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Experience Sharing on the New Washing Technology “PLUVIA CIRCUM DYE” with Textile Focus

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downloadPLUVIA launched an exclusive technology named PLUVIA CIRCUM DYE, emphasizing on productivity and water & energy consumption in dyeing after treatment and washing. The machine is suitable for both knit and woven process. This machine is developed by Turkish machine manufacturing company Tachyon and the machine is renowned after the brand name pluvia. This machine is said to play a significant impact for dyeing factories as Bangladesh is putting more priority in the area of water consumption, cost minimization and efficiency.  Recently, they have sold two units of machine in Epyllion Knitex and Libas Textiles.

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From left, Engr. Mr. Monowar Morshed, Service Manager, Mazim Corp., Md. Manjumul Huda Akand (Cony), Senior Dyeing Executive  of Epyllion Knitex; Mr. Imrul Quies, Assistant manager – Technical & Marketing Mazim Corp.; and M A Islam Riyadh, Editor, Textile Focus; during the experience sharing session at Epyllion Knitex.

Textile Focus arranged an exclusive experience sharing session with the concerned parties of the new technology including feedbacks from the local machinery supplier, Mazim Corporation, Tachyon representative, and the machine user, Epyllion Knitex.

We are highlighting all the new features of this machine along with the first-hand experience of the user in a view to providing technical insights of the pluvia technology to our valued readers and future potential customers.

Feedback of PLUVIA machine manufacturer, Tachyon, Turkey

A team of 4 engineer colleagues from Turkey came together to serve textile industry with energy efficiency studies and energy recovery systems. Energy and water consumption in textile mills, is the biggest cost issue, as well as being a global problem which have the most negative impact on the environment. Having this background, in 2013 they have founded TACHYON, meaning a theoretical particle faster than light and created PLUVIA brand which means waterfall. They have started studies as an R & D company for textile finishing machinery and achieved to produce textile finishing machines with the least water and energy consumption values so far.

TACHYON, aims to continue to maintain her presence by designing and producing smart machines for textile industry, together with valuable global partners. TACHYON consider Bangladesh as very potential market. Recently Mr. Murat Agagunduz, Co-Founder, TACHYON & Mr. Anil Bayrak, Regional Sales Manager, TACHYON visited Bangladesh to meet their potential customers. Textile Focus editorial team talked with Murat Agagunduz & Anil Bayrak about their products and services. Some of the key points are mentioned bellow for our readers-

Textile Focus: Can you give a brief of your company and how are you moving forward?

image003“I suggest the companies to concentrate on the cost of production so that they can increase their profit,”- Murat Agagunduz, Co-Founder, TACHYON

Murat Agagunduz: Actually, we have been in the textile business for more than twenty years. We first started with an energy-saving recovery solution for mainly the textile industry. We work at every corner of the dye houses that energy can be lost and power can be saved. So we are very experienced on the energy efficiency issue. At one point, we decided to stop energy saving but using energy efficiently. And we decided to make a new design. We also noticed that energy is mainly consumed on washing steps. So we concentrated on producing efficient washing machine. Eventually, we started our first design. By introducing this new design in turkey we got a better result than we expected. So as far as we know, currently our machines are the most energy-efficient machine in the world, especially for washing steps. We invented this textile machine by this story.

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“Bangladesh is one of the biggest textile producing countries all over the world. we want to take a share in Bangladesh Machinery market with our latest efficient machines”- Anil Bayrak, Regional Sales manager,  TACHYON

Textile Focus: How do you see the Bangladesh textile market as you are entering into this market?

Anil Bayrak: We have been studying the Bangladesh market for more than two years. Bangladesh is one of the biggest and important markets for our machinery. And we have started herein around 2018. We already sold two machines in the Bangladesh market. One is in Libas Textiles and the other one is in Eppylion. They are happily using our machine. For our future plan, Bangladesh is considered as a potential market. Because, as we know Bangladesh is one of the biggest textile producing countries all over the world. Mass production is going on here. Textile is also important for Bangladesh as it is driving their economy. So we want to take a share in Bangladesh Machinery market with our latest efficient machine. Another point is due to the COVID pandemic, countries other than China are getting more importance. We have the same situation in Turkey. Most of the knit producers are working with full capacity and I believe it will continue for the long term.

Textile Focus: What recent technology did you introduce which could help the post-pandemic situation?

Murat Agagunduz: Actually, our core design is concentrated on energy saving. I am not claiming that we are using high technology because all the machinery comes with stainless steel and the working idea is almost the same. However, we have some differences which make bigger results for especially energy savings. We concentrated on water savings which we can use for example washing the dark shaded fabric with 8-10 liters of water. This is for the time being the lowest value of water consumption in the world. Water reduction brings about energy reductions. As we use energy to heat water, if we reduce water, energy consumption will be automatically reduced. As I said, the difference is not coming from the technology but from the detail of the design on which we concentrated most. So we have several differences compared to the conventional machines. We focus on the washing effect by handling the fabric gently. The machine that has been sold in Eppylion is the CIRCUM DYE machine which saves 50-80% energy. And this is not what we are claiming. The result is obtained from practical experiments in the industry.

Textile Focus: How are you serving your clients in Bangladesh from Turkey HQ?

Anil Bayrak: We are working with Mazim Corporation here in Bangladesh which is one of the most experienced companies for textile machinery. We are handling our service needs by closely working with them. We are of course serving all the time with our technical team 24 hours a day. We are always ready to serve to make our customers satisfied.

Textile Focus: What is the difference between Bangladesh and other countries like India, Pakistan, Vietnam in terms of textile business?

Murat Agagunduz: Bangladesh, Pakistan, and India are concentrated on mass production of cheap price products where profit margins are very low. We believe that if a company concentrates on efficiency in each step of the whole production, they will be the pioneer of the market. I also believe, in the future Bangladesh will focus on value-added products. And we are seeing this development in the market.

Textile Focus: How are you observing the Covid-19 situation and how are you planning to move for the post-pandemic situation?

Murat Agagunduz: I believe; we just feel the same as you feel due to the COVID-19 situation. We are still confused about the situation. In the beginning, we overreacted about the COVID-19 and we had to follow some strict rules. We also had to shut down two weeks of production, however, we believe, we get accustomed to living with Covid-19. Now we are working with COVID-19 normally. Most of the companies are also working normally. Our production seldom stopped and still continuous. The demand for our machine is also continuous. So somebody will surely find the solution for COVID and I believe, we will not remember these days again.

Textile Focus: Any message for the Bangladesh textile Industry and your customers?

Murat Agagunduz: As I said before, Bangladesh is one of the leaders in textile productions. And it will get to increase their importance in the global textile market. I suggest the companies to concentrate on the cost of production so that they can increase their profit and compatibility to beat other countries. This is one of the biggest targets for all the market. We have a complete range of Rope Washing Machine After Dyeing, Rope Washing Machine After Printing, Drum Washing Machine, Open-Width Pad- Steam Bleaching, Optical Whitening Machine, and Open Width Form washing machine. We have designed a drum washing machine for normal fabric where we can wash silk fabric without a crease mark. The bleaching machine is the most compact machine in the world for the time being. We aim to continue designing and producing smart machines for the textile industry together with valuable global partners to make a better, resilient, and sustainable textile market

Feedback of Machine User, Epyllion Knitex

Epyllion Knitex has set up an 8-chamber pluvia circum dye machine in one of their dyeing floors in their textile factory. Epyllion Knitex Chief Operating Officer, Syed Sayeed Munir and Senior Dyeing Manager, Mr. Anowerul Amin shared their valuable experience and insights on the new machine.

Textile Focus: What are the key things that made you to consider the Pluvia machine for your factory?

image005“We are always looking for efficient technologies and arranging regular training programs to skill-up our employees.” Syed Sayeed Munir, COO,  Epyllion Knitex

Textile focus: How are you getting real-life benefit from this Machine?Syed Sayeed Munir: The main attraction of this Pluvia Circum dye machine is its less water consumption and processing time efficiency. In batch or exhaust dying machines, it needs to be cleaned after every step. We need to clean the machine before starting the process and after the process which consumes a huge amount of water and cleaning time. As pluvia is a continuous dyeing machine, it doesn’t need cleaning; as a result, we are experiencing less water and time consumption for every process. The interesting thing is that we can do subsequent washing steps like soaping, nitration, fixation, softening just after the dyeing of fabric by this new technologically advanced machine.

Syed Sayeed Munir: We can do subsequent washing steps like soaping, nitration, fixation, softening immediately after the dyeing of fabric by this new technologically advanced machine. So it’s a great benefit for us, as loading, unloading and cleaning take a huge amount of time. Again, water from the last chamber can be reused, so it is saving water in the process as well by reusing. I think the machine is still new to us and under the trial and error phase. We are still unable to use it to the full potential. We are performing different trials to see how we can yield more benefit from it. We did a wash of 175 kg fabric both in our previous machine and in this new pluvia machine. Our old machine took 3 hours for completing the whole process where pluvial took just 2 hours. So that is one hour saving in for 175 kg dyeing. For bulk production the time saving will be huge. Another important benefit area is the quality. We are very satisfied with the color fastness, shade consistency and fabric quality. This is the initial feedback. We will perform, more R&D and surely get more development. Still early days I think. Business is becoming very difficult now days as the profit margin depleting gradually. We have to control our costs in innovative ways. We are always looking for efficient technologies and arranging regular training programs to skill-up our employees. This machine is a long term investment of our company. I think it will help us achieve our goal of becoming a more sustainable company in future.

 

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Engr. Rothin Pallab Chakraborty, General Manager- Maintenance Department, Textile Division

Textile Focus: Are you satisfied with the service from Mazim Corporation and Turkish head office?

Rothin Pallab Chakraborty: Yes, we can say their service is till now satisfactory. From machine installment till today they are very cooperative. One more thing we would love to mention that we are always connected with Turkish head office for 24 hours through social media. When we face any problem, we inform them and they reply immediately. The service area of Pluvia is really praiseworthy.

Textile Focus: How are you saving water with this machine as the machine sellers are claiming?

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Anowerul Amin: The theory of reducing dyeing liquor ratio to lessen water usage is a misconception, because this concept increases the overall process which ultimately increase the water, energy and time consumption. So, with liquor ratio we have to manage other parameters also.  As this Pluvia machine perform both dyeing and washing simultaneously, our loading and unloading time for different machine is reduced here. There are 8 chamber in this machine. according to the Pluvia authority, we can just drop the first 3 chamber’s water and reuse the rest 5 chamber water. So this is a huge water saving which is adding new dimension to sustainability. issue.

Textile Focus: Is the machine energy efficient?

Anowerul Amin: Yes, this is another positive side of this technology. The machines come with an embedded system to reuse the heat lost with the outlet water. In our floor we do not have this system in other dyeing machines. The company claims it to be a very efficient machine in terms of electricity and steam consumption. We are really looking forward to it.

Feedback from Local Agent Mazim Corporation

Mazim Corporation represents Turkish Machine brand Pluvia, an initiative of TACHYON group, for Bangladesh Textile Market.

image008“Textile is an important income source of Bangladesh. The export of Bangladesh textile production takes an important role in the US, Europe, Canada, Australia and the Asian market. Made in Bangladesh ‘‘has taken an important place in the world textile market. The textile machinery Industry also plays a vital role in this great achievement. As a textile machine businessman I believe this upward trend will continue in the upcoming days as well” –   says, Ziaul Hassan Chisty, CEO, Mazim Corporation.


Textile Focus: How are you moving in this COVID pandemic situation especially in the textile machinery business?

Ziaul Hassan Chisty: Bangladesh is continuing to grow as a major textile machinery market as local textile and garments producers are expanding business riding on higher demand for garment items from international consumers. Due to covid-19, the whole industry got a huge shock. As a machine supplier we also faced some down market tendency, however, the situation has developed at present. During this global pandemic situation, we couldn’t approach the industry for selling our machine. So that we couldn’t earn much revenue. We have gone through a transition period.

Textile Focus: How are you getting a response from the industry for TACHYON?

Ziaul Hassan Chisty: Tachyon is one of the leading machinery companies which focus on energy issue especially in the phase of dyeing. Their machine is getting a notable response from the industry. We already sold two machines in the Bangladesh market. One is in Libas Textiles and the other one is in Eppylion. As our Bangladesh textile industry is focusing more on cost efficiency issues, so we believe these machines from Tachyon will surely help to reach prime success.

Textile Focus: How are you getting support from the TACHYON HQ?

Ziaul Hassan Chisty: One of the most important features of Tachyon is the quality of technical service after-sales. Their difference as a global brand is that they have adopted the principle of providing the fastest and highest quality service to customers with their expert technical team. We also have the characteristic of being a privileged company to meet the needs of our customers after sales with our expert engineers and technical staff. Tachyon’s service concept and quality are not only in discourse but also in its applications including spare parts support, material supply, after-sales technical consultancy, and the necessary services and assurance for customers; one-to-one satisfaction. We are proud of making cooperation with TACHYON which is very successful in the textile sector with its strong organizational structure. Their collaborative support from Head Quarter is praiseworthy.

Textile Focus: Based on your long experience in the textile machinery business how do you see the advancement of the industry in the last 20 years?

Ziaul Hassan Chisty: Our Bangladesh textile industry is moving so fast. Now we are the leader in the global textile and apparel market. If we talk about the industry transformation, 20 years ago our production capacity was very low and as we are moving with conventional machinery. Now the technology has been developed a lot. And we have increased our production capacity, the profit margin is also satisfactory whether competition has also been increased. Our new concept to minimize the production cost have lead us to technically suit.

Textile Focus: Any message from you for our industry regarding your products?

Ziaul Hassan Chisty: We have been representing some European textile machines (Bulk + Lab) in the Bangladesh market for the last 25 years. And we are leading this business in Bangladesh market. We are local agents of worlds reputed branded machinery for the textile sector. We have a much-experienced marketing team and highly skilled & professional engineers to provide the best possible services to our valued customers. We are marketing: knitting machine (flat and circular knitting), printing range: flatbed printing, rotary screen printing, digital printing, loop steamer, coating machine etc. Screen preparation unit (flat and rotary screen photoengraving equipment. Manual and automatic color kitchen. Rotary and flat-screen engraving equipment (screen exposing unit) for a printing project. Dyeing: yarn and fabric dyeing machine, fiber dyeing machine, rf dryer, hydro extractor, ghibli dryer, soft & hard winding, tfo : a complete range of lab testing, dyeing & finishing equipment, and accessories.  Our present collaboration with leading Turkish machinery company TACHYON will surely help to sustain the textile business in Bangladesh as their products are especially effective in the area of cost minimization. I wish this cooperation would be beneficial for both companies, we hope to contribute to this cooperation for BANGLADESH-TURKEY trade.

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