Overview
A textile manufacturing company faced inefficiencies in their shrinking process due to outdated machinery and manual operations. By integrating Honyee’s PLC+HMI All-in-One into their automatic shrinking machine, they achieved a 30-40% reduction in processing time, significant cost savings, and improved operational flexibility.
The Challenge
The company’s traditional shrinking process involved multiple steps, including washing, softening, drying, and fixing, each requiring separate machines and manual intervention. This led to:
- High labor costs: Each process required dedicated operators.
- Time inefficiencies: Processing a single batch of clothes took over 90 minutes.
- Inconsistent quality: Manual operations resulted in variability in the final product.
- High resource consumption: Excessive use of water, electricity, and steam.
The Solution
Honyee’s PLC+HMI All-in-One was integrated into the automatic shrinking machine to streamline the process. Key features included:
- Flexible Programming: Users could customize up to 27 steps in the shrinking process, with 15 different processing options per step.
- Real-Time Monitoring: Precise control of temperature and motor parameters ensured consistent quality.
- Automated Operation: Reduced the need for manual intervention.
- User-Friendly Interface: The 7-inch touchscreen HMI provided an intuitive interface for easy operation and adjustments.
The Result
After implementing Honyee’s PLC+HMI All-in-One, the company achieved:
- Increased Efficiency: Processing time reduced from over 90 minutes to just 30-40 minutes per batch.
- Labor Savings: One operator could now manage 3-5 machines simultaneously.
- Higher Output: Processed 9,600 pieces of clothing per day (8-hour shift).
Cost Savings
- Energy Savings: Electricity consumption reduced to 4.4 kWh/hour (from 6 kWh).
- Water Savings: Water usage dropped to 20 kg/batch (from 200 kg).
- Steam Savings: Steam consumption reduced by 50%.
- Chemical Savings: Chemical usage cut to 30% of previous levels.
Improved Flexibility
The ability to customize processing steps allowed the company to handle various fabrics, including leather, wool, cotton, and synthetic blends.
“Honyee’s PLC+HMI All-in-One has transformed our shrinking process. The system is easy to use, highly efficient, and has significantly reduced our operational costs. We’ve seen a dramatic improvement in both productivity and product quality.”
Economic Benefits Comparison
The table below highlights the economic benefits of the automatic shrinking machine compared to the traditional process:
| Metric | Automatic Shrinking Machine | Traditional Process | Savings |
|---|---|---|---|
| Processing Time | 30-40 minutes | 90 minutes | 50-60% reduction |
| Output per Hour | 600 kg | 200 kg | 3x increase |
| Labor Cost | 0.3 people/hour | 0.3 people/hour | No change |
| Electricity Usage | 3 kWh/hour | 6 kWh/hour | 50% reduction |
| Water Usage | 20 kg/hour | 200 kg/hour | 90% reduction |
| Steam Usage | 50% less | – | 50% reduction |
| Chemical Usage | 30% of traditional usage | – | 70% reduction |
Conclusion
By integrating Honyee’s PLC+HMI All-in-One into their automatic shrinking machine, the textile company achieved significant improvements in efficiency, cost savings, and product quality. The system’s flexibility and ease of use allowed the company to adapt to different fabric types and processing requirements, making it a valuable investment for their operations.
Ready to transform your textile processing operations?
Contact us to learn how Honyee’s PLC+HMI All-in-One can help you achieve similar results.
