Jayanta Sanyal
Head of Technical Sales and Processes Weko
Next step is integrating RotaSpray GmbH into Weko holding group
Since 1953, Weko has been developing and producing non-contact application systems for product optimisation and surface finishing with different types of fluids and powdery substances. Jayanta Sanyal, Head of Technical Sales and Processes, Weko, speaks about its range of textile products and their applications, the key differentiating factors between Weko and other manufacturers, and the products line up for DTG Online Expo 2021.
What are the major products of Weko for the textile industry and what are their applications like?
Since 1953 Weko has been developing and producing non-contact application systems for product optimisation and surface finishing with different types of fluids and powdery substances. In textile industry our focus is on the Weko-Fluid-Application (WFA) systems for functional finishing, dyeing and moisture management. This rotary spray technology invented by Weko enables the lowest possible, exact and replicable use of the respective spray liquid. This solution gives our customers a more environmentally friendly industrial production, which is an absolute must today.
Textile industry is very large and diverse. Not only there are fashionable garments and denim, there is also workwear, home textiles, terry towels and the big segment of technical textiles. Therefore, Weko offers different types of rotor carriers with diverse options to better meet the individual demands like Weko-Sigma, Weko-ProTec or Weko-Neo. Additionally, the users can choose the right supply unit for the rotor carrier from our portfolio with the help of our sales team.
Weko took over RotaSpray GmbH from Germany – also a specialist in yarn and fabric dyeing or finishing. Their RotoDyer and RotoDyer-Twin solutions are market proven and have some additional textile specific functions. This acquisition improves our know-how and strengthens our position to change the textile industry in a more sustainable one.
What are the major sustainable practices you comply with throughout the manufacturing process?
In Germany we still have very high standards which we must follow. Industrial wastewater is separated, and the trash separation is standardised. Chemical waste is expensive and therefore everything is controlled to create as less as possible. But additionally, our manufacturing units are equipped with solar roof modules and our car fleet includes electric cars for shorter distances up to 100 km one way. Weko also offers its employees sponsored electrical bicycles instead of using their car for daily way to work.
What new innovations and technologies do you plan to invest in near future?
The next step is integrating RotaSpray GmbH into Weko holding group and combining the best out of both products. After that we will focus on developing new dyeing processes together with chemical and other machinery partners as the conventional ones are not sustainable enough to meet today’s demand.
What differentiates your textile products from other manufacturers?
In conventional textile processing, liquid is applied on textile material by padding method where the material is in contact with the liquid. This contaminates the liquid and stresses the material by heavy squeezing. Also the pick-up is very high and single side use is impossible. Our technology is non-contact application of liquid. The liquid stays clean and lot change is fast. The application amount can be set easily, but very precisely in 0,1ml/m² steps and is kept constant over the full width. Also, Weko units can work in wide viscosity range from 1–100 mPa*s and with resins, microcapsules, binder-systems and many more. This underlines the high flexibility of our systems.
How does your non-contact rotor system for precise, metered application of liquids and chemicals to fabrics work actually? How can it be integrated in existing systems?
The user only has to set the target application amount in ml/m² or in per cent of fabric weight (gsm) on the touch panel. That`s it. Our software does the rest. Weko needs only a correct speed signal from the machine or customer could use the Weko-DigiTacho.
In line with the actual machine speed, the Weko control calculates the needed fluid amount and drives the frequency-controlled pump. A flow meter re-checks if the pump output is in line with the target and readjusts the pump if needed. The correct amount goes to the rotor carrier. The fluid is filtered after the tank output and before coming back to the Weko tank. This gives additional security to the operator.
Our system can be easily integrated in new or existing lines. Depending on requirement, our system can be incorporated in sanforising machine, in inlet or outlet of stenters, in the inlet of festoon steamers, in pad – steam - washing range, in denim slasher / loop dyeing, in CDR etc. The system can be installed on the floor at about 1.5 metres height or over a frame above the padder.
What products are lined up for display in DTG Online Expo 2021?
In DTG Online Expo we will show our different rotor carriers like Weko-Sigma, Weko-ProTec and Weko–Neo and different supply units like Flow C, Flow T, Basic flow etc. These are manufactured as per specific application requirement. We are focusing on the benefits of Weko application system over the conventional ones not only in the creation of fashion effect, but also to achieve the sustainability goal of the manufacturers.
How was your industry affected by the pandemic? What were the major problems faced?
Weko itself was affected, but not so strongly as we also serve the nonwovens and the tissue industry, and these segments are booming during the pandemic. But textile was 80 per cent down for us and now coming back to normal as the main buying markets start to re-open. We used the time to finalise our deal with RotaSpray and analyse our future textile strategy.
Nowadays we see some issues on the pre supplier market as some raw materials are scarcely available and prices have gone up a lot. Order books were refilled, and our task is to deliver our products in time.
What are your major markets application-wise and geographically?
With non-contact surface finishing Weko is serving various industries like textile, nonwovens, paper, plastic film, tissue, wood fibreboard, offset printing, gravure or flexo printing and digital printing. We also deliver our applicator in sandpaper industry and some metal industry.
For textile, our strongest markets beside Europe is India and Turkey. For 2022 we will also focus on Pakistan and Bangladesh markets to raise our market share in these important textile countries. Both have a big need to save fresh water and decrease their energy use.
Weko has global service and sales structure offices in Germany, Brazil, UK, US and Italy as well as a professional network of distributors. Beside Germany, a manufacturing unit in Brazil serves specifically the South American market.
What changes have you made to your overall operations to tide over the global crisis?
Not many changes were made as we had action plans in place for this type of situation. The biggest learning was to meet people online instead of in real life more frequently than before. This opened up new opportunities. But we are also missing the direct contact with people. Weko started to participate in online exhibitions very early. The first was in May 2020 for composites and nonwovens and we had good contacts. We also joined the famous Fibre2fashion sourcing exhibition and we really appreciated how it was set up. We got a lot of visits on our virtual booth.
What change in customer behaviour do you notice and how are you geared up for the same?
Indeed, we have observed change in customer behavior mainly in Asian textile market. Customers are more conservative about new investments. They are following the concept of wait and watch.
Heavily shrinked cash flow, low order intake due to long lasting lockdown and very slow market are the main reasons for this.
To sustain during the crisis time, potential savings in manufacturing process is extremely important. Weko wants to support the manufacturers with its unique concept of minimum application that helps the process houses to save fresh and wastewater, dyes, chemicals and auxiliaries, drying energy, yarns and fabrics etc.
What are your future expansion plans?
Our expansion plans are to focus on the nonwovens and textile segment in which we see a big chance for growth for Weko group. But we are open to discuss other opportunities also.
Published on: 04/08/2021
DISCLAIMER: All views and opinions expressed in this column are solely of the interviewee, and they do not reflect in any way the opinion of Fibre2Fashion.com.
