Continuous developments for denim by
As one of the leading
suppliers of finishing ranges to the denim industry globally,
the benefits of the latest Monfort Eco Line are already being
enjoyed by several leading denim manufacturers in Asia and South
America. This feature authored by Klaus A Heinrichs highlights a
new concept for the more economical and resource-efficient
production of denim.
The Monforts ThermoStretch.
Denim manufacturing consumes huge amounts of energy and
resources at virtually all stages of production, but especially
during shrink finishing, and on conventional ranges, large
volumes of water, steam, chemicals and thermal energy are
required. A significant portion of these resources, however, can
be wasted without precise feeding, monitoring and control.
This is an issue that Monforts engineers have successfully
addressed with the Eco Line for denim, based on two key
technology advances – the Eco Applicator for minimum application
of the selected moist finishing chemicals and the ThermoStretch.
Monforts Vice-President of Sales and
Marketing Klaus Heinrichs.
As an alternative to conventional padding, especially for
wet-in-wet solutions, the Monforts Eco Applicator can
significantly reduce the amount of applied humidity required
prior to the stretching and skewing of the denim fabric. It also
allows mills to apply finishes to just one side of the fabric,
or both, and even to apply separate finishes to each side, or to
specific areas of a fabric, for endless denim differentiation
The Monforts ThermoStretch unit carries out the skewing (weft
straightening), stretching and drying in a continuous process.
The ThermoStretch benefits from a structure detector
which carefully measures and controls the fabric
width and the skewing.
A modified hotflue with reinforced and adjustable rolls for
determining the longitudinal tension within the fabric, the
ThermoStretch benefits from a structure detector with Pleva SD 1
camera technology employing transmission and reflection lighting
for the highest detection capability, in order to carefully
measure and control the fabric width and the skewing.
Due to its large number of guide rolls, it is possible to
stretch damp fabric in a heated chamber at a longitudinal
tension of between 200-300 N with the ThermoStretch, compared to
the high forces of up to 4,000 N that have previously been
required to finish a typical denim fabric with a starting width
of 157cm and a finished width of 151cm.
Typical Eco Line configuration.
“Due to these innovations, the Eco Line system reduces energy
requirements and losses, increases thermal transfer and keeps
the drying energy on the textile material longer,” says Klaus A.
Heinrichs, Monforts Vice President Sales and Marketing . “As a
result energy savings of up to 50% are being achieved. We will
be introducing a number of new innovations for denim in the near
future, including a solution for the introduction of two-way
super stretch into denim in a single processing step.”