BEN-WASH

Solubilizing. Diffusion. Dilution.

BEN-WASH

The EXTRACTA principle:

High washing efficiency with low water usage

The EXTRACTA principle divides the
washing process into stages that can be
repeated with accuracy. Besides making
the whole process easier to follow it also
makes it amenable to calculation. In each
of the separate washing chambers the
dirt or chemical liquor present in the cloth
is exchanged 50 to 80% for wash liquor,
which is loaded commensurately with dirt
and chemicals. Entrainment of the conta-
minated liquor with this cloth is prevented
by the EXTRACTA roller. In the next
chamber the liquor exchange is repeated
but with much lower dirt concentration in
the wash liquor. Together with the known
freshwater throughput, this predictable
action provides the basis for calculating a
washing operation in advance.
Minimal fresh water consumption
leads to saving in water, effluent and
energy costs
Capital investment and operating costs
determine the economy of washing
machines. The water consumption for a
defined washing effect is depending on
the type and number of washing
compartments. Our palette of compart-
ment types permits a machine configura-
tion that is as flexible as it is economical.
The right machine combination for
every requirement
The diversity of washing compartments
available and the modular design provide
the means for every industrial textile
washing need. By correct selection of
type and number of washing compart-
ments, the plant layout is adapted to any
customer requirement.

2
With Benninger, crease-free operation is a matter of fact

A crease-free fabric run is guaranteed

■ Large guide roll diameters and adapted

roll spacing that prevent the fabric from

skewing and guarantee crease-free
treatment from entry to exit of the range
■ Computer controlled tension force

from 100–500 N with press rolls or,

200–600 N without press rolls
■ Screw expanders with separate drive

■ Free running outer bearings with mini-

mal friction
■ on bath rolls

Self-aligning ball-bearings, life-time

lubricated, with carbon sliding ring
seals;
■ on upper rolls

Self-aligning ball-bearings; life-time

lubricated, with PTFE labyrinth seals;
■ on press rolls

Self-aligning roller-bearings; life-time

lubricated, with PTFE labyrinth seals.

Drive control via swiveling

compensators and load cells
Intermediate squeezers (pulling/squeez-
ing device) are controlled via swiveling
compensator and frequency converter
in the next compartment. The upper roll
single drive is controlled with a separate
frequency converter; in compartments
followed by a pulling/squeezing device
via a measuring roll with a load cell;
in compartments without subsequent
pulling/squeezing device via the swive-
ling compensator of the following com-
partment.

Angle detector of Swiveling compensator for drive Load cell

control

3
BEN-WASH
Energy saving starts in the washing compartments
High-efficiency washing compartments DA with intermediate squeezer
DA 3 DA 5
Fabric content 13 m Fabric content 23 m
High-efficiency washing compartments DA C without intermediate squeezer
DA 3C DA 5C
Fabric content 15 m Fabric content 25 m
These high-performance, double loop
washing compartments with rubber coa-
ted press rolls, especially recommended
for medium to heavy fabric, achieve a
maximum washing effect.
In each washing chamber, the fabric is
immersed twice in the washing liquor
which is then pressed through the fabric
in the nip pools between roll and fabric.
The intensive liquor exchange in the fab-
ric is supported by the cross flow in the
chambers.
Good accessibility to the washing
compartments, covers can be lifted easily
4
DA 7
Fabric content 32 m
DA 7C
Fabric content 34 m
The single driven upper rolls with press
rolls (EXTRACTA squeezers) are a fully
fledged drive. Thus no other additional
drive in the form of an intermediate
squeezer is needed, as is the case with
sliding clutch and relax drives.
No steam escapes from the steamtight
EXTRACTA washing compartments
even at high temperature. The steam
sealing of the entire washing range
leads to a better washing effect, and
energy consumption is distinctly
reduced.
The variety of compartments gives you flexibility

High-efficiency washing compartments EA with intermediate squeezer

EA 3 EA 5 EA 7
Fabric content 9 m Fabric content 15 m Fabric content 20 m

High-efficiency washing compartments EA C without intermediate squeezer

EA 7C EA 5C EA 7C
Fabric content 9 m Fabric content 15 m Fabric content 20 m

The EA high-performance washing com-

partments use the same principle as the
DA compartments, with press rolls
(EXTRACTA squeezer) and individually
driven upper rolls.

Washing compartments with 3-, 5 or 7

chambers with single loop, upper roll drive
and press rolls for best liquor separation.

Single loop provides better accessibility

to the cloth and easier handling. As only
one immersion per chamber is possible,
the washing effect with the same amount
of water (per cloth weight) is lower than
with double loop. This effect is compen-
sated for by the greater number of wash-
ing chambers per compartment. The
residence time in the EA washing
compartments is, however, lower than
with double loop.

5
EXTRACTA

The plain wash compartments with stripper roll

Washing compartments E with intermediate squeezer

E3 E5 E7
Fabric content 9 m Fabric content 15 m Fabric content 20 m

Washing compartments E C without intermediate squeezer

E 3C E 5C E 7C
Fabric content 9 m Fabric content 15 m Fabric content 20 m

No rubber coated press rolls

The advantage of this model lies in the
low maintenance costs, as these com-
partments have no rubber coated press
rolls (EXTRACTA squeezers).

Optional single drives

For tension sensitive styles, upper roll
single drives are available as an option,
whereby the number of drives is freely
selectable.

The plain wash compartments with strip-

per roll for liquor separation are used with
individual drive for open and lightweight
cloths with single liquor separation.
Liquor exchange and washing efficiency
are much lower for reduction washing
than with the EXTRACTA roll system.

6
EXTRACTA compartments enable most economical washing

Reaction compartments D with intermediate squeezer

D3 D5 D7
Fabric content 13 m Fabric content 23 m Fabric content 32 m

Reaction compartments D C without intermediate squeezer

D 3C D 5C D 7C
Fabric content 15 m Fabric content 25 m Fabric content 34 m

This disadvantage can be compensated

only by making the machine longer or
using more water.

The high-performance ‘D’ wash compart-

ments follow the principle of the ‘E’ com-
partments.
‘D’ compartments are used mainly for
post-dye washing, where good diffusion
and long reaction time are demanded.

7
Profit from these advantages
■ Flexible machine layout due to the

variety of models and the modular

design
■ Operationally reliable and functional

design
■ Calculable washing effect

■ Controlled reproducible results

■ Closed steamtight machine

■ Best possible washing effect

■ Compartments with two separate

sections
■ Low water and power consumption

■ Only single drives applied

■ Constant fabric tension

■ Crease-free operation
FORTRACTA

High-performance washer for surface contamination

The FORTRACTA prewasher is a further

development of the proven Benninger gap
technique for washing-out contamination.
The cloth web is led upwards in two ducts.
The wash liquor flows down by gravity
similar to a waterfall. A strong washing
action is obtained by this counterflow prin-
ciple in the duct. Liquor separation is
effected by stripper rolls and flat jet nozzles
at the exit from the FORTRACTA compart-
ment.

Since the fabric carries large amounts of

chemicals especially at the beginning of
the wash, rubberized rolls are not provi-
ded in this compartment. The short dis-
tances between rollers and the large roll
diameters assure creaseless cloth
running.

10
Economics determine the washing procedure
With the classical roller vat washing
process where the fabric is moved
through stationary liquor with only short
reaction times, costs can hardly be
reduced. In this process high molecular
weight substances are fully swelled and
as consequence lead to an increase in
viscosity, conglutination and therefore a
high water consumption.
BEN-CONTROL Speak with data
The Benninger patented concept on the liquor circulation system. The INJECTA
other hand, is based on a significantly offers numerous process variations and
lower water and steam consumption and thus a high degree of flexibility in styles.
minimum use of chemicals. As opposed Through the shock heating of the wet
to conventional methods, comparable fabric to 100°C in the INJECTA the high
results are better and achieved substan- molecular weight substances swell up
tially quicker. immediately, with a simultaneous reduc-
tion in viscosity through the effect of the
A quite natural washing process high kinetic energy. This means that they
The fabric passes through a narrow cas- are removed with a significantly smaller
ing divided into two shafts. Steam and quantity of water.
water are directed onto both sides of the
fabric, either individually or in any desired
combination. Due to the slot and shaft
geometry high flow speeds are caused
which create a high kinetic energy.
According to the process used, operation
can be with counter-flow water only from
the following washing compartment and a
11
INJECTA

Rationalized removal of high molecular weight substances

Optimized desizing
The size is removed to the extent that sub-
sequent processes can be carried out in
the best possible manner and without diffi-
culty. Water-soluble sizes such as PVA,
PAC, PES and CMC, and also unmodified,
water-insoluble starch sizes are removed
with a very high removal rate and low
water application of 3–5 l/kg. 100% syn-
thetic fabrics can also be successfully
desized in this manner. Airbag fabrics are
cleaned to the required residual content
of < 0.5% by the INJECTA.

Do you wish to wash out conventional size

and printing thickeners, that is, high mole-
cular weight and adhesive substances with
a high swelling capability? Or must PVA,
PES sizes, spinning or spooling oils be
removed from synthetic fabrics? You can
solve all your critical tasks with the new
INJECTA washing system.

To facilitate infeeding the fabric the shafts can

be opened

The INJECTA makes the single-stage

BEN-BLEACH concept feasible: In one single step! – from
greige to finished, dry fabric.

12
Clean washing is a matter
of superior technology

Profit from INJECTA advantages

■ Significantly lower water and steam

consumption
■ Highly concentrated effluents provide

ideal conditions for partial flow dis-

posal or size recycling
■ The washing effect of a single

INJECTA compares to that of a

multi-chamber high-performance
full-width washing machine
■ Printing after treatment is no problem

with no danger of staining the ground

■ Continuous desizing of

water-insoluble starch sizes

13
TRIKOFLEX
Low-tension open-width treatment
Benninger, the leading manufacturer of
roller vat washing machines, is also
your best advisor for drum washing
machines.
The TRIKOFLEX system, ensuring low
tension treatment of knitted, pile and
woven fabrics, has set new standards in
textile finishing.
Incorporating a range of system improve-
ments, Benninger has found the best way
to meet increased market requirements.
The TRIKOFLEX LT-DB in a few words ■ Liquor separation due to two circulating
systems
■ Flexibility due to modular concept
■ Counter-flow by gravity possible over
■ Box design with excellent torsion and
the whole washing range
floor stability
■ Spray pipes adjustable from the outside
■ No transmission drives nor friction
■ Functional, modern design
clutches; only single motor drives
■ Level of automation as required
■ Separate intermediate squeezer
■ Connectable with EXTRACTA
compartments
■ Excellent accessibility to the squeezers
and compartments for cleaning/
maintenance
■ The entire machine is steamtight
■ Optimum shrinking results ensured by
single motor drives
■ Two side washing, specially important
for dense fabric
■ Large guide roll diameter and proper
spacing ensure crease-free operation
14
For mono- and bi-elastic woven goods

Result:
The new Benninger TRIKOFLEX genera-
tion enables the finisher to treat the entire
range from mono- and bielastic, as well
as crease sensitive woven fabrics without
problems and at low tension. This con-
cept also offers savings on water and
energy.

15
TRIKOFLEX

Flexibility in the structure

TRIKOFLEX LT-DB TRIKOFLEX LT-DB C TRIKOFLEX LT-DB C-R

with intermediate squeezer without intermediate squeezer with reaction zone

1 liquor circulation 1 liquor circulation 1 liquor circulation
Cloth content 8 m Cloth content 7 m Cloth content 12 m

TRIKOFLEX LT-DB 2 TRIKOFLEX LT-DB C2 TRIKOFLEX LT-DB 2/2-R

with intermediate squeezer without intermediate squeezer with reaction zone for neutralisation
2 liquor circulations 2 liquor circulation 2 liquor circulations
Cloth content 8 m Cloth content 7 m Cloth content 12 m

Taylor made concepts

Depending on the fabric and the process,
the modular build system TRIKOFLEX
can be delivered in various versions.

■ LT-DB with one liquor circulation

with 60 m3/h
■ LT-DB 2 with two liquor circulations
with 2 x 30 m3/h
■ LT-DB with intermediate squeezer
■ LT-DB C without intermediate squeezer
■ Direct steam heating, or indirect hea-
ting with heat exchanger
■ Mechanical, or automatic self-cleaning
filters
■ Various drive systems

16
Grooved drum

Drawing of the active washing

principle with grooved drum
1 Closed drum body
2 Groove profile
3 Mesh belt
4 Fabric
5 Outer liquor film
6 Spray pipe

The heart of the TRIKOFLEX washing The result: Spray battery

system is the grooved drum with a com-
bination of grooved profile and mesh
covering.
It serves as a supporting element for the
fabric. The large surface of the drum
ensures smooth and low-tension fabric
passage over a long contact path. The
enclosed design prevents impurities from
entering the drum.
Further features:
The washing liquor penetrates the fabric
and forms a liquor film on the front and
back side. In this way, impurities on both
sides are quickly removed. At the same
time a cleaning effect within the mesh is
created. The washing effect, compared
to standard mesh and screen drum sys-
tems, is considerably increased.
The spray battery with adjustable spray
angle is decisive for the optimum wash-
ing effect, in addition to the grooved
drum. The washing liquor is constantly
circulated through the spray pipes within
the compartment by means of a pump.
This produces a cross-flow and a heavy-
flowing liquor film on both sides of the
fabric. This ensures optimum mass trans-
fer and removal of the substances being
washed off.

■ Minimum deflection points

■ Short fabric path in the area of the
drum, trough and compensating roll
■ Large roll diameter
■ Low tension fabric transport through
controlled single motor drives

4 spray pipes are arranged around the

grooved drum and integrated into the cir-
culating system. These ensure the ex-
tremely high washing efficiency at great
circulating capacities.

The drum surface forms the groove pro-

file with a mesh covering. As the fabric
passes through the spray section, it is
supported by the drum surface and is
thus unable to avoid the hydrodynamic
water pressure.

17
TRIKOFLEX

Maximum washing efficiency through circulation and counter-flow

A meandering liquor guidance principle,

similar to that found in vertical washing
machines, has been used for the first
time in the TRIKOFLEX drum washing
machine. The liquor guidance, in con-
junction with the spray line mechanism,
results in the high washing effect of the
basic LT-DB model.

Compared to the LT-DB, the washing

effect of the TRIKOFLEX LT-DB 2 is in-
creased by the addition of a second,
independent circulation flow and bath
separation.

This bath separation allows the tempe-

rature of the liquor to be varied within
the drum washing compartment. This
is especially important for even fabric
shrinkage.

The washing effect of the TRIKOFLEX

washing machine has been tested under
production conditions. Results show a
40% increase in the washing effect at-
tributable to bath separation and second
circulation flow.

TRIKOFLEX LT-DB 2 with two liquor TRIKOFLEX drum washing machine comparison,
circulations and bath separation one (LT-DB), two circulation system (LT-DB 2) and EXTRACTA (DA 4)

Co/LY 97/3%
Twill 2/1 - 240 g/m2
V = 40 m/min
T = 95°C
Water: 4 l/kg

Number of chambers

18
Shrinking with lowest fabric tension

Continuous shrinking, desizing and washing of Filaments (PA 6.6, PET, PTT, PBT, PP)

Multi-flexible pre-treatment and washing range for tension-sensitive fabrics

Washing after Rinsing Oxidation Soaping Washing, Neutralizing, Rinsing

Vat-printing
Washing after Rinsing Reductive cleaning Washing, Neutralizing, Rinsing
Disperse-printing
Washing after Rinsing Washing, Neutralizing, Rinsing
Reactive CPB, Dyeing
Cold/Hot, Caustification Rinsing Impregnation, Caustification Washing, Neutralizing, Rinsing
Of Viscose
Washing after, CPB- Rinsing Impregnation, Bleaching Washing, Neutralizing, Rinsing
Bleach + Shock-bleaching
Washing after Washing, Neutralizing, Rinsing
CPB-Bleach

Use of the TRIKOFLEX drum washing
machine is called for when fibre mate-
rials show a high shrinking potential or
if an increased risk of creasing exists
in a roller vat.
Shrinkage occurs at the first contact with
hot water. The rate and degree of shrink-
ing is dependent on the temperature.
Dimensional changes (length/width) in the
fabric must not be inhibited during this
stage of processing.
The TRIKOFLEX makes processing at
different temperatures possible within a
washing compartment. The advantage
is that a slow and even shrinking can be
attained across the entire width of the
fabric.
The drive technology plays an equally
important role in achieving an optimal
result. TRIKOFLEX drums are controlled
by rotary magnet motors, or tension
control (load cells).
Should longer washing and dwelling
times be necessary the TRIKOFLEX can
be complemented with the EXTRACTA
roller vat washing compartments. Larger
fabric contents lead to longer diffusion
times. A high degree of washing efficien-
cy is guaranteed by separating the liquor
in different chambers.

19
REACTA

Diffusion washing processes

Washing in spray and reaction aggregates

Efficient washing is of central

importance during textile finishing and
is defined by the factors mechanical
action, time, temperature and water.

Depending on the washing task the

weighting of the individual factors varies.
Often the term washing is only associa-
ted with dilution washing whose success
essentially depends on the water tempe-
rature and mechanical washing action.
On the other hand, reaction processes
require a specific amount of time for the
chemical reactions to take place. The
fastness wash for obtaining wear-, wash-,
or water fastness falls under the term
diffusion wash. Objective of this washing
process is to bring the unfixed residual
dye in the core of the fibres to the fabric
surface and to remove it. Here time and
temperature are key factors.

20
Weighting of the factors that affect textile washing processes

Machinery-related requirements and

equipment for the diffusion wash Temperature

Diffusion washing processes cannot be

undertaken satisfactorily using common
washing systems; the investment
required is also excessive.

The fabric content is not sufficient, to

perform a soaping process for 2-8 mi-
Fresh water Time
nutes. Time-consuming washing pro-
cesses can be performed significantly
better in dwelling compartments.

For diffusion washing and reaction

processes Benninger relies on roller bed
dwelling compartments with additional
spraying areas. The washing principle
applied by Benninger is based on the
Mechanical washing action
principle of seeping wash, where liquor
is applied to the textile substrate and Dilution wash
slowly seeps through the fabric. caustic soda, salts, H2O2,
emulsified oils
Unlike storage racks, accumulator belts
or chains, the roller bed used by Fastness wash (diffusion
Benninger has the major advantage that wash) reactive dye, etc.
the pile of fabric is continuously in motion
and is passed from roller to roller. The re- Reaction processes
lative motion within the individual fibres demineralisation, oxidation,
and threads improves the penetration of neutralisation, emulsification
the capillary spaces by the seeping water.

21
HYDROVAC

Economic water removal with Vacuum Systems

The Hydrovac vacuum technology

is applied in situations where an efficient
bath separation is required. Simultaneous
to the extraction of water, lint, emulsified
and dispersed contaminants, hydrolysed
dyestuff and sizing agents are removed.
At the same time, the possibility exists to
separate this polluted liquor from the
process water. The fresh water consump-
tion is considerably reduced due to the
increased degree of concentration that
develops during the ensuing washing
processes. Partial disposal of this highly
polluted liquor can reduce waste water
contamination (COD) considerably.

Separator
The cyclone separator with pre-separa-
tor and the newly developed air flow
system guarantee optimum separation.

1 5

3
2

1 Suction tube
2 Pre-separator
3 Water separator
4 4 Diaphragm pump
5 Rotary pump

22
Increased washing efficiency and simultaneously reduced impact
on the environment

Suction tube Rotary pump blower Blower aggregate

The conical construction prevents the
accumulation of contaminant residues.
The fabric is exposed to practically no
friction at all as it passes over the slot
opening, which is adjustable and easily
accessible from above.
The so-called ‘Roots’ pump is the most The noise reduction hood offers easy
economic and efficient vacuum system access to the blower aggregate and its
available. various components, e.g. the suction
silencer.
Air control
A secondary air adjustment valve is
utilised to control the system (a frequen-
cy converter is used in some cases).

The efficiency of a vacuum system is contingent

upon the type of fibre and construction.
The table below shows average rates of residual
moisture achievable.

The advantages at a glance:

Acetate
Acetate Filament ■ Partial flow recycling is achieved
Cotton by separating the concentrated
polluted liquor
Lyocel/Tencell
■ Removal of contaminated liquor
Polyacryl from the process water enables
Polyamide Filament increased washing efficiency
Polyamide Staplefibre ■ Emulsified and dispersed
contaminants are removed
Polyester Filament ■ Especially suited to remove
Polyester Staplefibre printing thickener and size
Polyester/Cotton ■ High dewatering values particularly
for synthetic fabrics
Polyester/Viscose 65/35
■ Possibility for size recovery
Polyester/Wool 55/45
Viscose Filament
Viscose Staplefibre
Wool

23
Locations

Head office
Uzwil, Switzerland

Subsidiaries
Mumbai, India
Shanghai, China
Zell, Germany
Zittau, Germany

Representative office
Moscow, Russia

The Swiss company Benninger has been the textile industrys leading partner across the globe for one hundred and
fifty years with global branches and service representatives. Benninger develops and manufactures textile finishing
and cord production ranges as well as providing complete system solutions. As the market leader Benninger will
continue to rely on its comprehensive process know-how in order to be able to offer high-quality installations with
excellent customer service.

Benninger AG Benninger Zell GmbH Benninger India Ltd.

9240 Uzwil, Switzerland Schopfheimerstrasse 89 415 /416 & 417
T +41 71 955 85 85 79669 Zell i.W., Germany Sunshine Plaza
F +41 71 955 87 47 T +49 7625 131 0 Dadar (East)
benswiss@benningergroup.com F +49 7625 131 298 Mumbai 400 014, India
bengermany@benningergroup.com T +91 22 4322 7600
www.benningergroup.com F +91 22 4322 7601
Benninger Zittau benindia@benningergroup.com
Küsters Textile GmbH
Gerhart-Hauptmann-Strasse 15 Benninger Textile Machinery Co. Ltd.
02763 Zittau, Germany Room 904, Tower A
T +49 3583 83 0 City Center of Shanghai
F +49 3583 83 303 100 Zun Yi Road
kt@kuesters-textile.com Shanghai 200051, P.R. China
T +86 21 6237 1908
Benninger AG F +86 21 6237 1909
Moscow Office benchina@benningergroup.com
Leningradsky pr-t 72
Bld. 4, Office 802
125315 Moscow, Russia
T +7 495 721 18 99
F +7 495 721 30 84
benrussia@benningergroup.com

You can feel it’s Benninger