Fong’s National Engineering

Fong's Industries Co., Ltd. shall display their most advanced products and technology at Hall E1, Booth no.A05. 

JUMBOFLOW and JUMBOFLOW-SUPER: High Temperature Dyeing Machines

The latest JUMBOFLOW - high temperature dyeing machines are suitable for the processing of light to heavy weight fabrics. The main features are:

v     Total dyeing time is shorter which leads to substantial machine output and energy savings;

v     VL Variable Loading storage chamber design gives extra capacity to carry loading up to 280 kg per tube;

v     Multi Saving Rinsing System (MSR) shortens the dye cycle and reduces the water consumption;

v     Extremely efficient TIT Heat Exchanger gives the highest heating rate with minimum heat loss to the environment;

v     Advanced Intelligent Rinsing System Plus (AIR+) controls the rinsing water consumption and shortens the rinsing process; and

v     Highly optimized machine structure enables the machine running at the lowest liquor ratio of 1:4.5.

There are two models of machine are available:

ECO-88D: High Temperature Dyeing Machine

ECO-88D is high temperature dyeing machine suitable for the processing of light to medium weight fabrics made from synthetic fiber. Fabric structure suitable for the dyeing process inside the ECO-88D includes woven, warp knit and knitted goods made from lycra, nylon, rayon, polyester, etc.

ECO-88D has two storage compartments inside the machine tube. The maximum loading capacity of each tube is approx. 330 kg*, or each storage compartment has a maximum capacity of approximately 165 kg*.

The storage compartments are independent of each other whereas the liquor is common to each other. Each storage compartment has its own fabric conveyance tube which is arranged inside the machine tube. There is no heat loss by the conveyance tube thereby the liquor temperature inside is maintained at the same temperature as the liquor inside the storage chamber. The dispersion of dyestuff is thus improved.

The fabric travels through an LN nozzle which facilitates the smooth running of the fabric inside the conveyance tube and exits to the back of the storage chamber at the rear of the machine. The fabric is then supported by a Hydroski system which is an array of PTFE line bars submersed under the liquor. The smooth forward movement of the fabric from the rear to the front part of the storage compartment is thereby ensured.

Along the machine tube, there are specially designed CU spray nozzles. By turning on the CU spray nozzle, a thin liquor film runs along the wall of the vessel forming a lubricating layer which helps reducing the friction between the fabric and the metal surface.

This prevents the fabric from direct contact with dry metal surface thereby eliminates the formation of white spot on the fabric surface. The liquor sprayed form the nozzle also flushes away the dirt resting on the top of the fabric pile giving a good quality finish.

The design of the TWIN storage compartments in single machine tube, the LN fabric transport nozzle, the Hydroski fabric supporting system, and the CU Spray nozzles are so outstanding, making the ECO-88D High Temperature Dyeing Machine a versatile unit suitable for wide range of fabric types processed with an excellent quality.

* The maximum loading capacity is suitable for fabric having a unit weight larger than 120 g/m.

ALLWIN:  High Temperature Package Dyeing Machine

The ALLWIN High Temperature Package Dyeing Machine offers liquor ratio as low as 1:4 with its integrated design of REV centrifugal pump, heat exchanger and the flow reversing system (patent granted). The newly designed integrated circulating system results in space saving by approx. 30% as compared with conventional machine arrangements.

The versatile machine is suitable for various types of fibres: natural and man-made fibres and their blends: 100% cotton, polyester, polyester/cotton, acrylic, polyamide (nylon), wool, ramie/cotton etc. Different forms of yarns can be dyed such as packages, cheese, cones, hanks, loose fibre, etc. The capacity range goes from 28 kg to 9129 kg.

According to the test conducted by Fong’s National Engineering Co., Ltd, ALLWIN dyeing machines shorten the total processing time for cotton yarn down to 276 minutes, saving electrical and water consumption respectively by over 40% and chemical cost by 19% compared with conventional machines.

The ILC Intelligent Levelling Control System monitors the flow through the package from outside-in to inside-out and vice versa. The ILC improves the levelling of colour through out the whole package thereby reduces yarn loss and increases reproducibility from batch to batch. The outstanding performances of these features save total production cost by 30%, making it a premium choice for yarn dyeing facilities everywhere.

Main features of this series machine are:

v     Pressurized hydro-extraction reduces dripping water adhered to the yarn materials;

v     Advanced Intelligent Rinsing System Plus (AIR+) shortens the rinsing time and reduce water consumption;

v     Extremely low liquor ration of 1:4 consumes less dyestuff, chemical additives, steam, water and produces less effluent discharge;

v     The uniquely designed heat exchanger produces the highest efficiency in heating and cooling; and

v     ILC Intelligent Levelling Control System improves levelling throughout the whole package layer and reduces yarn lost.

ALLFIT-1: Small Batch Fabric Dyeing Machine

The ALLFIT-1 Small Batch Fabric Dyeing Machine designed for preparing sample fabric as little as 1 kg. It is suitable for the processing of knitted goods made from cotton and synthetic fiber and their blends. The low liquor ratio and power consumption and fast fabric running speed ensure the dyeing quality and results.

The dyeing recipes and process techniques developed from this machine can be applied to the normal production without modification.

The ALLFIT-1 is applying the Plug & Run concept; only water, compressed air, steam, electricity supply and drainage have to be connected to run the machine.

MicroWin Mini Sample Yarn Dyeing Machine

In the textile yarn and thread dyeing industry, mini sample is often required by the customer for approval before bulk production. It is a customary practice to produce a coloured sample by taking a standard weight package.

MicroWin Mini Sample Yarn Dyeing Machine is the most efficient machine to save expensive materials and process expenses.

The machine is purposely designed to produce a coloured package with a weight in the range of 200-300 gram. The machine adapts the standard dye tube of inner diameter 48 mm and with a maximum winding outside diameter 95 mm. There is at least 75% of saving as compared to producing a colored sample with a 1.2 kg package.

THEN-AIRFLOW® SYNERGY  - the lowest liquor ratio on the market

THEN-AIRFLOW® SYNERGY represents the combined result of the entire technological possibilities provided by the most innovative patented THEN-AIRFLOW® technology. All technical possibilities and functions, economic and ecological advantages are resulting in advantages which are unobtainable with other available dyeing technology.

The outstanding advantages are:

v     The lowest liquor ratio on the market: synthetic fibres approx. 1:2, natural fibres 1:3 to 1:4, depending on the article and structure;

v     Up to 2/3 of water and energy reduction due to a frequency converter;

v     Highest flexibility for knits and wovens with regard to all fibres (except pure wool) and fabrics weight classes between 30-800 g/m, as well as all standard market dyestuffs;

v     Air as a transport medium, while all other systems need water, as well as a reduction in the overall process time of around 25%;

The most advanced piece-dyeing machine available today, which provides a competitive edge through the lowest available processing costs and lowest water/wastewater levels, which represent an ecologically sound solution.

The One step leveller® fast dyeing process was developed up to serial production maturity in the course of intensive project work.

This fully automatically guided and controlled sequence of what is a highly complex process at the highest process technology level, results in a considerable shortening of the dyeing process and excellent reproducibility. Massive time savings being achieved through the effective use of the unique THEN-AIRFLOW® “Direct Rinse” method in combination with the “Power Rinse” process. These time savings are increased even further by precisely matching components, the most important of which are:

v     Traditional filter systems need a lot of manual operation time and therefore a lot of time for the exchange of the filter inlets. The newly “continuous self cleaning” filter system ensures a lint-free surface and greatly reduces the setting times between batches. The lint is washed away automatically at the end of the process.

v     THEN-AIRFLOW® SYNERGY is the only dyeing machine in the world to have a hot drop at temperatures up to 130°C while the fabric is in motion. This is possible during pre-bleaching and dyeing and, depending on the process, results in time savings of 15-30 minutes. In the case of polyester items, oligomers are removed in a dissolved state by the hot drop and therefore do not cover the fabric with a grey coating.

v     The “THEN– Flexport®“ is a separate storage chamber with variable loading for waistbands, collars and appliqué. The “THEN – Flexport®“ is controlled entirely autonomously. Consequently, in machines with six chambers, these articles can also be dyed with identical colours in the same machine.

Controlled dyeing with TDS

The THEN control product line was developed for an interconnected automation system in dye houses. The TDS supervisor system integrates THEN products, products of other manufacturers and PC-control systems or host-computers to a common dyehouse system.

The TDS shorten the dyeing processes, by optimizing the capacities of the dyeing machines.

This system can be linked for seamless database interactions with order handling systems, recipe management systems or process optimization systems. A life presentation will be given during the whole show to demonstrate the data exchange with Datacolor PROCESS® V 2.0.

CHD automatic chemical dispensing system

The THEN colour kitchen system is a modular system to meet all requirements in textile finishing. Starting with a weighing system with a barcode scanner for products, which cannot be automatically fed, to automatic chemical dispensing for liquid products and a solving station for dyestuffs and pulverized chemicals all requirements can be covered.

The CHD chemical and auxiliary dispensing unit offers a compact process-controlled measuring and distributing system. Chemicals and liquid dyestuffs can be dosed in quantities from 50 ml to several hundred litres. The latest achievement in process accuracy is a mass flow meter for the highest precision in dosing.

Savings in chemicals and auxiliaries up to 20% can be achieved. Savings in operator costs are also possible. Furthermore, an extensive gain in the reproducibility from batch to batch is achieved. The system can be used as standalone or integrated into an existing ERP-system via interface to all common recipe formulation and control systems. Not to underestimate is the fact that also avoids any injury with chemicals through contact or inhalation.

THEN Automatic Dissolving Station (ADS)

The THEN Automatic Dissolving Station (ADS) provides an interface between powder and liquid dyestuff. The ADS consists of up to seven new designed dissolving tanks in different sizes. The dissolving device with powder injection provides a fast and reliable dissolving of powdery products.

With the new design small, middle and big additions can be made within short time and optimized amount of rinsing water. A new addition pump allows high speed transportation to the dyeing machine to save process time.

THEN HST top class beam dyeing machine 

The THEN HST (Fig.9) is the highly versatile and economic system for the efficient and perfect bleaching and dyeing of woven fabrics and knitwear in open width. It can handle warp knits for automotive textiles and, on the other, has no problems with webs, which are processed into light linings, interlinings and thick felts. The machine is suitable for almost all kinds of fabrics made of natural and man-made fibres. The danger of creasing is eliminated by the fact that the material is always processed with a full width. Moreover, the range of applications is as large as the executed quantities.

The globally proven and reliable construction, based on profound experience, was completely reengineered based on the latest developments of fluid techniques and thermodynamics. The liquor pressure and quantity are adjusted to the respective type and quantity of fabric. The application of the optional available vacuum pump gives an optimum de-airing of the textile goods and allows a short time filling process.

Various beam diameters are available, depending on the type of fabric involved. Several beams are arranged in line within the machine for the dyeing of fabrics with smaller widths. The THEN HST can be supplied with either an axial reversible pump for knits and permeable weaves, or a high-performance centrifugal pump for dense woven fabrics. A specially developed sluice facilitates sampling during ongoing operations.

The outstanding advantages are:

v     Liquor circulation in line with the product type using either an axial flow or high-performance centrifugal pump. 

v     Pressure and injection pump with pressure regulation valve and recooler.

v     Preparation and expansion tank.

v     Liquor volume control.

v     Kier diameter of up to 1,550 mm.

v     Dye beams with diameters of 300 - 1,100 mm.

v     Collars for short resetting times when using various fabric widths.

v     Mobile carriers for dye beams of various diameters. 

v     Possibility of using one or more dye beams. 

v     Max. dyeing temperature: 140 °C at 4.5 bar.

The liquor linkage of two machines of the same size serves to assure the quality of large batch dyeing. To complete the set-up, a closed expansion tank can be fitted to reduce cooling water and heating energy consumption and an optional flow rate quantity and differential pressure measurement and control can be employed to secure dyeing process quality and optimization.