Great Interest in the new Montex Stenter and CYD Technology of Monforts

A. Monforts Textilmaschinen GmbH & Co KG, headquartered in Mönchengladbach, Germany, presented an energy-optimised new version of its industry-leading Montex stenter for the first time at ITMA 2019. The company’s new CYD yarn dyeing technology also attracted considerable attention at the show.

During ITMA 2019 we interviewed the company’s Textile Technologies Engineer Jonas Beisel.

Let’s start with the latest Montex stenter. What improvements have you made to the machine?

With the introduction of the new MonforClean exhaust air treatment system and other unique process innovations, we have been able to further reduce the energy consumption of Montex stenters by 13%. Exhaust air treatment on stenter frames has posed particular challenges over the years, since the air can contain significant amounts of oil, fibre and even wax particles that may see emission limits being reached in the processing of certain fabrics, depending on the legal specifications. In addressing this issue, we are incorporating the MonforClean module into the stenter frame. Among other benefits, this eliminates the need for secondary installations and the piping of the exhaust air treatment components, as well as supporting structures. In total, our latest Montex energy-optimised stenter frame will cut energy consumption by up to 40% compared to a conventional stenters without heat recovery or energy optimisation measures.

Monforts attaches great importance to Industry 4.0 and digitalization. Can you tell us about the latest technologies developed by your company?

Our developments in this field started with remote monitoring from mobile devices, which has led to the  introduction of ‘digital twinning’, now being made available for all Monforts machine systems. This allows comprehensive technical machine data to be virtually mapped in the cloud in real time by exploiting the latest advanced sensor technology. The data can be easily accessed anywhere using the new Monforts Smart Support and Smart Check apps for an instantaneous status overview. The major benefit to customers is that potential sources of error can be anticipated and eliminated for improved machine availability and reduced downtime.

Operators and mill managers are informed by the Smart Check app when maintenance or the replacement of key components is required, well ahead of time. Direct access to the integrated Monforts webshop allows users to instantly order such parts when they are needed.

Via the Smart Support app, customers can also contact Monforts service via smartphone or tablet, in order to access support on site via a remote visual link. Monforts service specialists can point out individual system parts on the customer’s smartphone and assist them in troubleshooting.

Another interesting product is the new CYD yarn dyeing technology. What are the key features and advantages of this line?

Monforts CYD denim technology is based on the Econtrol® technique* – the most effective and established dyeing process for denim fabrics that is now being applied for yarn dyeing. Econtrol® is a pad-dry process employed in Monforts continuous dyeing in which the reactive dyestuff is fixed to the cellulose fibres during drying.

The fixing medium is a controlled by a steam/air mixture within the Monforts Thermex unit.  With sulphur and reactive dyes in particular, the improvement in both dyed fabric quality and dye fixation is considerable, and with significant savings in energy and time due to the combined bleaching and padder fixation.

The CYD system also integrates new functions and processes into the weaving preparation processes – spinning, direct beaming, warping and assembly beaming, followed by sizing and dyeing – in order to increase quality, flexibility, economic viability and productivity. The multi-colour yarn dyeing system introduces a number of new concepts, including the unique Eco Bleach process.

This is the first bleaching system for yarn treatment available on the market and is combined with the washing units, after which the fabric is then dyed immediately, resulting in considerable savings in wastewater and chemicals.

How was the interest shown in CYD yarn dyeing technology at ITMA 2019?

Competition in the denim industry is currently fierce, and the major players are looking for technologies that will really give them the competitive edge, which we know this technology can provide, because it was developed in response to an already very strong demand from the market. We have a fully-operational line now installed at the ATC (Advanced Technology Centre) at our headquarters in Germany and it’s already now heavily booked out. We were inundated with requests for trials on our new CYD yarn dyeing pilot line by the leading denim manufacturers at ITMA 2019. We received a constant stream of visitors, particularly from the so-called ‘Denim Triangle’ – Bangladesh, India and Pakistan – seeking further information.

If you assess in terms of export market, what is the importance of Turkey for your company?

Turkey is a large and important market for us and we have several hundred installed machines already in full production for the country’s leading manufacturers. We are now fully supported in Turkey by our partner Neotek Tekstil, which was formed in February 2016 specifically to assume responsibility for Monforts dyeing and finishing technology throughout Turkey. Neotek is run by highly-experienced textile engineers who assist us with the installation and commissioning of our machines in Turkey, in addition to providing excellent aftersales service for Monforts customers. We held many fruitful discussions with both existing Turkish customers and potential new ones during ITMA 2019.

What is your plan for the next couple of years?

For the immediate forseeable future, we will be responding to the many enquiries that arose at ITMA 2019, but alongside this, the innovation will continue because it’s an essential aspect of enabling us to retain our market-leading position. We have far from exhausted the potential of Industry 4.0 and the automation of our technologies and we believe there is still much more that can also be achieved in terms of further resource efficiencies, whether savings in energy, water or raw materials.

*Econtrol is a trademark of DyStar Color Solutions

Interview: Dilek Hayırlı