
Fabric Type Length (%) Width (%)
S/J -5.50 -5.50
Lycra S/J -6.00 -6.00
Single Lacoste -7.00 -7.00
Lycra Single Lacoste -7.00 -7.00
1X1 Rib -7.00 -7.00
Lycra 1X1 Rib -7.00 -7.00
2X2 Rib -8.00 -8.00
Lycra 2X2 Rib -8.00 -8.00
Interlock -7.00 -7.00
Terry Fleece -5.00 -5.00
15. FUNCTION ONAL SELECTION LEGEND
1 – Fabric Brake 13 – Felt Centering Rollers
2 – Fabric Feeding roller 14 – Felt Tensioning Rollers
3 – Beater 15 – Heated Roller
4 – Safety Photocell indicating Lack of
Fabric
16 – Felt Drawing Rollers Covered with Rubber
5 – Fabric Conveyor Belt 17 – Rollers with Loading Cell for automatic
Fabric Tension Control
6 – Photocell Loop Control 18 – Exit Belt Drawing Roller
7 – Operator Platform 19 – Fabric Conveyor Belt
8 – Re – directing Roller 20 – Movable Arms
9 – Automatic Spreader Mod. AL-BATROS 21 – Fabric Conveyance Hopper
10 – Steaming Chamber 22 – Plaiting Roller
11 – Motorized Adjustable Rollers 23 – Fold Pressing Device
12 – Felt Re – directing Adjustable Rollers 24 – Plaiting Platform
OPTION:
A – Ring Spreader for Tubular
Fabric
C – Cardboard Positioning Device
B – Cooling Chamber at Exit D – Cutting Device
16. Machine Parameter Set Up Value
Steam Pressure 2 bar.
Air Pressure 4 bar.
Temperature 100-120 C.
Machine Speed 15-50 m/min
Over Feed 35 m/min
17.
18.
19. Brand name : Fabcon
Manufacturing country : U.S.A
Year of manufacturing : 2006
Maximum speed : 60 m/min Minimum speed
: 10 m/min
Production/day : 8 tons/day
Maximum Temperature : 70˚C
Tube compactor Machine
20.
21. Machine specification:
Brand name: HELIOT International
Type/model no: HC2000GL
Company: France
No of motor: 08
Over feed = m/min
Machine speed range: 13-22m/min
Termperature(0C) range: 100-1400C
Maximum width 86
Minimum width 36
Applied for: Open fabric
Left over feed: -20% +20%
Right over feed: -20% +60%
High production: -20% +60%
Front over feeding cylinder: -20% +60%
Middle belt: -20% +60%
Open fabric Compactor
22. Check point:
I)Check steam & air line pressure
II)adjust felt temperature
III)Blanket pressure:3.5-4.0-4.5
Some instructions for optimum performance:
1. Center the felt blankets on the cylinder. Ensure that all cylinders are running
parallel relative to each other. Adjust the limit switch against the edge of the felt.
2. Place the felt under tension. Upper felts tension-2 bar, Lower felt tension-1 bar.
3. raise the heated drum working temperature to 200 f| & set the speed to 11-22
yd/min(10-20 m/min)
4. Open the humidification ramp in order that felts are in a steam atmosphere.
5. As soon as these conditions are reached, let the felt run for 2.5 m
23. Machine specification:
Brand name: FERRARO
Type/model no: COMPTEX-RE 2800.
Company: ITALY.
No of motor: 17
Over feed = Max + 35%, Min -35%.
Machine speed = Max 32m/min, Min 4m/min.
Termperature range: 100-2000C
Maximum width =240cm
Minimum width =100cm
Applied for: Open fabric
Left over feed: -20% +20%
Right over feed: -20% +60%
High production: -20% +60%
Front over feeding cylinder: -20% +60%
Middle belt: -20% +60%
Open compactor
24. Heating system:
Steam
Main parts of the machine:
1. Heating chamber
2. Blower (2, one at the entry chain zone for uncurling and another
at the entry of compacting zone)
3. Synthetic blanket as a conveyor,
4. Folder
5. Exhaust fan
6. Unpinning cylinder (-40% +40%)
7. Belt cylinder (-40% +40%)
8. Uncurling device at entry of compacting zone.
9. sensor
10. brush roller
28. Overfeed % Up Setup for Lafer compacting Machine:
Overfeed % Up for Lycra Single Jersey : 60
Overfeed % Up for Single Jersey : 35/40.
Overfeed % Up for Lacost fabric : 35/40
Overfeed % Up for Rib fabric : 20/22
Overfeed % Up for CVC fabric : 45
29. Main Parts: (Lafer Compacting Machine)
Heat Padder: Control Motor Speed.
Heat Chamber: Three.
1. Lower Padder
2. Stenter
3. Compactor
Main Power
Blanket: For finishing Cloth.
Guide Roller
Clip: Straighten the fabric
Wheel raising
Steam Box: soften the fabric
Load Cell: Keep the delivery Roller for perfect tension.
Temperature: 1500C (Highest)
Speed: 50 M/Min
Overfeed % Up: More the Overfeed % Up More the GSM.
Steam Pressure: Up to 10 Kg
46. Support Structure:
It consists of sturdy body sides made of painted steel, supporting
the cylinders, the mechanical part and the plant system; they are connected by means
of longitudinal and transversal cross-section. The body sides are provided with special
safety locks.
Inlet Tightener:
The inlet tightner is designed to drag the fabric to the machine with an
adequate tension. Its effect can be varied by turning the hand wheel provided.
Fabric Draw Roller:
The draw rollers receive their movement from a variable speed
motor. They deter-mine the speed of fabric.
1. The rollers are normally covered with rubber and it is most important that the
surface of the covering is always in good condition so ass to avoid slipping of the
fabric. Should this not be so then it is necessary to replace the covering.
2. The processing of fabrics treated with chemical against might involve a rapid
deterioration of the drag rolls coating.
47. Idle Cylinders:
The idle cylinders are designed to change the route of the fabric to
convey it in the right position for subsequent working.
Dancing Roller Synchronizer:
The dancing roller is constituted by a cylinder mounted
on oscillating arm, connected to a rheostat for the synchronization of the various group.
Inlet fabric Guide:
It consists of shoulders supporting a couple of adjustable spreader
rollers operated by an independent motor, and a pneumatically operated fabric centering
unit with move-able staves, controlled by border guard photocells.
Steaming Tank :
It consist of no. 1 steam delivery chamber on the fabric, made of inox
steel and complete with metering valve and on-off solenoid valve.
48. •Compacting units:
They are the real compacting units. Each unit consists of:
1. A steam heated cylinder, diameter 500 mm., made of chromium plated and
ground steel; it is complete with a rotary joint for steam feeding, a thermocouple
feeler to feel the temperature, and an effective system for the condensate
drainage. The cylinder temperature can be adjusted with the utmost (+/-2˚C)
directly from the keyboard placed on the control board, and is shown on the
display.
2. A thick Nomex – Polyester compacting felt. The double action felt centering de-
vice ensures perfect felt alignment during running. The computer controlled felt
control mechanisms automatically releases felt tension after a machine stop.
3. An adjustable position counter-roller for the fabric shrinkage control during inlet
in the compacting group.
4. An inlet element in a special non-adherent fibre (shoe) equipped with a device for
adjusting both angle of incidence and insertion length.
49. Spreader Roller
It is a spreader roller, for the selvedge unwinding and the inlet of the fabric
perfectly spread in the machine.
Scroll Roll Unit
The adjustable spreading scrolls at entry are used for open width knits and for
all fabrics that have lengthwise creases. Consists of two adjustable spiral scroll roll
driven by an independent motor.
Device for Fabric Tension Check
It consists of a cylinder combined with a special load cell sensor. It allows
synchronizing the speed between the upper and lower compacting unit, and
adjusting the fabric tension between them with the utmost precision. The
adjustment is performed directly from the keyboard placed on the control board
and is shown on the display.
50. Cooling Unit
It consists of a steel structure including a conveyer belt, the drag and tension
cylinders Of the latter, a suction chamber with a net plane for a perfect distribution of
the cooling air. The chamber is connected to a high-efficiency centrifugal electric fan.
Checking Table:
The inspection table is composed by a steel structure that supports a table that
accompanies the fabric falling from the cooling band. In this phase the operator placed
in the rolling up unit zone can carry out a check on the quality of the worked fabric and
notice possible defects.
Fabric Storage Chute for the System Non-Stop:
It consists of a j-plate for the fabric storage during the phase of roll change. It
allows removing the finished roll, and starting a new roll without stopping the system.
51. Rolling Unit
It consists of a bearing structure and a moveable trolley which supports the
rolling cylinders. The trolley sides on two rails in order to allow the perfect alignment
of a selvedge on the roll of fabric. The movement is automatically controlled and is
operated by an electromechanical actuator. The reading of the selvedge border is
performed by two photocells, whose position can be adjusted by means of a hand
wheel. The rolling cylinders are covered with vulcanized rubber for a perfect adhesion.
The roll compactedness can be adjusted by a pneumatically operated device. The
rolling unit is complete with a spreader roller, operated by an independent motor,
placed immediately before the rolling cylinders.
Steam System
It is installed in the machine. It includes a filter, an on-off valve, a pressure
gauge for displaying the line pressure and a condensate separator. It is provided with a
series of servo-operated solenoid valves to feed the different elements of the machine
and wit automatic steam traps complete with by-pass for manual drainage.
Controls
The main controls are located on the left side at the machine entry; they
include a “Touch Screen” interface and a set of buttons. The auxiliary controls are
placed on the panel at the machine exit. The emergency stop buttons are located on
the sides of the machine.
52. S) Electric Board:
The electric board is installed in the machine. It includes the electromechanical instal-
lation, electronic cards, a set of inverters and the PLC controlling the machine. It is
also equipped with protection devices, and cooling devices. All operation func-tion is
shown in the “Touch Screen” on the main control board. The machine is equipped
with a direct grounding of all the electric components and of the metal frame. The
preventive measures to ensure immunity in the presence of electromagnetic dis-
turbances have been adopted, and have been taken the necessary precautions to atte-
nuate the disturbances of an electromagnetic nature produced by the electric/
electronic system of the machine
T) Pneumatic System
It includes an on-off valve, a filter-lubrication unit, a pressure regulator and a series of
solenoid valves for the operation of the pneumatic actuators.
60. Type: Blanket Compactor Machine
Minimum Fabric Dia Capacity: 126 cm
Maximum Fabric Dia Capacity: 28 cm
Steam Temperature: 120oC
Maximum Overfeed (%): 40%
Minimum Overfeed (%): -10%
No. of Cylinder: 2
Padder Pressure: 6-7
(Tubular Knitted Fabric Compactor)
61. Fabric type Colour Speed
(m/min)
Over
Feed
(%)
Temperature
(degree C)
Blanket
Pressure
Teflon
Pressure
Stretch
(%)
Single
jersey
White
Colour
15-18
15-18
25-30
25-30
90-110
110-120
1.5-2bar 36psi As required
Pique
(s/j,d/j)
White
Colour
15-18
15-18
30-35
30-35
100
110-120
1.5-2bar 36psi As required
Lycra s/j White
Colour
12-16
12-16
Full
over
feed
100-110
100-120
1.5-2bar 36psi As required
1x1 Rib White
Colour
15-20
15-20
20-30
20-30
100 110-
120
1.5-2bar 36psi As required
2x2 Rib White
Colour
12-15
12-15
25-30
25-30
100 110-
120
1.5-2bar 36psi As required
Interlock White
Colour
12-16
12-16
Full
over
feed
100 110-
120
1.5-2bar 36psi As required
62. Teflon speed (+) – More compaction
Teflon speed (-) – Less compaction, G.S.M because overfeed is less.
64. 1. Shade Check: In delivery side operator checks the shade of fabric with
customer approved swatch.
2. With Check: Operator measures fabric width by using measuring tape
and compared with required width.
3. Wight Check: Operator checks the weight by using GSM cutter and
electronic bal-ance& compares with the required finished width.
4. Fault Check: As mentioned before
5. Design & Slanting: Operator checks design and slanting at delivery side.
6. Edge line checking: check two edges of fabric at delivery side.
