Vario Line Jigger
A jigger has been constructed in such a way that the energy it requires is kept to a minimum despite maximum production efficiency. The result, the Vario Line jigger, is an all-purpose precise jigger which can even process the most complex of woven goods. The Vario Line jigger is built in roller widths of up to 4000 mm and in three different versions for maximum batching roll diameters (1000/1200/1400). The outstanding features of the Vario Line jigger include rational use of energy supported by the latest control technology as well as innovative design and materials from aerospace engineering.
The Vario Line jigger is controlled electronically using the very latest processors. All the electronic elements are produced in Germany and permit the smooth, problem-free running of the drive rollers, safe opening and closing of the cover hoods, checks on the liquor status etc.
Two large viewing windows allow optimum monitoring of the cloth during the process, supported by the very latest in fluorescent lamp technology. Both viewing windows are opened and closed electrically. The hermetic closing of the viewing windows guarantees a constant temperature within the hood area and ensures that lighter-coloured end pieces are minimised. The formation of condensation drips is also avoided.
The dyeing and washing result is improved by the design of the temple rollers. Both temple rollers are adjustable and make even gentler fabric transport possible. The shape of the temple roller lips also protects even the most sensitive of cloth types.
The use of a state-of-the-art high-performance plate-type heat exchanger guarantees the extremely fast heating up or cooling down of the liquor. The large surface allows a high degree of energy transmission. The plate design makes maintenance easier and reduces the risk of blockage through fluff. Both aspects significantly increase working efficiency. The treatment temperature is quickly reached and kept constant thanks to the good insulation of the Vario Line jigger. This results in considerably shorter passage times.
Ceramic roller bearings
The use of ceramic roller bearings rather than carbon/steel ball bearings means the main rollers run extremely smoothly in the jigger. The high tension exerted on the fabric, which can lead to heavy warpage and loss of elasticity, is thus reduced to a minimum or excluded completely. In the case of the Vario Line jigger, special self-aligning ball bearings are installed which absorb radial and low axial forces even more easily. These are double-row bearings with a hollow sphere outer ring raceway. The angle adjustment is relatively large and compensates alignment faults, shaft bending and housing deformation caused by high temperatures without any problem. Ceramic roller bearings are non-magnetic, non-conductive, resistant to abrasion and corrosion. They do not need any oiling or grease lubrication and work at any temperature. Ceramic bearings require much less maintenance.
The sturdy design of the Vario Line jigger guarantees a long service life. High costs for maintenance and repairs are a thing of the past.
The liquor trough has a special shape. This provides an extremely favourable and constant liquor ratio. A small trough version makes economical dyeing and washing possible for small batches. This allows a great deal of flexibility and fast reactions to any requirement.
The unique Vario Master Roll lowers the number of passages by about 35% and reduces water consumption. The special mounting of the guide rollers guarantees smooth fabric running in order to achieve the best possible dyeing and washing result. Intensive maintenance of the carbon or sleeve bearings is a thing of the past.
The two main carrier rollers, driven by two frequency-controlled three-phase motors with brake force recuperation (resulting in an energy saving of approx. 33%) have a high-quality stainless steel sheath and are mounted on special bearings at the ends of the rollers. We deliver the Vario Line jigger with an automatic changing jig as standard. Displacing the main roller in the longitudinal direction achieves a significant edge running advantage. The maximum fabric speed is 150 m/min. This drastically reduces production times.
The Vario Line jigger is setting new benchmarks. Versatility and flexibility are almost unlimited. Pre-treatment, post-treatment, nuance compensation following continuous dyeing are additional possibilities. Innovative process software and the latest technologies on a mechanical basis make a maximum degree of discontinuous dyeing, washing and bleaching possible.
For the first time, the unique ceramic roller bearings permit gentle pre-treatment and dyeing methods to be used on the jigger for elastic results. Knitwear and items containing spandex can be treated crease-free with low liquor relations.
Even temperature, constant material tension, even fabric speed and an optimum liquor ratio are some of the most important factors necessary for top quality. The controlled monitoring of the process data with the Vario Line jigger offers optimum reliability. The Vario Line jigger is economical, easy to use, environmentally friendly and Made in Germany.
General design data:
- Constant material tension
- Even fabric speed
- Favourable and constant liquor ratio
- Special shape of the temple rollers
- Perfect monitoring through large viewing windows
- Guide roller bearings without friction
- Stainless steel liquor trough with insulation and economy trough
- Vario Master Roll reduces passages
- Automatic changing
- Circulation pump for even distribution
- Filter station
- High-performance heat exchanger
- Batching tank with mixer and flushing lines
- Programmable dosing system
The supports are made of a very special polymer cast material:
the energy required to produce a cast polymer part is around one
tenth compared to the production of cast iron 25 or steel. Optimum use is made of
natural resources. This means that one kilogram of raw material results in one kilogram of machine. In the case of cast iron or steel, on the other hand, a multiple of the raw material recovered (ore, coal) must be moved in the form of waste (slag and ash).
With all processes involving cast iron and steel, the dust, carbon dioxide and carbon monoxide emissions are much higher than with the polymer casting process. Not forgetting the waste such as used sand, slag etc. which is produced, too. Cast polymer material has an outstanding eco-balance and can be recycled.
Apart from the cast polymer supports and ceramic bearings, the rest of the machine parts are made of high-quality stainless steel. Maximum resistance to acids and alkalis, reduction and oxidation agents, gases and vapours as well as most chemicals guarantee high operational safety. Excellent workmanship in the trough, in the rollers and all other steel elements is the key to problem-free production.
|Batching roll diameters||1,000, 1,200 and 1,400 mm|
|Max. fabric width||1,800 to 4,000 mm|
|Max. machine width||3,700 to 5,900 mm|
|Machine height||2,430 mm|
|Machine depth||2,200 mm|
|Hood projection||2,500 mm|
|Trough (min./max.)||110/880 to 330/1980 litres|