The world’s first fully automated and interconnected dyehouse, precursor to the Industry 4.0 concept

 

THE CUSTOMER

Coats Mez in Bräunlingen, Freiburg, a customer of Tecnorama, that over the years has supplied it with numerous innovative machines for both their laboratory (Dos&Dye® systems) and dyehouse production (Dosorama S and Dosorama LP), including dissolving units and automatic systems for the transfer of recipes dispensed to the various dyeing machines.

THE NEED

To design and build a system capable of transferring the “full automatic” concept of the Dos&Dye® system installed in the company’s laboratory to small production batches (from 1 to 36 kg).

THE CHALLENGE

To produce the world’s first fully automated and interconnected dyehouse, capable of working without the presence of personnel for many hours, with the possibility of remote control, and guaranteeing exceptional performance and extreme customer satisfaction.

THE Tecnorama SOLUTION

Dos&Dye® 6000 went into production in early 2005, and transferred to the Mez Craft dye-house in Budapest in 2014.

RESULTS

Output of up to 375 yarn baths a day, when fully operational up to 450 baths in 24 hours.
“Right first time” reproducibility performance for polyamide and polyester yarn: 98%.
The profitability of this technical solution, in terms of the cost of dyeing small yarn batches, was higher than the level achieved by the Coats Group in its new, top-performing plant built in China. The incidence of production costs in the new Coats unit in Germany was also less than half the global average for the Coats group as a whole.

Using the Dos&Dye® 6000 system, linked to the Coats order management system, the company was able to deliver the goods to its various clients in just 72 hours, from order to delivery.
Thanks to this operational speed, Coats was able to eradicate the need to stock dyed yarn ready for quick delivery. Warehousing was held to be necessary because at that time there was an increasing demand for rapid deliveries from their clients.
The dyehouse was working in three shifts: the first shift worked with all personnel present, while in the second and third shifts only one person was present, responsible solely for safety checks.
Remote control was also possible, with connection to mobile phones for the constant monitoring of the whole system and reception of warnings and alarms in the event of malfunction.
Thus the dye-house carried on working at night, and on Saturdays and Sundays with no staff present, with the dyeing of all raw materials present in machine storage units.

“A DYE-HOUSE MANAGED BY GHOSTS”

In 2007 a journalist from Melliand International (an industrial textile journal well known in Germany) went to Bräunlingen to see the dye-house working. The visit was arranged for a Saturday night. At that time the dyehouse was deserted, the lights turned off, with no staff present, while the various robots moved independently and automatically, each one doing its job, lights flashing.

The journalist was stranger to similar dye-house shows and hersurprise was such that she gave the following title to the article that appeared in the pages of “Textilveredlung”: “FARBEN WIE VON GEISTERHAND” or in English: “A DYEHOUSE MANAGED BY GHOSTS”.

Melliand International article

 

Date: 2003

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