Tintatex orders its 8th iMaster to become a 100% Thies dyehouse

Since its formation in 2005, Colombia’s leading commission dye house, Tintatex SA has reduced its water consumption from 200 litres/kg to 50 litres/kg – whilst increasing its production capacity from 80 t to more than 460 t; relying on new dyeing equipment from Thies including eight iMaster H₂O’s. The newly formed company initially relied on an old second hand Chinese dyeing unit producing 80 t/month. By 2006, with a restricted cash flow, the company was to purchase two new Chinese 150 kg capacity units.

“Whilst we were able to increase our production further with the new units they required long process times, high production costs and had high liquor ratios; nevertheless production was increased to 120 t – but at a cost.”

Within 12 months however, and based on his previous experience with Thies, Tintatex  General Manager, Jairo Ernesto Correa Sanchez had ordered two 250 kg, twin chamber, Luft Roto Plus dyeing units.

“With the market place changing towards polyester and synthetic fabrics, the improvements were instant with shorter process times and reduced liquor ratios. The Chinese models were considerably slower,” said Jairo Correa. “Production increased to180 t/month and water consumption was reduced to 200 litres, unfortunately energy costs were still too high,” he added.

In 2009 however, everything changed with the delivery of two 250 kg capacity, Thies Eco Masters; replacing the original Chinese unit.

Since then, Tintatex has ordered a further two 250 kg capacity units for delivery in February 2013 and, with another two 100 kg capacity units on order, both Chinese models will be resold; making Tintatex a 100% Thies dyehouse.

Water consumption has been dramatically reduced to 50 litres/kg and production capacity is expected to reach 460 t/month. The significant reduction of water consumption together with a decrease in the consumption of chemicals, dyestuff and energy has been an added focus for the iMaster H₂O.

“In practise it is possible to work comfortably with a liquor ratio of 1:4 or less,” said local dealer, Arjar’s, José Mario Rodriguez.

Jairo Correa confirmed liquor ratios of 1:3.5 are being used with synthetic fabrics and 1:4 for cotton.

Complex rinsing systems combined with ‘intelligent functions’ for the pre and post treatment of the fabric help to further reduce the total water and energy treatment.

iMaster H₂O transport winch

Another feature appreciated by Jairo Correa is a completely new design of rope dyeing for the processing of knit and woven goods.

By installing the transport winch inside the kier, cotton, synthetic fibres and their blends, including articles with a high elastane content are processed with significantly reduced elongation, resulting in fabrics of improved stability and surface appearance, while offering increased flexibility in the processing of a wide range of products.

In concluding, Jairo Correa said that he could not praise the Thies Setex electronic control system enough. “It’s the brain of the iMaster, very specialised, very smart and very fast. The software is excellent and it’s also easy to operate.”

Tintatex provides dyed fabrics for fashion wear in high quality viscose. lycra and cotton blends as circular knits and weights between 120 gm/m² - 300 gm/m².

Since those early days in 2005, Tintatex has continued to supply some 20% of its production to its original four associate companies but has also grown as a commission dyer with a customer base of almost 50 customers; with several growing at the same rate as Tintatex – to match Colombia’s textile boom.