Trützschler launches energy-efficient card – magazine for the nonwoven industry


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Global energy consumption hit an all-time high in 2019, after a 40-year trend of rapidly increasing energy demand that was only halted by the coronavirus pandemic. It is estimated that over 80% of this energy is still generated from fossil fuels which produce CO2 emissions and contribute to climate change. Renewable energies offer a solution to this problem, but saving energy whenever possible is an even more efficient approach. That is why Trützschler developed the TC 19i smart card, which sets a new benchmark in energy efficient carding.

Only the Trützschler TC 19i smart card is equipped with the unique T-GO spacing optimizer, which continuously and automatically monitors and adjusts the carding space to an ideal position during production. Today, more than 2,000 smart cards sold around the world demonstrate leaps in quality and production every day within a double-digit percentage range, reducing the demand for energy per kilogram produced. Innovative drive and air technology further reduces the power consumption of the TC 19i. In this way, the TC 19i saves energy to help protect the planet – and also increases the profitability of yarn production.

The most energy-intensive parts of a card are the drive, the dust extraction process and the compressed air system. Permanent vacuuming is required to remove dust and cotton waste at key locations. Unlike Trützschler cards, many cards on the market also use compressed air for the extractor hoods in the pre-carding and post-carding areas, for example. The intelligent optimization of these areas has made the TC 19i smart card a benchmark in energy efficiency in carding as it uses less electricity, lower suction pressure and less compressed air than others. machines, while offering the highest production rates currently available on the market.

In a direct comparison between the TC 19i and a competitor’s high performance board, the TC 19i consumed at least 10% less energy per kilogram of material produced when fabricating rotor wire from a blend of cotton and cotton waste. The energy values ​​compared included the consumption of electrical energy and the energy required for suction and compressed air and were measured in both maps at the same output of 180 kg / h. A 10% reduction in energy per kilogram of sliver produced, as demonstrated here by the TC 19i, can have a significant impact on the profitability of a spinning mill; annual savings of a five-digit value are often possible, depending on factors such as plant output. The customer test also showed the excellent reliability of the TC 19i at the customer’s usual production rate of 180 kg / h, and even demonstrated stable performance at 300 kg / h in the same application. Because the TC 19i with T-GO spacing optimizer achieves maximum production rates without compromising on quality, manufacturers can significantly reduce their energy demand and capital costs: fewer machines are required to achieve the desired yield and energy consumption per production is reduced.

In addition to increasing productivity, air technology plays a central role in the energy balance of the TC 19i. Christian Freitag, Head of Air Technology at Trützschler, explains how he has optimized the TC 19i in this area: “Firstly, we have reduced the need for compressed air as much as possible,” he says. “And secondly, we have reduced the suction pressure and the air requirements for the suction. All of our air collectors, for example, are carefully developed to eliminate potential resistance and facilitate ideal flow.

This improvement was made possible by a long and sometimes difficult process of innovation involving mathematical models of air flow, as well as flow simulations and prototypes. By combining the flow-optimized end pieces in the TC 19i, the experts at Trützschler have developed a card that operates with a suction pressure of only -740 Pa and with an air requirement of only 4200 m3 / h. This translates into less than 40% energy demand for air technology compared to the latest high performance competitor model.

“These accomplishments are fantastic, but we didn’t stop there,” says Ralf Helbig, R&D engineer for Air Technology at Trützschler. “We have also made it possible to further reduce the energy demand in polyester applications, which are increasingly important to our customers. In a polyester configuration, the TC 19i can reduce the pressure required to vacuum waste by an additional 14% thanks to improvements to the elements of the pre-card and post-card areas and the removal of the suction hoods. The suction is still as reliable as ever, but it requires a lot less energy.

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