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THE
COMPANY
TEXCENE is an Italian company located
in Cene (Bergamo) processing yarns on reels, sponge
and cotton cloths. Fabrics are supplied by other manufacturers
and bleaching and dyeing treatments are made according
to requests.
The company produces about 25,000 tons of fabrics per
year, including about 1300 tons of cotton yarns on reels,
which is about 5% of its total production. The company
works three shifts per day 250 days/year for a total
of about 6000 hours/year.Total yearly energy consumption
is about 7300 Mwh electric energy and 4,200,200 methane
gas.
(
TEXCENE S.p.a., Via E. Capitanio 9,24020 Cene (Bergamo)
).
THE
PROBLEM
Yarns on reels processing
include washing, bleaching, dyeing and drying. Drying
is a critical phase in yarns production and, taking
into account TEXCENE drying levels, water content is
brought from 200% down to 6%. It has a greta influence
on the overall process efficiency.Product quality and
standard levels are also very important factors for
TEXCENE yarns on reel production and commercialisation.
With conventional drying methods significant factors
include: high energy consumption, high temperature of
the working environment, risk of damaging the product
surface, uncertainty on homogeneous drying inside reels
and the need to minimise processing time.
For these reason, TEXCENE attention was focused on yarns
on reels considering all these factors in choosing the
most suitable drying system satisfying its need.
THE
SOLUTION
RF drying systems
were installed for yarns on reels drying process. Two
RF continuos tunnel plants were installed: 2 modules
70 kW power reach with relevant accessories for a total
installed power of 216.5 kW. RF drying phase was introduced
after a centrifuge stage (where water content passes
from 200% to 50%; yarns on reels water content is brought
by RF drying system from 50% to 6%.
Radio frequency technology, allowing a selective heating
of the material, only the reels mass is heated, allowed
limiting energy consumption and costs, and ensuring
uniform drying and easy control of residual humidity
inside the reels.RF, System and ALEA supplied TEXCENE
RF drying plants.
The
use of radio frequency in the production chain in place
of conventional hot air technology resulted in a significant
improvement in outgoing product quality.RF allows more
uniform and intense colouring, as moisture levels inside
the reels are more uniform; moreover, drying process
does nit alter fabric properties.Constant and standerdised
drying is achieved, which also result in product quality
enhancement.Energy savings were obtained thanks to selective
heating of the material, absence of start, up transients
and better process control. Global energy savings of
43% were obtained in yarns on reels drying process.
Better working conditions and environmental benefits
were also obtained: about 60% primary energy savings
may be estimated by replacement of conventional methods
with RF technology.
RESULTS
aim : PRODUCT QUALITY
The use of radio frequency
in the production chain in place of conventional hot
air technology result in a significant improvement in
outgoing product quality.RF allows more uniform and
intense colouring, as moisture levels inside the reels
are more uniform; moreover, drying process does nit
alter fabric properties.Constant and standerdised drying
is achieved, which also result in product quality enhancement.Energy
savings were obtained thanks to selective heating of
the material, absence of start, up transients and better
process control. Global energy savings of 43% were obtained
in yarns on reels drying process.Better working conditions
and environmental benefits were also obtained: about
60% primary energy savings may be estimated by replacement
of conventional methods with RF technology.
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