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To Face International Crisis & the Competition Increase, Dye plants have to : Reduce theirs productions costs (water / times / dyestuff / chemicals) Be.

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Presentation on theme: "To Face International Crisis & the Competition Increase, Dye plants have to : Reduce theirs productions costs (water / times / dyestuff / chemicals) Be."— Presentation transcript:

1 To Face International Crisis & the Competition Increase, Dye plants have to : Reduce theirs productions costs (water / times / dyestuff / chemicals) Be Right First Time (to respect delivery time & improve productiveness) Improve the Quality of theirs productions (customers satisfaction) These aims cant be reach with Universal Process and with Blinds eyes ! « Lets break again the Dye Limits with Optilab » Why OPTILAB in Dye plant ?

2 2 Receipe from Laboratory STANDARD PROCESS REDYE & REDYE Unlevelling No Reproducibility Lower Quality & Expensive Production Cost No respect of Delivery time Receipe from Laboratory Optimized Process OPTILAB High Efficiency Of Production Dyeing Machines High Quality & Low Production Cost Without Possibility to see ? With Possibility to see RFT OPTILAB

3 Optimization Acrylic process LEACRYL 3,3 OPTILAB CALLEBAUT DE BLICQUY 31 de la Fonderie – BP 70160 – 59202 Tourcoing cedex (France) Tel. / Fax. : 0033 3 20 38 89 50 / 0033 3 20 38 89 70

4 Receipe and actual process Acrylic Receipe : Actual process : Yellow OR 200%0,05 % Red GRL 200%0,05 % Blue GRL 300%0,05 % Acetic Acid 1 cc/l Pérustol AMC (Anti-static) 1 cc/l Cellolube (softner) 1 cc/l OPTILAB Initial Temperature55°C Plate10 Min Heating104°C with 1°C/min Plate15 Min Cooling80°C

5 Exhaustion curves actual process Acrylic OPTILAB

6 Receipe and optimized process Acrylic Receipe : Optimized process : Yellow OR 200%0,05 % Red GRL 200%0,05 % Blue GRL 300%0,05 % Acetic Acid 1 cc/l Pérustol AMC (Anti-static) 1 cc/l Cellolube (Softner) 1 cc/l OPTILAB Initial Temperature55°C Plate10 Min Heating76°C with 3°C/min Heating85°C with 0,2°C/min Heating104°C with 2°C/min Plate15 Min Cooling80°C

7 Exhaustion curves optimised process Acrylic OPTILAB

8 BEFOREBEFORE AFTERAFTER

9 Before Optimization After Optimization Annuals Saving Re-dyeing13%3% Water16,1 L/Kg 14,7 L/Kg 507 m³/an COD12,3 Kg/T 9,5 Kg/T 760 Kg/an + Time saving : 32 min / process SAVING

10 Optimization Cotton process TENCEL OPTILAB CALLEBAUT DE BLICQUY 31 de la Fonderie – BP 70160 – 59202 Tourcoing cedex (France) Tel. / Fax. : 0033 3 20 38 89 50 / 0033 3 20 38 89 70

11 Receipe and actual process Cotton Receipe : Actual process : Yellow cibacrone F3R 1% Red cibacrone FNB 1% Blue cibacrone FR 1% Croscour WPD (mouillant) 1 cc/l Rapidoprint XRG (anti-réducteur) 1 g/l Anti-foam 0,3 cc/l Salt 80 g/l Soda Solvay 10 g/l OPTILAB 30 40°C 60°C dyestuffs1/103/106/101/103/106/10 Soda Solvaysalt 1°C/min 15 3015

12 Rinsing and Soaping OPTILAB T°CTime (min) Rinsing 140°C10 Rinsing 280°C10 Neutralization50°C5 Soaping 195°C15 Rinsing 380°C10 Soaping 2100°C15 Rinsing 440°C10 Rinsing 565°C10 Softness50°C5

13 Exhaustion curves actual process Cotton OPTILAB

14 Receipe and optimized process Cotton Receipe : Optimized process: Yellowcibacrone F3R 1% Red cibacrone FNB 1% Blue cibacrone FR 1% Croscour WPD (mouillant) 0,75 cc/l Rapidoprint XRG (anti-réducteur) 0,75 g/l Anti-foam 0,3 cc/l Salt 64 g/l Soda Solvay 10 g/l OPTILAB 30 40°C 60°C dyestuffs3/5010/5036/501/10 3/10 6/10 Soda Solvaysalt 1°C/min 15 1/50

15 Rinsing and Soaping OPTILAB T°CTemps (min) Rinsing 140°C10 Rinsing 280°C10 Neutralization50°C5 Soaping 195°C15 Rinsing 380°C10 Soaping 2100°C15 Rinsing 440°C10 Softness50°C5

16 Exhaustion curves optimized process Cotton OPTILAB

17 BEFOREBEFORE AFTERAFTER

18 Before Optimization After Optimization Annuals Saving Re-dyeing13%3% Water115 L/Kg 93 L/Kg 367 m³/an COD140,2 Kg/T 78,8 Kg/T 1 025,4 Kg/an + Saving in Chemicals (Auxiliaries Products) and Time ( 40 min / process ) SAVING

19 Optimization Polyester Process OPTILAB CALLEBAUT DE BLICQUY 31 de la Fonderie – BP 70160 – 59202 Tourcoing cedex (France) Tel. / Fax. : 0033 3 20 38 89 50 / 0033 3 20 38 89 70

20 Receipe and actual process PES Receipe : Actual Process : Yellow RD4GRL 0,031 % Red RD4GFL20 0,007 % Blue RDGL 0,007 % Dilatine (carrier) 3,75 ml/l Eganal EDP (levelling) 1,25 ml/l 102°C 60 20 ° C 96°C 1°C/min OPTILAB

21 Exhaustion curves actual process PES OPTILAB

22 Receipe and optimized process PES Receipe : Optimized process : Yellow RD4GRL 0,031 % Red RD4GFL20 0,007 % Blue RDGL 0,007 % Dilatine (carrier) 0 ml/l Eganal EDP (levelling) 0,625 ml/l 130°C 30 20 ° C 96°C 1°C/min 2°C/min 85°C OPTILAB

23 Exhaustion curves optimized process PES OPTILAB

24 BEFOREBEFORE AFTERAFTER

25 Auxiliaries products Annual quantity Unit costAnnual cost Dilatine480 Kg6,49 /Kg3 115,20 Eganal EDP180 Kg 4,22 /Kg 759,60 TOTAL660 Kg 3 874,80 Auxiliaries products Annual quantity Unit costAnnual cost Dilatine0 Kg6,49 /Kg0 Eganol EDP90 Kg 4,22 /Kg 379,80 TOTAL 90 Kg 379,80 Before Optimization After Optimization OPTILAB Saving Chemicals products Reduction cost of 90% in Chemicals products Time saving : 15 min / process

26 Optimization Polyamid process OPTILAB CALLEBAUT DE BLICQUY 31 de la Fonderie – BP 70160 – 59202 Tourcoing cedex (France) Tel. / Fax. : 0033 3 20 38 89 50 / 0033 3 20 38 89 70

27 Receipe and actual process PAM Receipe : Actual process : BrownCiba JNH 100% 0,03 % Grey Ciba NH 0,02 % Yellow Ciba 2GC 0,01 % Sandacid VS (acid donor) 2,5 ml/l Felosan R.G.N 0,312 ml/l OPTILAB 102°C 60 20 ° C 96°C 1°C/min

28 Exhaustion curves actual process PAM OPTILAB

29 Receipe and optimized process PAM Receipe : Optimized process : Brown Ciba JNH 100% 0,03 % Grey Ciba NH 0,02 % Yellow Ciba 2GC 0,01 % Soda Solvay 2,0 g/l Acetic acid 1,5 ml/l Felosan R.G.N 0,234 ml/l OPTILAB 102°C 30 96°C 1°C/min 2°C/min 80 ° C Dosing of acetic acid

30 Exhaustion curves optimized process PAM OPTILAB

31 BEFOREBEFORE AFTERAFTER

32 Before Optimization After Optimization Auxiliaries products Annual quantity Unit costAnnual cost Sandacid VS130 Kg7,05 /Kg916,50 Felosan RGN120 Kg 3,73 /Kg 447,60 TOTAL250 Kg 1 364,10 Auxiliaries products Annual quantity Unit costAnnual cost Carbonate396 Kg0,43 /Kg170,28 Acide acétique78 Kg0,48 /Kg37,44 Felosan RGN90 Kg 3,73 /Kg 335,70 TOTAL564 Kg 543,42 Saving Chemicals Products Reduction cost of 60% Chemicals products Time saving : 30 min / process


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