Wednesday, February 4, 2015

No dyno grays? Really?

Yes, really.  The new FireFly curing system is the answer to zero dye migration.  It is the answer to flexible production.  It is the answer to reduced power consumption and reduced floor space.

It is the future of curing decorated textile garments.

So, how can we make these claims?  Easy.  By having these claims proven in production in large production houses around the US.  But enough bragging.  What exactly are we saying.

Let's start with the size of the oven.  The one pictured above has 3 belts that are 27" wide.  The total length of the oven is 15'.  So the final floor space is 12' x 15'.

That does not appear to be anything to get excited about.  But wait.

The production rates on a unit of that size is what gets attention.  
  • Plastisol  400 pieces per hour
  • Waterbase/Discharge 200 pieces per hour
  • Kornit 150 pieces per hour
  • Digital 85 pieces per hour
Yes, small but powerful.  But wait, there's more.

Size does matter, but flexibility is the key.

We understand that these numbers are impressive for a unit this small.  However, what really catches attention is what each lane can do.  Typical with split belt ovens, the chamber is at a constant temperature and air volume.  The only change available is the belt speed.  So if you set a chamber air temperature of 350F, then the operator can adjust the different belt speeds to accommodate white shirts versus black ones.

The FireFly is very different.  These units see every job as its own production item.  Each job has its own set of parameters that are programmed in.  Each garment has a bar code that will match its proper program.  The bar code is scanned and the oven lane will change all variables for that one garment.  Time, temperature, air flow is all modified for each garment as it is fed into the chamber.

Wait, what?  Read that again!  Time, temperature, air flow is all modified for each garment.  

That doesn't seem possible.  However, with the latest technology in thermal imaging cameras and our own software, the FireFly does just that.  Custom cure each garment.  One right after the other.

So how does that save power?

If a lane is idle, such as a job switch or break time, the machine heaters power down.  So, instead of running a large oven during lunch break making the dial on the electric spin, the oven would sit cold.  When the first garment of the next run appears, the lane will run a short pre-warming cycle and then allow the garment to enter.  Crazy stuff, right?

Also, if one lane is needed but the others are not, then only the one lane is hot. 

So the big question.  How does all this eliminate dye migration?

Dye migration is caused by the temperature of the garment getting high enough to reactivate the dye.  This dye will travel into other liquids, like plastisol.  So how does the FireFly fix that?  Each lane has a constant monitoring system that reads the temperature of the garment. The garment's allowed temperature is programmed into the software and the heaters are cycled on and off to stay within that temperature range.  If the temperature of the garment is kept below dye activation temperature then the dye migration is stopped. Bingo.  No Dyno inks needed.

Seriously!  This is all possible.

So, if the FireFly can do all of these amazing things, why doesn't everyone make them?  Well, that little secret is why this is a patent pending product.  But it is also the reason why you should own one. 

Call today for additional information.