Since its formation in 2005, Colombia’s leading commission dye house, Tintatex SA has reduced its water consumption from 200 litres/kg to 50 litres/kg – whilst increasing its production capacity from 80 t to more than 460 t; relying on new dyeing equipment from Thies including eight iMaster H2O’s.
The newly formed company initially relied on an old second hand Chinese dyeing unit producing 80 t/month.
By 2006, with a restricted cash flow, the company was to purchase two new Chinese 150 kg capacity units.
“Whilst we were able to increase our production further with the new units they required long process times, high production costs and had high liquor ratios; nevertheless production was increased to 120 t – but at a cost.”
Within 12 months however, and based on his previous experience with Thies, Tintatex General Manager, Jairo Ernesto Correa Sanchez had ordered two 250 kg, twin chamber, Luft Roto Plus dyeing units.
“With the market place changing towards polyester and synthetic fabrics, the improvements were instant with shorter process times and reduced liquor ratios.
The Chinese models were considerably slower,” said Jairo Correa.
“Production increased to180 t/month and water consumption was reduced to 200 litres, unfortunately energy costs were still too high,” he added.
In 2009 however, everything changed with the delivery of two 250 kg capacity, Thies Eco Masters; replacing the original Chinese unit.
According to Jairo Corrrea, production costs were dramatically reduced with lower energy consumption, less steam and reduced chemicals. Water consumption was reduced to 120 litres/kg and production increased to 250 t/month.
In 2011 the company had ordered its first two, newly introduced, iMaster H2O dyeing units and, on delivery, Jairo Correa promptly ordered another two units.
Since then, Tintatex has ordered a further two 250 kg capacity units for delivery in February 2013 and, with another two 100 kg capacity units on order, both Chinese models will be resold; making Tintatex a 100% Thies dyehouse.
Water consumption has been dramatically reduced to 50 litres/kg and production capacity is expected to reach 460 t/month.
The significant reduction of water consumption together with a decrease in the consumption of chemicals, dyestuff and energy has been an added focus for the iMaster H2O.
“In practise it is possible to work comfortably with a liquor ratio of 1:4 or less,” said local dealer, Arjar’s, José Mario Rodriguez.
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