BEN-WASH Solubilizing. Diffusion. Dilution

BEN-WASH Solubilizing. Diffusion. Dilution.

2

Minimal fresh water consumption leads to saving in water, effluent andenergy costsCapital investment and operating costs

determine the economy of washing

machines. The water consumption for a

defined washing effect is depending on

the type and number of washing

compartments. Our palette of compart-

ment types permits a machine configura-

tion that is as flexible as it is economical.

The right machine combination for every requirementThe diversity of washing compartments

available and the modular design provide

the means for every industrial textile

washing need. By correct selection of

type and number of washing compart -

ments, the plant layout is adapted to any

customer requirement.

The EXTRACTA principle divides the

washing process into stages that can be

repeated with accuracy. Besides making

the whole process easier to follow it also

makes it amenable to calculation. In each

of the sepa rate washing chambers the

dirt or chemical liquor present in the cloth

is exchanged 50 to 80% for wash liquor,

which is loaded commensurately with dirt

and chemicals. Entrainment of the conta-

m inated liquor with this cloth is prevented

by the EXTRACTA roller. In the next

chamber the liquor ex change is repeated

but with much lower dirt concentration in

the wash liquor. Together with the known

freshwater throughput, this predictable

action provides the basis for calculating a

washing oper ation in advance.

The EXTRACTA principle:High washing efficiency with low water usage

BEN-WASH

3

A crease-free fabric run is guaranteed■ Large guide roll diameters and adapted

roll spacing that prevent the fabric from

skewing and guarantee crease-free

treatment from entry to exit of the range

■ Computer controlled tension force

from 100–500 N with press rolls or,

200–600 N without press rolls

■ Screw expanders with separate drive

■ Free running outer bearings with mini-

mal friction

■ on bath rollsSelf-aligning ball-bearings, life-time

lubricated, with carbon sliding ring

seals;

■ on upper rollsSelf-aligning ball-bearings; life-time

lubricated, with PTFE labyrinth seals;

■ on press rollsSelf-aligning roller-bearings; life-time

lubricated, with PTFE labyrinth seals.

Drive control via swivelingcompensators and load cellsIntermediate squeezers (pulling/squeez -

ing device) are controlled via swiveling

compensator and frequency converter

in the next compartment. The upper roll

single drive is controlled with a separate

frequency converter; in compartments

followed by a pulling/squeezing device

via a measuring roll with a load cell;

in compartments without subsequent

pulling/squeezing device via the swive -

ling compensator of the following com-

partment.

With Benninger, crease-free operation is a matter of fact

Angle detector of Swiveling compensator for drive

control

Load cell

4

Energy saving starts in the washing compartments

These high-performance, double loop

washing compartments with rubber coa -

ted press rolls, especially recommended

for medium to heavy fabric, achieve a

max imum washing effect.

In each washing chamber, the fabric is

immersed twice in the washing liquor

which is then pressed through the fabric

in the nip pools between roll and fabric.

The intensive liquor exchange in the fab-

ric is supported by the cross flow in the

chambers.

The single driven upper rolls with press

rolls (EXTRACTA squeezers) are a fully

fledged drive. Thus no other additional

drive in the form of an intermediate

squeezer is needed, as is the case with

sliding clutch and relax drives.

No steam escapes from the steamtightEXTRACTA washing compartmentseven at high temperature. The steamsealing of the entire washing range leads to a better washing effect, andenergy consumption is distinctly reduced.

DA 3 Fabric content 13 m

DA 7Fabric content 32 m

DA 3C Fabric content 15 m

DA 5Fabric content 23 m

DA 5C Fabric content 25 m

DA 7CFabric content 34 m

High-efficiency washing compartments DA C without intermediate squeezer

High-efficiency washing compartments DA with intermediate squeezer

Good accessibility to the washing

compartments, covers can be lifted easily

BEN-WASH

5

The variety of compartments gives you flexibility

The EA high-performance washing com-

partments use the same principle as the

DA compartments, with press rolls

(EXTRACTA squeezer) and individually

driven upper rolls.

Washing compartments with 3-, 5 or 7

chambers with single loop, upper roll drive

and press rolls for best liquor separation.

Single loop provides better accessibility

to the cloth and easier handling. As only

one immersion per chamber is possible,

the washing effect with the same amount

of water (per cloth weight) is lower than

with double loop. This effect is compen-

sated for by the greater number of wash-

ing chambers per compartment. The

residence time in the EA washing

compartments is, however, lower than

with double loop.

High-efficiency washing compartments EA with intermediate squeezer

High-efficiency washing compartments EA C without intermediate squeezer

EA 5Fabric content 15 m


EA 5CFabric content 15 m

EA 7CFabric content 9 m

EA 7C Fabric content 20 m


6

No rubber coated press rolls The advantage of this model lies in the

low maintenance costs, as these com -

partments have no rubber coated press

rolls (EXTRACTA squeezers).

Optional single drivesFor tension sensitive styles, upper roll

single drives are available as an option,

whereby the number of drives is freely

selectable.

The plain wash compartments with strip-

per roll for liquor separation are used with

individual drive for open and lightweight

cloths with single liquor separation.

Liquor exchange and washing efficiency

are much lower for reduction washing

than with the EXTRACTA roll system.

Washing compartments E C without intermediate squeezer

Washing compartments E with intermediate squeezer

E 3 Fabric content 9 m

E 5Fabric content 15 m

E 7Fabric content 20 m

E 3C Fabric content 9 m



The plain wash compartments with stripper roll

EXTRACTA

7

EXTRACTA compartments enable most economical washing

Reaction compartments D with intermediate squeezer

Reaction compartments D C without intermediate squeezer

This disadvantage can be compensated

only by making the machine longer or

using more water.

The high-performance ‘D’ wash compart-

ments follow the principle of the ‘E’ com-

partments.

‘D’ compartments are used mainly for

post-dye washing, where good diffusion

and long reaction time are demanded.

D 3Fabric content 13 m

D 5 Fabric content 23 m

D 7Fabric content 32 m

D 3C Fabric content 15 m

D 5C Fabric content 25 m

D 7CFabric content 34 m

Profit from these advantages■ Flexible machine layout due to the

variety of models and the modular

design

■ Operationally reliable and functional

design

■ Calculable washing effect

■ Controlled reproducible results

■ Closed steamtight machine

■ Best possible washing effect

■ Compartments with two separate

sections

■ Low water and power consumption

■ Only single drives applied

■ Constant fabric tension

■ Crease-free operation

10

High-performance washer for surface contamination

The FORTRACTA prewasher is a further

development of the proven Benninger gap

technique for washing-out contamination.

The cloth web is led upwards in two ducts.

The wash liquor flows down by gravity

simi lar to a waterfall. A strong washing

action is obtained by this counterflow prin-

ciple in the duct. Liquor separation is

effected by stripper rolls and flat jet nozzles

at the exit from the FORTRACTA compart-

ment.

Since the fabric carries large amounts of

chemicals especially at the beginning of

the wash, rubberized rolls are not provi -

ded in this compartment. The short dis-

tances be tween rollers and the large roll

diameters assure creaseless cloth

running.

FORTRACTA

11

With the classical roller vat washingprocess where the fabric is movedthrough stationary liquor with only shortreaction times, costs can hardly bereduced. In this process high mo lecularweight substances are fully swelled andas con sequence lead to an increase inviscosity, conglutination and therefore ahigh water con sumption.

The Benninger patented concept on the

other hand, is based on a significantly

lower water and steam consumption and

minimum use of chemicals. As opposed

to conven tional methods, comparable

results are better and achieved substan-

tially quicker.

A quite natural washing processThe fabric passes through a narrow cas-

ing divided into two shafts. Steam and

water are directed onto both sides of the

fabric, either individually or in any desired

combi nation. Due to the slot and shaft

geometry high flow speeds are caused

which create a high kinetic energy.

According to the process used, operation

can be with counter-flow water only from

the following washing compartment and a

liquor circulation system. The INJECTA

offers numerous process variations and

thus a high degree of flexibility in styles.

Through the shock heating of the wet

fabric to 100°C in the INJECTA the high

molecular weight substances swell up

im mediately, with a simultaneous reduc-

tion in viscosity through the effect of the

high kinetic energy. This means that they

are removed with a significantly smaller

quantity of water.

BEN-CONTROL Speak with data

Economics determine the washing procedure

12

Rationalized removal of high molecular weight substances

To facilitate infeeding the fabric the shafts can

be opened

The INJECTA makes the single-stage BEN-BLEACH concept feasible: In one single step! – from greige to finished, dry fabric.

Optimized desizingThe size is removed to the extent that sub-

sequent processes can be carried out in

the best possible manner and without diffi-

culty. Water-soluble sizes such as PVA,

PAC, PES and CMC, and also unmodified,

water-inso l uble starch sizes are removed

with a very high removal rate and low

water application of 3–5 l/kg. 100% syn -

thetic fabrics can also be successfully

desized in this manner. Airbag fabrics are

cleaned to the required residual content

of < 0.5% by the INJECTA.

Do you wish to wash out conventional size

and printing thickeners, that is, high mole -

c ular weight and adhesive substances with

a high swelling capability? Or must PVA,

PES sizes, spinning or spooling oils be

removed from synthetic fabrics? You can

solve all your critical tasks with the new

INJECTA washing system.

INJECTA

13

Clean washing is a matter of superior technology

Profit from INJECTA advantages■ Significantly lower water and steam

consumption

■ Highly concentrated effluents provide

ideal conditions for partial flow dis -

posal or size recycling

■ The washing effect of a single

INJECTA compares to that of a

multi-chamber high-performance

full-width washing machine

■ Printing after treatment is no problem

with no danger of staining the ground

■ Continuous desizing of

water-insoluble starch sizes

14

Low-tension open-width treatment

Benninger, the leading manufacturer ofroller vat washing machines, is alsoyour best advisor for drum washingmachines.

The TRIKOFLEX system, ensuring low

tension treatment of knitted, pile and

woven fabrics, has set new standards in

textile finishing.

Incorporating a range of system improve-

ments, Benninger has found the best way

to meet increased market requirements.

The TRIKOFLEX LT-DB in a few words

■ Flexibility due to modular concept

■ Box design with excellent torsion and

floor stability

■ No transmission drives nor friction

clutches; only single motor drives

■ Separate intermediate squeezer

■ Connectable with EXTRACTA

compartments

■ Excellent accessibility to the squeezers

and compartments for cleaning/

maintenance

■ The entire machine is steamtight

■ Optimum shrinking results ensured by

single motor drives

■ Two side washing, specially important

for dense fabric

■ Large guide roll diameter and proper

spacing ensure crease-free operation

■ Liquor separation due to two circulating

systems

■ Counter-flow by gravity possible over

the whole washing range

■ Spray pipes adjustable from the outside

■ Functional, modern design

■ Level of automation as required

TRIKOFLEX

15

For mono- and bi-elastic woven goods

Result:The new Benninger TRIKOFLEX genera-

tion enables the finisher to treat the entire

range from mono- and bielastic, as well

as crease sensitive woven fabrics without

problems and at low tension. This con -

cept also offers savings on water and

energy.

16

with reaction zone

1 liquor circulation

Cloth content 12 m

with reaction zone for neutralisation

2 liquor circulations

Cloth content 12 m

Flexibility in the structure

with intermediate squeezer


Cloth content 8 m

with intermediate squeezer

2 liquor circulations

Cloth content 8 m

without intermediate squeezer


Cloth content 7 m

without intermediate squeezer


Cloth content 7 m

Taylor made conceptsDepending on the fabric and the process,

the modular build system TRIKOFLEX

can be delivered in various versions.

■ LT-DB with one liquor circulation

with 60 m3/h

■ LT-DB 2 with two liquor circulations

with 2 x 30 m3/h

■ LT-DB with intermediate squeezer

■ LT-DB C without intermediate squeezer

■ Direct steam heating, or indirect hea-

ting with heat exchanger

■ Mechanical, or automatic self-cleaning

filters

■ Various drive systems

TRIKOFLEX

TRIKOFLEX LT-DB 2 TRIKOFLEX LT-DB C2 TRIKOFLEX LT-DB 2/2-R

TRIKOFLEX LT-DB TRIKOFLEX LT-DB C TRIKOFLEX LT-DB C-R

17

Grooved drum

The heart of the TRIKOFLEX washing

system is the grooved drum with a com -

bination of grooved profile and mesh

covering.

It serves as a supporting element for the

fabric. The large surface of the drum

ensures smooth and low-tension fabric

passage over a long contact path. The

enclosed design prevents impurities from

entering the drum.

Further features:

■ Minimum deflection points

■ Short fabric path in the area of the

drum, trough and compensating roll

■ Large roll diameter

■ Low tension fabric transport through

controlled single motor drives

4 spray pipes are arranged around the

grooved drum and integrated into the cir-

culating system. These ensure the ex -

tremely high washing efficiency at great

circulating capacities.

The drum surface forms the groove pro-

file with a mesh covering. As the fabric

passes through the spray section, it is

supported by the drum surface and is

thus unable to avoid the hydrodynamic

water pressure.

The result:The washing liquor penetrates the fabric

and forms a liquor film on the front and

back side. In this way, impurities on both

sides are quickly removed. At the same

time a cleaning effect within the mesh is

created. The washing effect, compared

to standard mesh and screen drum sys -

tems, is considerably increased.

Drawing of the active washing principle with grooved drum1 Closed drum body

2 Groove profile

3 Mesh belt

4 Fabric

5 Outer liquor film

6 Spray pipe

Spray batteryThe spray battery with adjustable spray

angle is decisive for the optimum wash-

ing effect, in addition to the grooved

drum. The washing liquor is constantly

circulated through the spray pipes within

the compartment by means of a pump.

This produces a cross-flow and a heavy-

flowing liquor film on both sides of the

fabric. This ensures optimum mass trans -

fer and re moval of the substances being

washed off.

18

Maximum washing efficiency through circulation and counter-flow

A meandering liquor guidance principle,

similar to that found in vertical washing

machines, has been used for the first

time in the TRIKOFLEX drum washing

machine. The liquor guidance, in con -

junction with the spray line mecha nism,

results in the high washing effect of the

basic LT-DB model.

Compared to the LT-DB, the washing

effect of the TRIKOFLEX LT-DB 2 is in -

creased by the addition of a second,

independent circulation flow and bath

separation.

This bath separation allows the tempe -

ra ture of the liquor to be varied within

the drum washing compartment. This

is espe cially important for even fabric

shrinkage.

The washing effect of the TRIKOFLEX

washing machine has been tested under

production conditions. Results show a

40% increase in the washing effect at -

tributable to bath separation and second

circulation flow.

TRIKOFLEX LT-DB 2 with two liquor

circulations and bath separation

TRIKOFLEX drum washing machine comparison, one (LT-DB), two circulation system (LT-DB 2) and EXTRACTA (DA 4)

Number of chambers

Co/LY 97/3%

Twill 2/1 - 240 g/m2

V = 40 m/min

T = 95°C

Water: 4 l/kg

TRIKOFLEX

19

Shrinking with lowest fabric tension

Continuous shrinking, desizing and washing of Filaments (PA 6.6, PET, PTT, PBT, PP)

Multi-flexible pre-treatment and washing range for tension-sensitive fabrics

Use of the TRIKOFLEX drum washingmachine is called for when fibre mate-rials show a high shrinking potential orif an increased risk of creasing existsin a roller vat.

Shrinkage occurs at the first contact with

hot water. The rate and degree of shrink-

ing is dependent on the temperature.

Dimensional changes (length/width) in the

fabric must not be inhibited during this

stage of processing.

The TRIKOFLEX makes processing at

different temperatures possible within a

washing compartment. The advantage

is that a slow and even shrinking can be

attained across the entire width of the

fabric.

The drive technology plays an equally

important role in achieving an optimal

result. TRIKOFLEX drums are controlled

by rotary magnet motors, or tension

control (load cells).

Should longer washing and dwelling

times be necessary the TRIKOFLEX can

be complemented with the EXTRACTA

roller vat washing compartments. Larger

fabric contents lead to longer diffusion

times. A high degree of washing efficien-

cy is guaranteed by separating the liquor

in different chambers.

Washing after

Vat-printing

Rinsing Oxidation Soaping Washing, Neutralizing, Rinsing

Washing, Neutralizing, Rinsing





Reductive cleaning

Impregnation, Caustification

Impregnation, Bleaching

Rinsing

Rinsing

Rinsing

Rinsing

Washing after

Disperse-printing

Washing after

Reactive CPB, Dyeing

Cold/Hot, Caustification

Of Viscose

Washing after, CPB-

Bleach + Shock-bleaching

Washing after

CPB-Bleach

20

Diffusion washing processesWashing in spray and reaction aggregates

Efficient washing is of centralimportance during textile finishing andis defined by the factors mechanicalaction, time, temperature and water.

Depending on the washing task the

weighting of the individual factors varies.

Often the term washing is only associa -

ted with dilution washing whose success

essentially depends on the water tempe -

rature and mechanical washing action.

On the other hand, reaction processes

require a specific amount of time for the

chemical reactions to take place. The

fastness wash for obtain ing wear-, wash-,

or water fastness falls under the term

diffusion wash. Objective of this washing

process is to bring the unfixed residual

dye in the core of the fibres to the fabric

surface and to remove it. Here time and

temperature are key factors.

REACTA

21

Dilution wash

caustic soda, salts, H2O2,

emulsified oils

Fastness wash (diffusion

wash) reactive dye, etc.

Reaction processes

demineralisation, oxidation,

neutralisation, emulsification

Time

Mechanical washing action

Fresh water

Weighting of the factors that affect textile washing processes

Machinery-related requirements andequipment for the diffusion wash

Diffusion washing processes cannot be

undertaken satisfactorily using common

washing systems; the investment

required is also excessive.

The fabric content is not sufficient, to

perform a soaping process for 2-8 mi -

nutes. Time-consuming washing pro -

cesses can be performed significantly

better in dwelling compartments.

For diffusion washing and reaction

processes Benninger relies on roller bed

dwelling compartments with additional

spraying areas. The washing principle

applied by Benninger is based on the

principle of seeping wash, where liquor

is applied to the textile substrate and

slowly seeps through the fabric.

Unlike storage racks, accumulator belts

or chains, the roller bed used by

Benninger has the major advantage that

the pile of fabric is continuously in motion

and is passed from roller to roller. The re -

lative motion within the individual fibres

and threads improves the penetration of

the capillary spaces by the seeping water.

Temperature

22

5

4

3

2

1

1 2 3 4 5

Economic water removal with Vacuum Systems

The Hydrovac vacuum technologyis applied in situations where an efficient

bath separation is required. Simultaneous

to the extraction of water, lint, emulsified

and dispersed contaminants, hydrolysed

dyestuff and sizing agents are removed.

At the same time, the possibility exists to

separate this polluted liquor from the

process water. The fresh water consump-

tion is considerably reduced due to the

increased degree of concentration that

develops during the ensuing washing

processes. Partial disposal of this highly

polluted liquor can reduce waste water

contamination (COD) considerably.

SeparatorThe cyclone separator with pre-separa-

tor and the newly developed air flow

system guarantee optimum separation.

HYDROVAC

Suction tubePre-separatorWater separatorDiaphragm pumpRotary pump

23

The advantages at a glance:

■ Partial flow recycling is achieved

by separating the concentrated

polluted liquor

■ Removal of contaminated liquor

from the process water enables

increased washing efficiency

■ Emulsified and dispersed

contaminants are removed

■ Especially suited to remove

printing thickener and size

■ High dewatering values particularly

for synthetic fabrics

■ Possibility for size recovery

Increased washing efficiency and simultaneously reduced impact on the environment

Suction tubeThe conical construction prevents the

accumulation of contaminant residues.

The fabric is exposed to practically no

friction at all as it passes over the slot

opening, which is adjustable and easily

accessible from above.

Rotary pump blowerThe so-called ‘Roots’ pump is the most

economic and efficient vacuum system

available.

Air controlA secondary air adjustment valve is

utilised to control the system (a frequen-

cy converter is used in some cases).

Blower aggregateThe noise reduction hood offers easy

access to the blower aggregate and its

various components, e.g. the suction

silencer.

Acetate

Acetate Filament

Cotton

Lyocel/Tencell

Polyacryl

Polyamide Filament

Polyamide Staplefibre

Polyester Filament

Polyester Staplefibre

Polyester/Cotton

Polyester/Viscose 65/35

Polyester/Wool 55/45

Viscose Filament

Viscose Staplefibre

Wool

The efficiency of a vacuum system is contingent

upon the type of fibre and construction.

The table below shows average rates of residual

moisture achievable.

You can feel it’s Benninger

The Swiss company Benninger has been the textile industrys leading partner across the globe for one hundred and fifty years with global branches and service representatives. Benninger develops and manufactures textile finishingand cord production ranges as well as providing complete system solutions. As the market leader Benninger will continue to rely on its comprehensive process know-how in order to be able to offer high-quality installations withexcellent customer service.

Benninger AG9240 Uzwil, Switzerland

T +41 71 955 85 85

F +41 71 955 87 47

[email protected]

www.benningergroup.com

Benninger Zell GmbHSchopfheimerstrasse 89

79669 Zell i.W., Germany

T +49 7625 131 0

F +49 7625 131 298

[email protected]

Benninger ZittauKüsters Textile GmbH

Gerhart-Hauptmann-Strasse 15

02763 Zittau, Germany

T +49 3583 83 0

F +49 3583 83 303

[email protected]

Benninger AGMoscow Office

Leningradsky pr-t 72

Bld. 4, Office 802

125315 Moscow, Russia

T +7 495 721 18 99

F +7 495 721 30 84

[email protected]

Benninger India Ltd.415/416 & 417

Sunshine Plaza

Dadar (East)

Mumbai 400 014, India

T +91 22 4322 7600

F +91 22 4322 7601

[email protected]

Benninger Textile Machinery Co. Ltd.Room 904, Tower A

City Center of Shanghai

100 Zun Yi Road

Shanghai 200051, P.R. China

T +86 21 6237 1908

F +86 21 6237 1909

[email protected]

Locations

Head officeUzwil, Switzerland

SubsidiariesMumbai, India

Shanghai, China

Zell, Germany

Zittau, Germany

Representative officeMoscow, Russia

Documents

BEN-WASH Solubilizing. Diffusion. Dilution