Award-Winning Finishing Technology

Then Maschinen's Wilhelm Christ receives prestigious award for Airflow® technology.

Jürg Rupp, Executive Editor

W hat began in 1979 with an ingenious idea has developed over the years into one of the most environmentally friendly technologies in the dyehouse sector of the textile finishing industry. In February 2008, the reward came: Wilhelm Christ, the long-time head of technological development at Then Maschinen GmbH, Germany, was awarded the Economic Medal of the State of Baden-Württemberg, Germany.

Outstanding services on the part of personages, companies and other institutions to the economy of the federal state of Baden-Württemberg can be honored with a medal that bears the designation, “Wirtschaftsmedaille des Landes Baden-Württemberg.” It is awarded for special professional or entrepreneurial achievements in the service of the economy of Baden-Württemberg. All areas of economic activity should be taken into account, especially those relating to professional training, research and development, technology, environmental protection, foreign trade and development aid.

Ernst Pfister, the minister for trade and commerce, medium-sized companies and technology, presented the award to Christ. Numerous prominent guests from the worlds of politics and business as well as from his employer paid tribute to Christ’s life work, which commenced in 1966 when he joined Then Maschinen and eventually developed the Airflow® technology.

A Short History

Rudolf Then gathered initial experience in dyeing-machine production in his barrel- and tub-making shop, which he opened in 1919. At that time, textiles were frequently dyed by hand in wooden tubs, and even the growing number of mechanical dyeing machines and pieces of apparatus were made of wood. However, as this material was a source of constant problems, Then adopted a new approach, covering the wooden slats with a durable porcelain lining, which prevented the formation of spots and facilitated cleaning.

Then also was one of the first people to recognize the significance of stainless steel, which was invented at the end of the 1920s, especially with regard to its acid-resistant properties. Unfortunately, after World War II, Then shared the fate of many Saxon industrialists as his company was confiscated. He fled west and in 1949 founded a new firm in Schwäbisch Hall-Hessental and commenced production in the local barrel factory belonging to Karl Kurz. Steady growth necessitated expansion, and in 1955, Rudolf Then Färbereimaschinen GmbH was founded jointly with Karl Kurz Hessental KG. A new plant was built on a 36,000-square-meter site in Michelbach/Bilz. The year 1960 saw the production of the first special steel pressure vessels, which included high-temperature winch vats and beam-dyeing equipment. In-house control systems were integrated into this equipment as early as 1964, in order that the equipment and the increasingly complex controls and switchgear could be supplied from a single source. This still applies today and is one of the special features of Then machines.

As Then had no children, at the end of the 1970s, his partners gradually bought up his holding. Following the death of company co-founder Kurz, the company passed into the hands of Kurz’s heirs, comprised of his children and grandchildren.


New Ideas From Wilhelm Christ

Just two years after his arrival at Then in 1966, Christ developed his first dyeing machine, which at the time was already regarded as revolutionary. This was a fully flooded, high-temperature jet-dyeing machine designed primarily for the treatment of man-made fibers that had recently come onto the market.

New fibers in the textile sector repeatedly demand the development of new machinery. Accordingly, the search for solutions that would save water and energy started as early as the mid-1970s, and Christ first developed a partially flooded jet-dyeing machine with a horizontal fabric storage chamber, a new type of jet, as well as machines with a round storage chamber — all of which became successfully established in the market. At the same time, Christ was working intensively on the design of equipment for the yarn-dyeing shop and, above all, the development of yarn dryers, where he also achieved fundamental breakthroughs.

Rethinking began in 1979, when Then developed the Airflow technology. Up to this point in time, increasingly expensive water, which was not available everywhere in sufficient quantities, served as the dye transportation medium. In the 1970s, a winch-dyeing machine required a massive volume of around 150 liters to dye 1 kilogram (kg) of fabric. In addition, this water had to be heated. It was in view of these statistics that Christ, the head of Then’s research and development department, tackled the question of how the enormous water consumption needed for piece dyeing could be cut, along with the accompanying energy costs.

This was impossible with the traditional machines, as they employed a bath. Even with a jet, water remained the transport medium, and therefore, consumption was high. In 1979, work started on the development of the Airflow technology in cooperation with Hoechst AG, Germany. As Christ remembers, “The starting point was the ‘Rapidcolor’ process for isothermal dyeing. This was used primarily for yarns in a creel system and we upgraded the system to our development, which meant that following heating in a steam flow, the separately heated treatment bath was conducted into the jet nozzle for fabric transport and was thus kept in circulation.”


Initial Success: The Patent

The next task was to distribute the reduced quantities of dyestuff and additives across the fabric evenly, which could only be achieved using an aerosol. The aerosol replaced the treatment bath and resulted in a completely changed mass ratio. The development work now advanced at speed, and in 1981, the fundamental Airflow patent was registered. The German inventors were Christ, Dr. Hans-Ulrich von der Eltz, and Albert Reuther.

The European patent was registered in 1982, and use of the technology commenced simultaneously in numerous countries around the world. A European patent was granted in 1982, and a US patent in 1984. The machine made its public debut at the 1983 ITMA in Milan and was met with general ridicule from the world’s experts. Nonetheless, a 10-kg-capacity machine was installed in the Hoechst technology center, and after lengthy customer trials by Hoechst and Then, the market breakthrough was achieved. The first Airflow machine with a 150-kg-capacity was launched as early as 1985 and changed the previous design — with its parallel use of individual storage chambers — to one involving the simultaneous employment of several chambers in a single autoclave.

On May 29, 1986, Christ was awarded the Egon Elöd Prize 1986 by the German Association of Textile Chemists and Colorists. Another career highlight came on Sept. 16, 1996, with the presentation of the Henry E. Millson Award for Invention by Frederike Kuper Jones, then-president of the American Association of Textile Chemists & Colorists.

The first autoclave-design Airflow machine made its debut at the 1991 ITMA in Hannover and possessed the basic features of the present-day Then Airflow. If one compares the machines from 1991 with the current one, it is evident that targeted optimization of the process technology has resulted in a massive reduction in chemical and water consumption. The most important characteristics of the technology are time savings, cost efficiency, reliable dyeing, material protection and reduced ecological impact.

Air, The Gentle Giant

An airflow constitutes the key element in the technology, as it represents an ideal transport medium. The replacement of the dyebath by air as the transport medium for piece goods in jet-dyeing machines is a patented, pioneering achievement from Then. The nozzle pressure is only minimally lower than that in the jet nozzle used to apply the bath liquor, which secures optimum protection of the sensitive surface of the fabric. At the same time, the employment of the mass flow principle ensures greatly improved hank spreading, which prevents creasing.

The moisture-saturated airflow furnishes uniform temperature distribution across the fabric and in the machine, which is a prerequisite for even and reproducible dyeing. As a result of the low liquor content in the dyeing autoclave, the goods are lighter than in a conventional machine and can therefore be more quickly accelerated to high speeds. The risks of draft or yarn strain are minimal, which is of special advantage with regard to the finishing of articles containing elastane. The actual Then-Airflow model represents the result of the interplay between all the technical possibilities and functions, offering economic and ecological advantages, which were unobtainable with the dyeing technology used in the past. The outstanding advantages are:
•    unlimited flexibility for all fibers except pure wool and fabrics in a weight range of 30 to 800 grams per meter, as well as all standard dyestuffs;
•    the lowest liquor ratio on the market: man-made fibers approximately 1:2; and 1:3 to 1:4 for natural fibers, depending on the article and the fabric structure;
•    energy savings of 40 percent with a frequency inverter — air as a transport medium instead of the water is required by all other machines;
•    a reduction in total processing time of around 25 percent;
•    the most advanced piece-dyeing machine currently on the market;
•    the competitive edge derived from extremely low processing costs; and
•    minimum water/wastewater volumes for an ideal, ecological solution.

Takeover By The Fong’s Group

At the end of 2002, Then merged with Switzerland-based Scholl Switzerland AG, which specialized in the discontinuous wet finishing of textiles. In January 2003, joint sales commenced under the name, Scholl-Then. However, in 2004, Scholl filed for bankruptcy, and proceedings commenced for both the Then Maschinen- und Apparatebau GmbH and Scholl-Then GmbH in Germany. In August 2004, a new start was made possible by an investment by the Hong Kong-based Fong’s Group. With this investment, the former Scholl-Then GmbH was transferred into the new Then Maschinen GmbH.

A Promising Future

With a workforce of around 165 at its location in Schwäbisch Hall-Hessental, Then manufactures dyeing machines, control systems and dyehouse networks for global markets. As a result of a sales network with more than 80 offices in all the important international markets and a solid business situation, the future is seen with optimism.

More than 30 of the German patents registered in Christ’s name, as well as numerous international patents and his machine developments for Then Maschinen GmbH, form the foundation of the company’s existence and the securing of employment for its workforce. Moreover, at the award ceremony, the management and staff thanked Christ not just for his outstanding technical achievements, but also for his commanding and modest manner.

Summer 2008

 

整理技术获殊荣

于 1979年构思的独特创意，经过多年发展，终晋身为现今纺织整理界内印染业的高效环保技术。有关构思更在2008年2月荣获奖项：长期担任德国特恩机械有限公司 (Then Maschinen GmbH)技术研发部主管的Wilhelm Christ，获颁授德国State of Baden-Wurttemberg 经济奖项。

德国对能为Baden-Wurttemberg联邦经济提供卓越服务的个人、企业及各个组织颁发奖
项，上书"Wirtschaftsmedaille des Landes Baden-Wurttemberg"，以表扬他们的贡献。

奖项主要颁赠与于特别专业或企业具有杰出成就、对Baden-Wurttemberg的经济深具贡献的人士或组织。评选的准则包括所有经济活动，尤其着重的范畴是专业培训、研究及发展；科技；环保；支援海外贸易及发展等方面。

有关奖项由中型企业与科技商贸部长Ernst Pfister颁发予Christ。莅临观礼者，包括全球多名政经界知名人士，而Christ的雇主亦到场就Christ的成就及工作往绩致词。
Christ于1966年加入特恩机械有限公司 (Then Maschinen)，后来更成功发展Airflow 萍肌。

气流是 Airflow 专利技术的要素，也是匹染喷射漂染机器的最理传送媒介。

展概况

Rudolf Then 于1919年开设制桶厂，继而累积了生产染色机的基本经验。当时，纺织品多于木桶以人手染色，而染色机及有关器材，亦以木制成。不过，木材的来源向来是一大问，他的解决方法是在木板表面加上一层耐用的陶瓷衬垫，以避免木材留下污迹，便于清洁。< /span>

 此外，Then亦是最早认识不锈钢的业者之一。不锈钢于1920年代末期面世，具有抗酸的特性。可惜的是，第二次世界大战后，Then与其它Saxon工业家的遭遇无异，企业被充公。他向西逃走，并在1949年于Schwabisch Hall-Hessental 成立新公司，开始在Karl Kurz设于当地的桶厂进行生产。生意稳步增长，Rudolf Then 遂于1955年与Karl Kurz Hessental KG 合作，组成Rudolf Then Farbereimaschinen GmbH，并于Michelbach/Bilz 建成面积达36000平方米的厂房。 至 1960年，厂房制造了首个独特的钢材气压容器，内备高温绞盘染缸及经轴染色设备。最早至1964年，设备更添加了厂内的操控系统，以便厂方可以透过同一系统，操控器材、日渐复杂的控制器及配电联动器。这个操控系统至今仍然保留下来，亦成为Then设备的特色一。由于Then膝下无儿，企业伙伴遂于1970年代后期逐渐买下他的股分。至公司另一成立人Kurz逝世后，公司便由Kurz的子孙继承下来。

Wilhelm Christ (左) 从商务贸易、中等企业及技术部长Ernst Pfister手中接受了State of Baden-Wurttemberg 经济奖项。

造新思维Wilhelm Christ

Christ于1966年加入Then。两年后，他制造了自己的首部染色机，这于当时来说，实属革命性的创举。机器为全浸染式的高温喷射染色机，主要处理当时刚面世的人造纤维布料。
布料不断推陈出新，业界由是亦不断需求新的设备。同时，业者亦早于1970年代中期开始，寻求可节省水、电的生产方式。至于Christ首创的半浸染式喷射染色机，具有平置式布料储存室，以及创新的喷射模式及圆形储存室等各种器材，深受市场接受。与此同，Christ不断致力为染纱厂设计机器，终于发明了为自己带来突破发展的纱线烘燥机。至1979年，Then重新检讨设备，结果发明了 Airflow术。一直以来，作为染料传送媒介的水，不单成本愈来愈昂贵，而且水源亦难以于各地充足供应。1970年代，绞盘绳状染色机的耗水量极大，染1公斤布料约耗水150公升，而且必须使用热水。这些数字，让当时身Then 研发部主管的 Christ十分关注，他因而着手研究减少匹染庞大耗水量，以及节省能源的方法。以使用浸染方式进行染色程序的传统机器来说，要达至以上目标根本不可能。就是使用喷射模式，仍必须以水作为输送染料的媒介，因此耗水量仍然高企。1979年，Christ开始与德国Hoechst AG合作，发展Airflow 技术。Christ忆述说："技术的起点是等温染色技术的‘Rapidcolor' 程序。程序起初主要用于处理纱线的纱架系统，我们按研究的需要提升系的效能，亦即在加热形成蒸气流后，蒸气将独立的热浸染液带到供输送布料的喷嘴，并 循不息地运作。"

由左至右:  Erwin Pfister、Wilhelm Christ及方国忠。方国忠为立信工业有限公司欧洲业务执行董事。

初步成果:  技术专利权

Christ的下一项任务，是如何将减少剂量的染料及附加物料平均地散布至整幅布料上。要达至这效果，唯一的方法是使用气溶胶。气溶胶可以取代浸染过程，并会全面改变布料的线布质量比率。研究的进展甚为快速，至 1981年，企业已就初步的Airflow技术进行专利权注册，技术的德国发明者分别为Christ、Hans-Ulrich von der Eltz博士及AlbertReuther。
欧洲的专利权于1982年进行注册，公司继而立即于全球多个国家同时使用有关技术。公司于1982年获得欧洲专利、1984年获得美国专利。机器于1983年的米兰ITMA 正式公开展出，却普遍受到当时业界的批评。不过，Hoechst及Then继续于Hoechst 科技中心安装容量达10公斤的设备，并长期予公司客户试用，结果于市场上取得突破。公司于1985年向市场推出首部Airflow机器，设备容量为 150公斤，设计较前有所不同--之前分别运作的各个储存室，现时可以在使同同一压热器下，同时运作。1986 年5月29日，Christ获德国纺织化学家及色彩家协会颁发Egon Elod 奖项。他的另一个事业高峰，是于1996年916日荣获美国纺织化学家及色彩家协会Then的主席Frederike Kuper Jones颁发Henry E. Millson 创新奖项。公司首部以压热器设计的Airflow机，于1991年的汉诺威 ITMA展出；该机器已具有现Then Airflow的基本功能。如将1991年的Airflow机与今日的相较，便可以证明现时以提高生产科技效能为本的设计，能大幅减少化学品及水的消耗。这项技术的最大特色，是
省时间、成本效益高、染色水平稳定、具保护物料功能，以及能减低对生态的影响。

温和的巨人:  气流

气流是理想的传送媒介，也是这项技术的核心。Then以气流取代浸染，于印染织物的喷射染色机中作为染色媒介，可谓一大创举；而Then亦取得了此项技术的专利权。设备内喷嘴的压力，仅仅较以往喷射染液的喷嘴为低，可以为布料的纤细表面提供最大的保障。同，设计以质量流动原理为本，可以改善纹纱的输送，避免皱褶。湿度饱和的气流，为布料及机器内部提供了一致的温度，这对均匀地漂染布料及重复染色来说，极为重要。由于漂染压热器内的水位较低，织物的重量较在其它染色机为轻，因而可以相对地以较高速运作。此外，牵伸及纱线拉紧的情况亦较为少见，这于处理含有弹性的物来说，可谓另一特点。事实上，< /span>Then-Airflow 模式可说是揉合了所有技术的可能性与功能，致力在经济及生态方面为用户带来优势，这是以往的漂染技术难以比美的。Airflow 技术的出色之处，包括：
--高度灵活，可以处理除了纯棉及每米30至800克重的布料以外的所有纤维，亦能使用各种准的染料；
--为市场上提供最低液剂比率的设备：人造纤维约为1:2；至于天然纤维，则按织物及布料，可选用低至1:3 至1:4 的比率；
--选用频率换流器，能节省能源 40% -- 所有机器均必须以气流为传送媒介，而非液体；
--可节省约25%运作时间；
—为现时市场上最先进的织物染色设备；
--成本低廉，可以为客户缔造竞争优势；以及
--为理想的生态保护方案，耗水量及污水量均极低。

立信集团收购

2002年底，Then与瑞士的Scholl Switzerland AG合并，后者从事不连续湿整理纺织行业。2003年1月，两公司开始联名，以Scholl-Then品牌于市场营售。期后，Scholl于2004年破产，Then Maschinen- und Apparatebau GmbH 及Scholl-Then GmbH 均必须于德国进行诉讼程序。2004年8年，公司在香港立信集团的投资下，得以重新开始营运，而前Scholl-Then GmbH 的资产，均注入至新的特恩机械有限公司。

前景光明

Then于Schwabisch Hall-Hessental聘有约165名员工，主要为全球市场制造染色机、控制系统及染厂网络。公司于各个主要的国际市场共设有约80个办事处，销售网络庞大，商业情况稳定，故前景甚为乐观。系统现时以Christ为名注册的，包括逾30 项德国专利权、多项国际专利权，以及他为特恩机械有限公司开发的多项设备。这些产品是公司现有规模的基石，也是为员工提供工作的基本。颁奖典礼上，管理层及员工一致对Christ的杰出技术及成就加以赞赏，也同时向他的指导及谦逊态度表示谢意。

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