Dyeing – Loris Bellini

Machines for Dyeing

PULSAR

Innovative dyeing system for packages, tops and warp beams

Pulsar is the result of a brave but simple idea aimed at redefining the standard concept of yarn dyeing in package. Due to its completely innovative concept, Pulsar ensures both relevant savings of costs as well as an overall improvement on the quality of the final dyed product.
This last aspect — plainly confirmed by extensive laboratory tests and by the end users who could personally have a direct evidence — finds explanation from the reduced installed power and from the totally renewed hydraulic circuit. Due to the combination of these two aspects, liquor circulation has an increased “respect” for the treated fiber.

Pulsar takes advantage from a completely reengineered hydraulic circuit, which divides the base plate of the dyeing carrier in three different sectors. By means of dedicated butterfly valves, liquor circulates through them at pre-set intervals marked by the dedicated software.
Combined with a specific mixer (Thermocolormix) installed in the lower portion of the main kier, this solution brings unprecedented savings along the complete dyeing process, such as 70% less electric energy and nearly 30% less water (LR 1:4).

Even for steam — which is now required in smaller quantity due to the reduced level of water — Pulsar brings savings of approximately 20% over a traditional system.
As per all the machines produced by Loris Bellini, Pulsar is designed and manufactured following the highest standards of quality, for its materials as much as for its total safety.

Pulsar does not require an overall different approach if compared to a traditional machine.
Process controller Leonardo 600, which is fully developed by our engineers, allows a very easy and intuitive approach with the final intent to simplify the interaction of the final end user, thanks to the highly automated functions expressly conceived for this machine.
In case a larger integration with pre-existing Management Systems is required, Pulsar is also ready to accept process controllers manufactured by third parties.

This machine is available in different capacities, starting from the small size of 50kg up to very large lots of 1,5 tons each. By means of a pressurized air-pad system, Pulsar allows variable loading down to 50% of the nominal capacity of each kier, while keeping liquor ratio to a nearly constant level.

By assuring a concrete reduction in the consumption of water, steam and, in some cases, chemical products, as well as savings of electric energy up to 70%, Pulsar is projected into the future and make it the best choice for all those Customers who intend to accelerate the payback of their investment, while improving the final dyeing quality of the end products.

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RBNVI

Vertical machine for dyeing bobbins, tops, bumps, staple, tow

Introduced on the market in the early 80’s, the pressurized air-pad system is part of the RBNVI as well as of all other machines in our portfolio. The implementation of such technology makes it possible to achieve great advantages by flooding just the pump and the packages alone, thus significantly reducing liquor ratio (1:6) and lowering the global consumptions of water, steam and electric energy.

The use of the air-pad system ensures an unaltered liquor ratio even when the machine is loaded at 50% of its nominal capacity.
The variable loading logic (100-50%), along with the automatic system for the continuous monitoring of the differential pressure between the inner and outer portion of the material, guarantees total flexibility of the machine in regards of the material (cotton, polyester, wool, blends, etc.) and its relative configuration (packages, tops, tow, loose fiber).

By means of the helico-centrigfugal pump designed by Loris Bellini, the amplitude of the spectrum of available differential pressure (0.2 to 2.5 bar) gives the opportunity of dyeing very different fibers within the same machine, from acrylic to wool with excellent permeability, to cotton and viscose with reduced permeability,
as well as very dense packages of polyester.

The flow reversal device, which is integrated in the pump, does not require to slow down the liquor circulation
at each inversion (thus preventing peak absorptions) and avoids the formation of turbulence within the dye bath.

The machine can be configured in different ways depending on the materials that need to be dyed — such as high temperature drain, linear/exponential alkali dosing system, preparation/recovery tank — which are all managed by the Leonardo system installed on a industrial PC.

The air-pad system, combined with an extremely compact hydraulic circuit, ensures very low figures for the liquor ratio.
This leads to global savings of water and chemical products, with a consequent reduction of production costs and a faster payback over the initial investment.

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RBNOI

Vertical machine for dyeing bobbins, tops, bumps, staple, tow

Presented in world premiere during ITMA 1983, its peculiar design was object of an international patent during the month of December the following year, with file number 89.109.914.0. No horizontal machines for the dyeing of packages were seen anywhere on the market before that moment.

RBNOI was born to give a substantial answer to all those customers with challenging needs in terms of logistics for both the infrastructures and the handling of the final product. In fact, horizontal machines can easily be installed in low clearance buildings where the vertical option is otherwise not compatible.

RBNOI takes advantage from the same proven technology of its vertical counterpart: pressurized air-pad system, which allows the flexibility of variable loading (100%-50%) while keeping liquor ratio at a nearly constant level; flexible approach for the dyeing of different fibers due to a very much efficient helico-centrifugal pump that amplifies the spectrum of differential pressure between the inner and outer portion of the material. In addition, as per the vertical machines, the automatic system for the continuous control of the differential pressure ensures a very high repeatability of the dyeing process.

The horizontal machine is based upon the concept of modular dyeing carriers such as they are all interchangeable between them: the minimum working batch defines the size of the single loading carrier and all the machines are based on its multiple (1, 2 or 3 loading carriers).
Each machine can easily work at 50% of its nominal capacity and this is possible by means of a heat exchanger installed outside of the main kier.

RBNOI machine is installed at floor level and does not require environmental structures such as mezzanines or roof cranes. Handling of the loading carriers occurs by means of manual trolleys on wheels or through the use of a shuttle on rails conceived for automation.

This machine brings several advantages. The absence of structures of support (mezzanines and roof cranes) reduces the global investment, while the pressurized air-pad system brings a substantial benefit on containing running costs. All these aspects concur in a faster and more profitable payback over the initial investment.

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APPC-LV

Cabinet for skeins

True strongholds of our portfolio, the APPC-LV cabinets are manufactured by using 6mm thick 316L stainless steel plates, usually purchased from European manufacturers of the highest quality.

These cabinets use an axial pump which is directly fitted on the main body of the machine and this completely eliminates connecting pipes, from which derives the compact design of the hydraulic circuit and the consequent optimization of the liquor ratio.
In fact, APPC-LV cabinets can assure a very low liquor ratio that, according to the type of material and to the cycle of reference, can range between 1:12 and 1:15.

As all the other components of the machine, the pump itself is easily accessible from all sides, thus making maintenance a breeze in every context.

APPC-LV cabinets are installed at floor level and do not require holes, nor civil work.
Such solution makes these cabinets true “plug & play” and facilitates the loading/unloading operations of the loading carriers by means of trolleys on wheels.

Ideal for the dyeing of wool, acrylic HB and mercerized cotton, APPC-LV cabinets frequently are the first choice for all those customers who prefer to dye such fibers in hank form with exceptional results.
Being the direction of the flow parallel to the fibers, there is a total absence of turbulence inside the machine, such as yarn is not compromised by entanglements, for smoother and more consistent hank-to-cone operations. The pressurized air-pad system gives the chance for a 50% variable loading at almost constant liquor ratio and ensures a very high level of flexibility for every production needs.

APPC-LV are available in different sizes, starting from 5kg up to very large lots of 420 kg. Such maximum capacity can easily be doubled by considering two APPC-LV 250 (2-door) in coupling mode.

Investing in APPC-LV cabinets means purchasing machines for the dyeing of yarn in hanks with unique characteristics, either for the reduction of running costs and for the highest dyeing quality, unparalleled in this field.

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ABEP

Arm machine

ABEP is the technical solution that consolidates the range of products manufactured by Loris Bellini for the application of special fine yarn in hanks:

• cashmere, alpaca, mohair, wool and blends • natural silk and blends of viscose/wool
• filament viscose
• mercerized cotton

• very high bulk (VHB) acrylic for knitting.

The structure of ABEP is entirely manufactured using thick 316L stainless steel plates.
Its arms, which are mirror polished and have an internal liquor distributor, are designed to guarantee a uniform and constant flow along the entire length of the arm.
The tilting opening door of the machine is now provided with pneumatic pistons that grant even a higher level of safety and simplify further the global user experience with this system.

The pressurized air-pad system allows a working temperature of 102°C at sea level. This makes our ABEP independent from the variation of atmospheric pressure, thus allowing VAT dyeing and a more accurate regulation of the process temperature.
The arms are of extractable type for an easy loading/unloading operation of the hanks.

As standard, all ABEP machines are equipped with a magnetic flowmeter in continuous communication with the inverter for a constant flow no matter how many arms are in operation. In fact, all ABEP machines can work at variable loading by means of the manual exclusion (automatic as an option) of arms down to 50% of the nominal installed capacity, thus reducing the total production of each batch in accordance with the requirements of the dyehouse.

The rotating mechanism of the arms, entirely built with AISI 316L stainless steel, is self-lubricating and does not require maintenance.

The control of liquor level allows working at constant liquor ratio by setting the volume of the liquor in accordance to the arms in operation. Such solution brings a very high shade repeatability with a strong reduction of any possible shade corrections.

ABEP machines are available in different sizes, starting from 10 kg of the 2S up to 200 kg of the ABEP 20. In addition, it is possible to connect two machines in coupling mode for a total installed capacity of 400 kg.

ABEP machines have a very low liquor ratio of 1:10. Such reduced consumption of water, in combination with a low requirement of maintenance, ease of use and a very high dyeing quality, make it our ABEP a very special machine in its field, which is able to satisfy even the most demanding user.

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RBNV/PULSAR 270

Laboratory machine

End users consider our RBNVI/PULSAR 270 as a very useful machine between the actual lab and the industrial production.
This machine benefits of all the same peculiarities of a proper production machine and it consequently gives the possibility to work on a sample of material adapting the same parameters and the same configuration of bulk production (1 or more packages).

Despite its very compact design, RBNVI/PULSAR 270 is equipped with all the devices available for larger industrial machines. In virtue of such full configuration, this machine is meant for working on small lots and their respective cycles to be consequently transferred to the bulk production.

RBNVI/PULSAR 270 is pressurized at 5 bar and has a working temperature of 140°C.
Complete with electronic sensors, probes and pneumatic/automatic valves, this machine can go through the different phases of the dyeing cycles in an automatic way by means of our process controller Leonardo 600.

Considered as a true “bridge” machine, it allows the transition between the laboratory stage and the production, thus minimizing the risk of error on the final product and assuring savings on production costs.

The availability of specific loading carriers for packages — but also for hanks, loose fiber and small tops — makes this machine a true support for a more efficient management of the dye house.