The cotton yarn is winded on plastic dyeing tubes in pineapple shaped precision packages with our cutting-edge technology Fadis Syncro and Murata Machconer.
Precision winding ensures the best quality and eveness in the dyeing process making sure there aren’t any crossed lines within the cone, which will interfere with the optimal flow of the dyeing batch.
Our Murata machines are equipped with Uster and Fadis machines all have Mesdan Aquasplicer.
Yarn packages are put in our Laip and Loris Bellini pressurized machines with pumps powerful enough to penetrate evenly into the yarn. They firstly get prebleached to remove spinning mill oils, impurity and dirt. After that they are dyed and finished with special softners according to the composition and the shade in order to give a smooth and silky hand touch to the cotton.
After being dyed the yarn needs to be dryed. The packages are getting centrifuged at high speed to extract the majority of the water, after that they are positioned on a coveyer belt which goes through a radiofrequency system. To ensure a perfect and even drying, the speed of the conveyer belt is adjusted according to the size of the packages, the count and the composition of the yarn
This is a simple yet crucial passage. The yarn is put from dyeing cones to paper cones. We ensure that the density will not change among the cones and within the cone itself, since it may generate different tension in the knitting machine and defects. The yarn, during this passage is coated with a layer of paraffin to reduce the friction and have a smooth release during final use. We use only the best quality paraffins: Italian Pellizzari and German Reseda and we choose different characteristics according to the weather temperature and the yarn composition.
We have 200 spindles of Italian RITE gassing machine. The yarn passes through a flame which burns out the short fibers protruding, significantly reducing the hairiness. The result is a cleaner and brighter cotton. The speed of the machine is adjusted according to the yarn count.
The yarn from the cones is put on a 137 cm diameter hank, with our Italian Fadis reeling machine, fully electronic for precision winding. It is important not to have the wires crossing each other and to have a perfetcly homogeneous hank. This is why in Hatfil we choose the latest technology.
We have two Jaeggli Meccanotessile HL2000 mercerizing machines, for a production of 4 tons per day.
They are equipped with automatic robotic loaders. Here the yarn goes into a caustic soda batch and gets stretched. This operation gives higher tenacity and a silky brightness to the yarn.
The hanks are positioned in sticks carrying 4 or 5 hanks each and loaded into the dyeing tanks. The pressure is inferior compared to cone dyeing, therefore the yarn is stressed less during the process, giving a softer hand touch. All our machines are Italian Cubotex and Loris Bellini.
After the dyeing process the hanks are loaded into an automated Galvanin drying system. Firstly they are getting squeezed with rolls then they enter the chain inside the heated room. During their 10 hours journey on the chain, the hanks are slowly turning upside down, to make sure that they are homogenuosly dried.
The dried hanks are winded back on a cone and during this operation they are coated with paraffin.
Every lot has its friction tested, to make sure that the paraffin amount is optimal. If not sufficient we reprocess the lot.
We have mechanical Savio and Fadis electronic controlled TUAN-D machine.