Robotics to rule textile & apparel manufacturing processes

12 Sep '15

7 min read

Jurgen Brockmann (Thies GmbH & Co KG)

Explaining the dyeing process in the automated plants designed by Thies, he said that the dye silos receive a signal from the control system. The instruction could be, dispense 30 grams each of red, yellow and blue dyes. On receiving the signal, the dyes are automatically weighed, dispensed into a container and transported to a dye dissolving station. Here, the dye is brought to required temperature, and then made to run into the dyeing machine at the correct time. Before dyeing, the product undergoes the bleaching process, where again automation is introduced for right quantity, time and temperature. It also applies to solids like salts and hydrosulfite for vat dyeing. This method has the potential to achieve high levels of colour authenticity.

A similar process holds for introducing liquor into the dyeing machines through their machine, Icone which uses optimised liquor ratio in the dyeing process. This means, less usage of water. This system has been further redesigned for more savings. It is equipped with additional functions such as the new Dynamic Rinsing System (for reducing process time by rinsing) and Dye Control (an optional function to measure bath saturation and to automatically adjust the rinsing times and the number of rinsing baths). These functions make the dyeing process economical, reliable and easy to monitor.

All upstream and downstream process steps are taken care of during the dyeing process. Robots pick up the bobbins with yarn, individually or in batches, and load them onto a self-propelled bobbin carrier for transport to a dyeing machine or a dryer. Lids on the dyeing machines need to open at the right time for this process to be carried out. After dyeing, unloading of the bobbin carrier is also automated, saving human interference at almost all the steps and saving human beings from hazardous chemical exposure. Brockmann explained that automation gives better results, impacting very tight profit margins in a positive way. In many state-of-the-art machine parks, work is done by robots.

As robotics and full-automation continue to become an integral part of textile manufacturing, the day is not far when human intervention in textile manufacturing will be reduced to nil. Better quality textiles and garments will be manufactured with the least cost. The plants will work by themselves and supervision will not be required at any stage. Mass markets will be dominated by robotics, not just in textile or apparel, but in many more manufacturing sectors.

Fibre2Fashion News Desk - India

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