ISSUE: Decrease production costs, improve energy efficiency, protect equipment from corrosion and moisture.

SOLUTION: Nansulate® Translucent High Heat offers an inexpensive means to increase the lifespan of equipment, protect against corrosion, and decrease the amount of energy used for equipment processes

"Why insulate? Why Nansulate?

Global competition forces manufacturing companies to reduce production costs, where energy and metal prices are increasing rapidly.

Therefore a good way to decrease production cost is to make maximum use of the energy available and to install systems with much longer usable lifetime.

We need to use more technology in both insulation and corrosion protection.

It is possible to insulate with conventional materials only to a degree because;

1. You cannot insulate wet areas,
2. Conventional insulation does not prevent corrosion, sometimes increases it
3. Useful lifetime of conventional insulation is much less,
4. Application of Nansulate is simple and cheap, but takes a longer time.
5. Conventional systems do not offer long term protection against moisture.

We used Nansulate in our textile dyeing and finishing plant; especially for thermal insulation of dyeing machines which operate at 130 C. Our aims were

i) with a minimum surface temperature reduction of 70 C,
  a) decrease energy cost
  b) increase process stability(which would mean increased product quality and decreased re-work)),and process reproducibility 
ii)increase machine metal parts lifetime by increased protection against corrosion
iii) increase usable lifetime of cold water and steam valves
iv) decrease dyeing process times.

In this respect, we are aiming to achieve a minimum of 20% gain in energy consumption, and overall 10% reduction in unit material production cost.

You cannot buy energy cheaper, but with a good insulation,you can achieve maximum gains.

If you are looking for a solution to insulation as well as corrosion protection, offering long-term usage, Nansulate is the ideal solution"

Ahmet Turgut
Factory Manager
Erenko Tekstil
www.erenko.com.tr

Industrial Nanotech's Distributor for Turkey is Kolorgen Ltd. Contact information can be found on our Distributor Map

TEXTILE DYEING MACHINES - ERENKO TEXTILE

ISSUE: Minimize oscillation of the reaction temperture for dyeing machine to improve reproducibility (color consistency). Insulate to decrease amount of energy used in equipment process.

SOLUTION: Nansulate® Translucent High Heat was used to insulate the dyeing machine. Monitoring a process that takes place at 60C for a 60 minute reaction time; the steam-based heat-exchanger of the un-insulated machine needed 24 heat-on cycles, whereas the Nansulate® coate machine's heat-exchanger only needed 2 heat-on cycles. Nansulate® also improved reproducibility - helping to keep the color of the fabric identical.

"Importance of Temperature Stability in Reactive Dyeing Process

In reactive dyeing of cotton, there are 5 important process parameters. (temperature, pH(acidity/alkalinity), salt concentration, bath ratio, reaction time)

For right-first-time dyeings, and reproducable quality, all of these 5 parameters should be the same, every time.

Parameters like bath ratio, pH, salt concentration and reaction time is nowadays closely monitored and faultlessy administered with the use of computerized controllers.

Reaction temperature is closely related to heat losses, as a result the reaction temperature oscillates below and above the reaction set temperature. This oscillation of temperature causes variability in dyeing so that reproducibility is quite low.

For reproducibility to be acceptable, dyeing machine and piping and circulation assembly should have proper insulation.

In pipes and certain other parts, conventional insulation is possible.

The problem area is the insulation of dyeing machine itself. It has large areas for heat loss, also it needs to be kept at a certain temperature for a defined duration.

Therefore, it may be possible to have better reproducability by dyeing machine insulation.

We have closely monitored a dyeing process which takes place at 60 C for a 60 minute reaction time; the steam-based heat-exchanger of the un-insulated machine needed 24 heat-on cycles, whereas Nansulate machine's heat-exchanger only needed 2 heat-on cycles.

This proves that by proper insulation, heat losses are minimized, it also shows that oscillation of temperature is decreased.

With a Nansulated dyeing machine, we have observed that the colour of fabric was surprisingly identical to one another, whereas in un-insulated machine, there is always a small difference in colour.

Ahmet Turgut
Factory Manager
Erenko Tekstil
www.erenko.com.tr

Industrial Nanotech's Distributor for Turkey is Kolorgen Ltd. Contact information can be found on our Distributor Map

HEAT EXCHANGERS - TEXTILE DYEHOUSE

ISSUE: Decrease LNG (Liquified Natural Gas) expense, improve energy efficiency.

SOLUTION: This Dyehouse, located in the Trakya region of Turkey, manufactures products for clientele which includes two of the largest sports apparel manufacturers in the world.

Nansulate® Translucent High Heat had been applied to all heat exchangers of the customer's dyeing machines. After monitoring closely their consumption of LNG (liquified natural gas) for a period of 5 months, it was shown that they experienced an energy savings of more than 20%. From this data, the company anticipates that their savings is approx. $40,000 per month in energy costs, and based on this data have contracted to have other areas throughout the factory coated with Nansulate®, such as their LNG burners, dye machines, fabric drying and ranges, steam pipes, valves and hot water storage tanks; with an expected further increase in the money they save per month on their factory's energy costs.

Customer savings: $100,000/year

Material cost for project: $40,000
Payback period: 4 months
Energy costs reduce by approximately 10%