Portuguese family-owned terry towelling specialist Fábrica de Tecidos do Carvalho recently took delivery of its first Thies dyeing machine, an iMaster H²O ‘F’version, and promptly ordered a further five units from local distributer Francisco Sampaio, Lda, as part of a phased modernisation programme to replace its existing dyehouse.
The iMaster H²O ‘F’ model has been purpose-designed for dyeing ‘terry’ applications and features a stronger- build winch for heavier terry, weighing up to 1.5 kg/m² and a larger diameter 2200 mm nozzle.
The six Thies units, each featuring a 400 kg capacity, will replace Carvalho’s existing dyehouse of 7×500 kg units producing 3500 kg. The new Thies iMasters will produce 2400 kg, but, with a faster cycle time, Carvalho anticipates increased production.
“Whilst this is an added bonus for us,” said Manager, Francisco Xavier, “our principal goal in the investment is to offer an improved quality product and reduce energy consumption – steam, water and electricity – together with a reduction in dyestuffs and auxiliaries to make us more competitive.”
Since taking delivery of the first Thies iMaster, the company has already identified a 50 per cent reduction in steam and a 50 per cent saving in water using a liquor ratio of 1:6.
“We initially opted for the 1:6 ratio but are now beginning to reduce it even further to 1:5 and anticipate even greater savings,” said Carvalho Manager, Francisco Xavier. “The existing dyehouse incorporates 20 years old technology and operates in a 1:10 liquor ratio. It was essential therefore that we reduced the costs of utilities and dyestuffs with the latest technology in order to become more competitive with our global competitors.”
His brother and Manager, Joaquim Moreira Gomes, also highlighted that the special techniques used with the final wash in the dyeing process with the iMaster requiring far less water than the older dye machines, providing additional savings.
The operators have also quickly taken to the new Thies units, according to Dyehouse Director, Anibal Magalhães. “Operation is very simple and takes far less time consuming for the operator with features such as the automatic self-clean filters.”
Terry production at Carvalho’s is principally cotton in a variety of forms, including combed, low twist and micro plus a number of blends such as viscose/cotton and linen/cotton. Weights generally vary between 250 gm/m² and 1.5 kg/m².
“Production is currently geared towards 150 t/month, but we plan to increase this, to meet market demands, by up to 180 t/month with the all-new Thies dyehouse”, confirmed Joaquim Gomes. “With the new iMaster’s we will be able to achieve our goals, but it is just one step but nevertheless an important one.”
Located in the village of Lordelo-Guimarães, close to Porto, and formed in 1925, Carvalho remains a family-run business with its fourth generation already joining the company.
During 1960-80 the company produced blankets for the domestic and European markets. By 1983, however, a rationalisation process and market trading conditions saw Carvalho devote itself exclusively to manufacturing terry towelling. Since then the company continues investing in technology, quality and design to achieve a more competitive edge and quality product.