INDIGOROPE “GENIUS/C”, highly popular denim dyeing machine
INDIGOROPE “GENIUS/C”, the popular warp rope dyeing system for denim fabric from MASTER S.r.l. of Italy, is considered to be the most classic processing method, representing the most widely used one in the world. It has been used for over a hundred years and has never been subject to substantial technical changes, either technical or architectural.
For two customers that are among the most qualified world denim producers, MASTER has built its first rope dyeing machines. These machines are to be clearly distinguished from the classical ones not only because they are totally automated and monitored, but also because they present a series of technical changes which had been previously tested on the company’s INDIGOFLOW, the most complete and versatile slasher machine still remaining unrivalled.
In particular, the technical upgrades were the introduction of the front-to-front circulating bath; strengthening of its recycles per hour; use of squeezing pads with equipressure rolls; radical reduction of the oxidiser laps length with the use of big diameter rollers; positioning on the ground of all the colour kitchen tanks; completion of the rollers driers with side guards and suction hoods so as to keep the working environment healthy; addition of a series of safety devices for the operators, the supply of the machines and colour kitchens already complete with all the stainless steel hydraulic plant design; and the addition of a third upper gangway to guarantee the necessary ergonomics for intervention in case of cleaning and maintenance.
Besides, MASTER is today able to transfer on its INDIGOROPE and even on the already existing ropedyeing the new ecological and economical advanced technology of indigo and sulphur dyestuff dyeing. This kind of dyeing has been widely tested on its dyeing slasher machines, particularly the INDIGOGENIUS which today represents the most advanced machine in the world. This ingenious technology, purely based on ecological and economical parameters, allows cut by half the number of dyeing vats which are substituted by as many GENIUS/C (pat.) modules.
GENIUS/C (pat.) is an integrated dyeing module made up of a combination of a dyeing vat with a special group of dyestuff diffusion/fixation at soluble condition (leuco) in the yarn adjustable through heat activation and timing variation in inert environment.
Thanks to the GENIUS/C (pat.) modules, the indigo and sulphur dyestuffs dyeing technology plays an important role in terms of high technology and ecology.
In the GENIUS/C (pat.) modules the indigo chemical reduction is really total and perfect: the dyeing leuco ability makes one think of a particular particles disintegration at nanometric level, which puts the dyeing bath in condition to penetrate and fix itself onto the fibre in a much better way compared to the traditional system. In some cases, this also allows elimination of the fixing agent even though there is a higher concentration of dyestuff in the bath, meaning that the dyeing quality is therefore better.
Moreover, during the dyeing process of sulphur dyestuffs, the sulphur black in particular, we can see a better colour output which can be visually evaluated at around 40 per cent with an obviously higher fixing grade if compared to the dyeing process by traditional machines.
Basically if compared to the classical indigo dyeing method, common to all traditional machines and which foresees three operating steps repeated several times – yarn soaking with dyestuff, squeezing to eliminate the bath excess contained into the yarn itself and leuco oxidation by yarn staying at air – GENIUS/C adds a fourth operating step and that is the hot leuco diffusion/fixation for a long timing in inert environment where yarn immersion and yarn squeezing take place simultaneously.
Thus is born MASTER’s new INDIGOROPE “GENIUS/C” (pat.) a machine that, besides the traditional dyeing process, also allows other special dyeing methods that can be achieved in an exclusive way, thanks to the possibility to combine in different ways the physical/chemical characteristics of the dyeing bath with the mechanical/technical versatility the machine can provide. This interaction is very important and can lead to such results as achievement of dyeing with particular effects to launch new products that are original and cannot be created with traditional machines.
Therefore the new INDIGOROPE “GENIUS/C” (pat.) not only represents the right answer to a constantly changing trend, but also to the problems of ecology and environment, aiding efforts towards “green” products. This machine also represents the right solution to realize these products at considerably lower prices.
INDIGOROPE “GENIUS/C” (pat.) has already established itself as the dyeing machine for the ecological denim of the future.
* The dyeing process independent of external factors
* Better indigo and sulphur dyestuffs penetration, diffusion and fixing to the fibre
* Higher dyeing output (with sulphur dyestuffs, about 40 per cent)
* Use of just four or more dyeing vats
* Dyeing baths volume reduction
* Reduction (about 50 per cent) in soda and hydrosulphite consumption
* Reduction in washing water consumption
* No nitrogen consumption when the machine is in operation
* Drastic sulphites and sulphates reduction in the sewing waters
* Operative flexibility enhances the possibility to operate with indigo at high concentration and even at high temperature, and that is “green dyeing” for the denim of the future.