The final preparation is intended to pre-shrink, add a wrinkle treatment and mangle our textiles. Today's consumer requires that home and interior textiles are equal as easy to care for as clothing. Our final processing facility is developed by our own staff and offers unique characteristics that make less of an impact to the environment than traditional technology. Our system is fully self-contained and do not require a public sewer system while it at the same time using halve the energy consumption.
We manufacture multiple textiles side-by-side on the same loom. The process makes no marks on the edges from pins holding the fabric as done with traditional techniques. This saves on water and chemicals. The table below shows our preparation environmental advantages over conventional processing technology.
Description of the final preparation process.
1. At the Sewing Station, the various bolts of woven textiles is sewn together when a new bolt is added. The fabric is clamped with clamps perpendicular and then a self-propelled sewing machine sews end of one bold to the beginning of the next.
2. The feeding machine that pulls the textile fabric from the bolt.
3. The J-box is an intermediate station that is necessary for the final processing machine so that it does not have to be stopped when station A requires the sewing of the next bolt of textiles.
4. At the spray booth the fabric is sprayed with a liquid formulation. The nozzles are offset on both sides of the textile fabric for smooth application. The used chemicals arrive from a mixing station where the various fluids are pumped into a mixing vessel located on a scale.
(Thechemicals are mixed with our own rainwater. The resin and catalyst allows the fabric to gain permanent properties which makes it smoother after consumer laundry. Ekelund uses a formaldehyde-free resin since 2010. Surfactants facilitate resin penetration into the fibers and will be removed at the first wash. A softening agent prevents damage and gives the product a slightly softer feel. This agent is also removed by the first consumer wash.)
5. An extended transportation distance allows the liquid formulation more time to penetrate into the fibers of the textile.
6. The drying and curing machine. The textiles are transported flat on a belt through the dryer. We feed more fabric in than what comes out as the textile is pre- shrunk by a process of blown hot air at a temperature of 180 Celsius (360 F).The dryer is heated by propane gas. The processing speed is 8 meter per minute (26 feet/min).
7. Steaming, when the textile comes out of the dryer is the over-dried, and moisture is added back into the textile from steam the allow the correct moisture level for the next step. The steam is generated from a separate propane boiler which also heats the steel rollers of the mangle being part of the next step.
8. Mangling and Shrinking, the blanket covered mangles the textile on both sides. Warm highly polished steel rollers are presses against the thick felt blanket. Utilizing the features of the blanket under pressure we can further shrink the fabric lengthwise.
9. The finishing process is concludes with an inspection station with folding of the textile.
10. Folding is made with a plastic tube which prevents permanent pleats in the textile.
11. Shrinkage test samples are obtained from each finishing processing run.
Environmental Hazards: Leakage of processing liquid and chemicals. There are limited quantities used and given the lack of drainage in the room there is no risk of pollution. The procedure for collection of leaks and cleaning fluids is to collect it in its appropriate container, and sending it to local storage until processed. Ekelund has an environmentally safe storage space.
Environmental Benefits: Our final processing room has no drain. We have reduced our power consumption with 50%. We can run narrow textile widths simultaneously. Our operation saves on water and chemicals.
Total environmental gain
O = savings, * = reduced pollution
Energy(o) 66,000 kWh
Water usage (o) 33,000 liter
Nitrogen dioxide(*) 72 kg
Sulfur dioxide(*) 46 kg
Hydrocarbon(*) 8 kg
Carbon(*) 16,700 kg
Dust(*) 4 kg
Chemicals(*) 620 kg
Remaining environmental effect
Energy 29,000 kWh
Rain water use 21,000 liter
City water use 0
Water treatment 0
Nitrogen dioxide 9 kg
Sulfur dioxide 0
Hydrocarbons 0 Carbon(*) 9750 kg Dust less than1 Kg