Yarn Carpet Treatments

YarnCarpets

FURTHER PROCESSING FOR IMPROVED QUALITY


Carpets and upholstery manufactured from wool to perform under the toughest conditions – they enhance the 21st century design statement by delivering fashionable designs, superior performance characteristics in durability and fire retardant properties. ANDAR has been instrumental in developing carpet and yarn technologies in partnership with the Wool Research Organisation of New Zealand (Canesis) and Wools of New Zealand.

 

SUPERIOR PERFORMANCE CHARATCTERISTICS

Whether processing yarns or finishing carpets ANDAR Advanced Natural Fibre Processing systems meet the demands of todays increasingly competitive business environment. ANDAR uses advanced technology to enhance fibre properties adding value through consistency of processing, while maximising return on investment to its customers. Wool yarns processed via ANDAR systems produce carpets with pinpoint tuft definition that are both durable and attractive, particularly in high traffic areas. These value added characteristics ensure a product with a competitive edge at marketing and retail levels.

The ANDAR Hankscour is designed to efficiently remove spinning oil and entrained contaminants from wool yarns in hank form. This results in a high quality, consistent product that will attract premium prices.

 

Using modern technology, the ANDAR Hankscour includes automated chemical metering, an electronic control system and accurate liquor management. Further additional chemical treatments can be supplied such as sodium metabisulphate (MBS) dosing in a five bowl Hank Set Master.
Hanks pass through inbowl rollers and a squeeze press, which releases contaminants into the bowl from the product. The wet hanks are supported by rollers, a bottom belt and top tapes to prevent damage. Depending on the type of process requirement, up to five bowls and squeeze press units can be used.

 

Electrical Control System


With the chemical dosing required along with the automation of the process, a control system assists with increasing efficiencies in the Twistset. This process wide system optimises controls, functionality and reporting requirements for this specific application.

 

Hank master (4 bowls)

Designed to provide excellent washing performance of yarns in hank form.

Hank set master (5 bowls)

Designed with an extra long second bowl, the Hank Set Master provides all of the functionality of the 4 bowl system with the added flexibility to MBS set the twist in the hank form yarns.

Hankscour Squeeze Press

The Yarn Press is adapted to squeeze excess moisture from the hanks, reducing carry over of liquor and allowing both counter current liquor flows and bowl isolation depending on processing mode.

Unidryer

A specialist Unidryer has been adapted for this application. The two bay Unidryer has longer bays than its scouring counterpart to provide a larger residence time for the drying requirements of hanks.


The Twistset process is a continuous yarn processing system allowing both yarn washing and sodium metabisulphite (MBS) setting to be carried out. Based upon the ‘package to package’ principle the Twistset system is less labour intensive, removing the need for hanking and reprocessing. Continuous processing eliminates inconsistencies in processing, usually associated with Dye Vessel or Hank setting systems.

 

A creel supplies a number of ends of yarn to a coiler, which gathers the yarn into a rope and then forms it into a coil against a short vertical transfer conveyor. This conveyor inverts the blanket onto a much larger polyester belt that passes through the treatment bowls and their associated squeeze presses.

 

The blanket travels through each of the four wet treatment bowls where it is initially scoured (at 60-65°C), set in sodium metabisulphite solution, and rinsed with water at 85°C to ensure that there is adequate removal of any residual sodium metabisulphite, thereby optimising the degree of set.

 

After the final squeeze the blanket is passed to a Unidryer and then to a yarn accumulator. This latter is necessary to enable doffs or yarn breaks at the winder to be accommodated without interrupting the flow of yarn through the bowls and Unidryer.

 

The yarn rope is unwound from the coil in a controlled manner and the individual ends separated and wound onto large tufting packages.

 

Electrical Control System


With the chemical dosing required along with the automation of the process, a control system assists with increasing efficiencies in the Twistset. This process wide system optimises controls, functionality and reporting requirements for this specific application.

 

Creel

The Creel supplies a maximum of 36 ends of yarn to the bowls, (18 to each coiler). The yarn travels through tensioners and yarn breakage detectors, then out of the creel to the coilers.

Coilers

Two coilers are mounted on the coiler stand before bowl 1. Each coiler pulls 18 ends of yarn from the creel, gathers the yarn into a rope and forms the rope into a continuous coil on the wet treatment bowl line main belt.

Bowls

Scouring, setting of the yarn and insect proofing is performed in the Twistset wet treatment bowls.

 

Twistset Bowl

Rollers inside the bowl guide the yarn blanket through the bowls retained between the continuous belts.

Setting Bowl

The setting bowl is longer than other bowls in the process, to maximise the residence time of the yarn in the MBS solution.

Rinsing Bowl

Similar to the Twistset bowl, the rinsing bowl is required to remove any excess setting agent.

Mothproofing Bowl

This specialist bowl applies the mothproofing treatment, utilising a complete closed loop flow – ensuring no chemicals flow to drain.

Twistset Squeeze Press

A specialist version of the yarn press tailored to process yarn blankets.

Unidryer

The wet yarn discharges onto the Unidryer infeed conveyor and is carried through the dryer sandwiched between two belts. Blanking plates deflects the airflow directly onto the Twistset coiled blanket of yarn to maximise airflow and dryer performance.

Unicoiler Conveyor

The uncoiler conveyor provides an area where controlled uncoiling of the twin yearn blankets can take place. Each channel is provided with a fluorescent tubes below and a photocell above the belt to detect the presence of coils and control the speed of the accumulators, while sensors to identify any gaps in the yarn blanket.

Accumulators

The Superba MAT yarn accumulators provide a temporary yarn storage area to enable delays in the separating and winding process to be accommodated without stopping the flow of yarn through the bowls. Photocells and reflectors mounted on the chutes of the accumulators control the take-up speed of the winders.

Yarn Separators and Break Detection

The yarn rope drawn from the accumulators by the winders passes through the separator bars and the break detectors. The separator bars split the yarn rope into single ends of yarn and the spring-loaded microswitch stops the winder if they detect a loss of tension in one or more ends caused by a yarn break.

Winders

ANDAR works with Superba, Belmont, and Gilbos to provide winders to suit customer specific requirements.

Chemical Mixing Plant

The chemical mixing plant includes dissolving tanks for various chemicals, including sodium carbonate and sodium metabisulphite, and a larger tank used to mix and store neutralised MBS solution for addition to bowl 2 of the Twistset line.

Main Control Panel

The main control panel houses the programmable logic controller (PLC), all fuses, motor contactors and power supplies. The Twistset plant is started and stopped at the control desk while the control cabinet displays provide the operators with a readout of the operating conditions.