To Face

International Crisis & the Competition Increase, Dye plants have to :

Reduce theirs production’s costs (water / times / dyestuff / chemicals) Be Right First Time (to respect delivery time & improve productiveness) Improve the Quality of theirs productions (customer’s satisfaction)

These aims can’t be reach with Universal Process and with Blinds eyes !

« Let’s break again the Dye Limits with Optilab »

Why OPTILAB in Dye plant ?

2

Receipe from Laboratory

STANDARD PROCESS

REDYE & REDYEUnlevellingNo Reproducibility

Lower Quality & Expensive Production Cost No respect of Delivery time

Receipe from Laboratory

Optimized Process OPTILAB

High Efficiency Of Production Dyeing Machines

High Quality & Low Production Cost

Without Possibility to see

?

With Possibility to see

RFT

OPTILAB

Optimization Acrylic processLEACRYL 3,3

OPTILAB

CALLEBAUT DE BLICQUY

31 de la Fonderie – BP 70160 – 59202 Tourcoing cedex (France)

Tel. / Fax. : 0033 3 20 38 89 50 / 0033 3 20 38 89 70

Receipe and actual process Acrylic

Receipe : Actual process :

Yellow OR 200% 0,05 %

Red GRL 200% 0,05 %

Blue GRL 300% 0,05 %

Acetic Acid 1 cc/l

Pérustol AMC (Anti-static) 1 cc/l

Cellolube (softner) 1 cc/l

OPTILAB

Initial Temperature 55°C

Plate 10 Min

Heating 104°C with 1°C/min

Plate 15 Min

Cooling 80°C

Exhaustion curves actual process AcrylicOPTILAB

Receipe and optimized process Acrylic

Receipe : Optimized process :

Yellow OR 200% 0,05 %

Red GRL 200% 0,05 %

Blue GRL 300% 0,05 %

Acetic Acid 1 cc/l

Pérustol AMC (Anti-static) 1 cc/l

Cellolube (Softner) 1 cc/l

OPTILAB

Initial Temperature 55°C

Plate 10 Min

Heating 76°C with 3°C/min

Heating 85°C with 0,2°C/min

Heating 104°C with 2°C/min

Plate 15 Min

Cooling 80°C

Exhaustion curves optimised process AcrylicOPTILAB

B E F O R E

A F T E R

OPTILAB

Before Optimization

After Optimization

Annuals

Saving

Re-dyeing 13% 3%

Water 16,1 L/Kg 14,7 L/Kg 507 m³/an

COD 12,3 Kg/T 9,5 Kg/T 760 Kg/an

+ Time saving : 32 min / process

SAVING

Optimization Cotton processTENCEL

OPTILAB

CALLEBAUT DE BLICQUY

31 de la Fonderie – BP 70160 – 59202 Tourcoing cedex (France)

Tel. / Fax. : 0033 3 20 38 89 50 / 0033 3 20 38 89 70

Receipe and actual process CottonReceipe : Actual process :

Yellow cibacrone F3R 1%

Red cibacrone FNB 1%

Blue cibacrone FR 1%

Croscour WPD (mouillant) 1 cc/l

Rapidoprint XRG (anti-réducteur)1 g/l

Anti-foam 0,3 cc/l

Salt 80 g/l

Soda Solvay 10 g/l

OPTILAB

30’

40°C

60°C

dyestuffs 1/10 3/10 6/10 1/10 3/10 6/10

Soda Solvaysalt

1°C/min

15’ 15’ 30’ 15’ 15’ 15’

Rinsing and SoapingOPTILAB

T°C Time (min)

Rinsing 1 40°C 10

Rinsing 2 80°C 10

Neutralization 50°C 5

Soaping 1 95°C 15

Rinsing 3 80°C 10

Soaping 2 100°C 15

Rinsing 4 40°C 10

Rinsing 5 65°C 10

Softness 50°C 5

Exhaustion curves actual process CottonOPTILAB

Receipe and optimized process Cotton

Receipe : Optimized process:

Yellowcibacrone F3R 1%

Red cibacrone FNB 1%

Blue cibacrone FR 1%

Croscour WPD (mouillant) 0,75 cc/l

Rapidoprint XRG (anti-réducteur)0,75 g/l

Anti-foam 0,3 cc/l

Salt 64 g/l

Soda Solvay 10 g/l

OPTILAB

30’

40°C

60°C

dyestuffs 3/50 10/50 36/50 1/10

3/10

6/10

Soda Solvaysalt

1°C/min

15’ 15’ 15’15’

1/50

Rinsing and SoapingOPTILAB

T°C Temps (min)

Rinsing 1 40°C 10

Rinsing 2 80°C 10

Neutralization 50°C 5

Soaping 1 95°C 15

Rinsing 3 80°C 10

Soaping 2 100°C 15

Rinsing 4 40°C 10

Softness 50°C 5

Exhaustion curves optimized process CottonOPTILAB

B E F O R E

A F T E R

OPTILAB

Before Optimization

After Optimization

Annuals

Saving

Re-dyeing 13% 3%

Water 115 L/Kg 93 L/Kg 367 m³/an

COD 140,2 Kg/T 78,8 Kg/T 1 025,4 Kg/an

+ Saving in Chemicals (Auxiliaries Products)and Time (40 min / process)

SAVING

Optimization Polyester Process

OPTILAB

CALLEBAUT DE BLICQUY

31 de la Fonderie – BP 70160 – 59202 Tourcoing cedex (France)

Tel. / Fax. : 0033 3 20 38 89 50 / 0033 3 20 38 89 70

Receipe and actual process PES

Receipe : Actual Process :

Yellow RD4GRL 0,031 %

Red RD4GFL20 0,007 %

Blue RDGL 0,007 %

Dilatine (carrier) 3,75 ml/l

Eganal EDP (levelling) 1,25 ml/l

102°C

60’

20°C

96°C

1°C/min

OPTILAB

Exhaustion curves actual process PESOPTILAB

Receipe and optimized process PES

Receipe : Optimized process :

Yellow RD4GRL 0,031 %

Red RD4GFL20 0,007 %

Blue RDGL 0,007 %

Dilatine (carrier) 0 ml/l

Eganal EDP (levelling) 0,625 ml/l

130°C

30’

20°C

96°C1°C/min

2°C/min85°C

OPTILAB

Exhaustion curves optimized process PESOPTILAB

BEFORE

AFTER

Auxiliariesproducts

Annualquantity

Unit cost Annual cost

Dilatine 480 Kg 6,49 €/Kg 3 115,20 €

Eganal EDP 180 Kg 4,22 €/Kg 759,60 €

TOTAL 660 Kg   3 874,80 €

Auxiliariesproducts

Annualquantity

Unit cost Annual cost

Dilatine 0 Kg 6,49 €/Kg 0 €

Eganol EDP 90 Kg 4,22 €/Kg 379,80 €

TOTAL 90 Kg   379,80 €

Before Optimization

After Optimization

OPTILAB

Saving Chemicalsproducts

Reduction cost of 90% in Chemicals products

Time saving : 15 min / process

Optimization Polyamid process

OPTILAB

CALLEBAUT DE BLICQUY

31 de la Fonderie – BP 70160 – 59202 Tourcoing cedex (France)

Tel. / Fax. : 0033 3 20 38 89 50 / 0033 3 20 38 89 70

Receipe and actual process PAM

Receipe : Actual process :

BrownCiba JNH 100% 0,03 %

Grey Ciba NH 0,02 %

Yellow Ciba 2GC 0,01 %

Sandacid VS (acid donor) 2,5 ml/l

Felosan R.G.N 0,312 ml/l

OPTILAB

102°C

60’

20°C

96°C

1°C/min

Exhaustion curves actual process PAMOPTILAB

Receipe and optimized process PAM

Receipe : Optimized process :

Brown Ciba JNH 100% 0,03 %

Grey Ciba NH 0,02 %

Yellow Ciba 2GC 0,01 %

Soda Solvay 2,0 g/l

Acetic acid 1,5 ml/l

Felosan R.G.N 0,234 ml/l

OPTILAB

102°C

30’

96°C1°C/min

2°C/min

80°C

Dosing of acetic acid

Exhaustion curves optimized process PAMOPTILAB

BEFORE

AFTER

OPTILAB

 

Before Optimization

After Optimization

Auxiliariesproducts

Annualquantity

Unit cost Annual cost

Sandacid VS 130 Kg 7,05 €/Kg 916,50 €

Felosan RGN 120 Kg 3,73 €/Kg 447,60 €

TOTAL 250 Kg   1 364,10 €

Auxiliariesproducts

Annualquantity

Unit cost Annual cost

Carbonate 396 Kg 0,43 €/Kg 170,28 €

Acide acétique 78 Kg 0,48 €/Kg 37,44 €

Felosan RGN 90 Kg 3,73 €/Kg 335,70 €

TOTAL 564 Kg   543,42 €

Saving ChemicalsProducts

Reduction cost of 60% Chemicals products

Time saving : 30 min / process