Portugal's high quality 'terry' towelling specialist, Carvalho, takes delivery of its first Thies iMaster 'F' dyeing machine and immediately orders another five units to replace its existing dye house plant in a phased modernisation programme.
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 x 500 kg units producing 3500 kg. The new Thies iMasters will produce 2400 kg but, with a faster cycle time, Carvalho anticipate 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."
With high water costs, significant savings can be made with the iMaster dyeing units, said João Sampaio, Francisco Sampaio, Lda.
Since taking delivery of the first Thies iMaster earlier this year, the company has already identified a 50 % reduction in steam and a 50 % 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.
He elaborated further, "The existing dyehouse incorporates 20 years old technology and operates at 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 required far less water than with 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 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 up to 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.
He continued, "with the new iMaster's we will be able to achieve our goals but it is just one step – but nevertheless an important one." A total of 160 people are employed and work 24/5 although, said Francisco Xavier, "Business in Portugal today means fast turnaround to meet delivery deadlines. So if necessary we work 24/6 or 24/7."
Located in the village of Lordelo-Guimarães, close to Porto and formed in 1925, Carvalho remains a family-run business with its 4th generation already joining the company.
Between the 1960's – 80's 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 has continued to invest in technology, quality and design to achieve a more competitive edge and quality product.
