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WUMAG TEXROLL reduces Life Cycle Cost of Cylinder Dryers


The overall energy consumption of the cylinder dryer was reduced by up to 30%.

The challenge in terms of sustainability:

Life Cycle Cost (LCC) refers to the total cost of ownership over the life of an asset. For example, the LCC defines the cost of owning an automobile from the time of purchase by the owner, through its operation and maintenance to the time it leaves the possession of the owner. Comparative LCC studies between various vehicles help consumers to choose a car. LCC consists of the total of the Cost of acquisition (e.g. Initial investment in the machine) and the Operating cost accumulated over the useful life of the investment. Looking at the different cost factors it became obvious that for a typical cylinder dryer in a textile wet finishing application the acquisition costs can almost be neglected compared to the operating costs. Inside the various operating costs the energy costs burry the highest potential for optimisation.

The initial situation:

The cylinder dryer operates in an interactive relationship to surrounding area and hall ambient climate. The evaporated water is extracted with simple steam extraction hoods and extraction fans. The air extraction speed underneath the hood has to be chosen very high in order to avoid steam escaping to the surrounding and also to avoid condensation because the relatively cold air can not carry enough evaporated water.
In an open installation of a cylinder dryer drastic energy loss is caused by radiation and convection. Especially the extraction of great quantities of ambient air creates a loss of expensive steam energy and therefore of valuable fossil fuels. The energy costs during the lifetime of a cylinder dryer are normally a 2 figure multiple factor of the investment costs. Another problem is the influence to the hall climate – especially during winter time the hall heating has to replace the large amounts of extracted air.
Last but not least it is a very hot place for the machine operators to work next to a cylinder dryer.

The solution:

The WUMAG TEXROLL Cylinder Dryer is separated from hall ambient by a special encapsulation and equipped with the new developed WUMAG TEXROLL SteamPlus and AirPlus performance systems. Due to these features the evaporation capacity is increased and simultaneously the quantity of extracted air is drastically reduced. AirPlus stands for energy recuperation which is directly brought back into the drying process. The SteamPlus system stands for perfect temperature accuracy, improved regulation dynamics and a complete saving of the bypass steam loss. All systems are designed as Add-on packages and can also be retrofitted onto existing machines.

The sustainable strengths:

The overall energy consumption of the cylinder dryer was reduced by up to 30%. The hall climate is highly improved and the hall air conditioning is released which gives another energy saving effect. The operators are now working in a normal temperature condition next to the cylinder dryer. The fabric is produced under defined reproducible conditions with exactly adjustable residual moisture which gives a great benefit in production quality.

The inventors:

Mr. Karl-Heinz Vaassen: General Manager
Mr. Müller: Sales Director
Mr. Römer: Design Manager
Mr. Ravi Jathar: Area Sales Manager

Brief profile of the company:

Headquarters: Krefeld, Deutschland
Year established: 1948
Employees: 95
Solutions: Rolls, Cylinder Dryers, Calenders, Laminators, Heatsetting Machines

Internationality: WUMAG TEXROLL Shanghai Office