MASTER

The past…
“JIGGER” - 1890

The future…
“BINGO” - 2019

The starting concept

Even good ideas, sometimes, need to be re-interpreted to be adapted to technology and market evolutions.

BINGO is exactly the most modern and advanced example of this concept.

Master, strongly supported by his long experience in dyeing machines, has started analyzing today key points of textile market to develop this brand new machine that, recovering some classic production technology concepts, represents a revolutionary solution for fabric dyeing.

The targets Master has pursued while designing Bingo have been:

• Flexibility in processes
• Elasticity in lot lengths from short to long lot
• Absolute reliability of results
• Advanced sustainability.

The technology concepts identified as the most suitable to achieve these targets are coming from the “jigger”, one of the most flexible dyeing machine still today largely utilized.  

In the past Master has already contributed to the development of special jigger versions with the famous “Jumbo” version, realized for M/s Candiani, for the dyeing of workwear fabrics with Blue Hydron dyes.

(Jumbo Jigger Candiani)

The main advantages offered by the jigger are:

• All-in-one machine: the complete process takes place in the machine
  
• Bi-directional movement of the fabric allowing the succession of process steps
• Reduced space
• Flexibility in lot lengths, including short lengths

The innovation

Master has strongly worked to re-engineer the jigger concept, combining the mentioned advantages with his well experimented dyeing technology in Nitrogen atmosphere.
The result is Bingo: a revolutionary machine, the combination of a strong background with the most innovative and sustainable dyeing process.
Bingo can perform dyeing processes based on indigo and other reduction dyes (sulphur, VAT, etc.) for denim and other fabrics.

Machine key features

• Two-way alternate fabric directions: this solution, typically belonging to jigger machines, is allowing to perform the entire process in the same machine, in a reduced space and in a much more economical way, compared with the long and expensive classic dyeing lines.
• Compact construction: the machine has been designed considering the increasing demand of short lots and the necessity to minimize wastage.  The use of a leader cloth is allowing a “zero wastage” production.
• Nitrogen dyeing technology: this innovative dyeing technology, developed and improved by Master in the last 15 years, is assuring process conditions not possible with traditional machines, allowing drastic and considerable savings in chemicals, water and energy.  No nitrogen consumption, except the initial filling.
• Single and Multi-dip versions: Bingo is available in two versions, depending of dyeing targets.  The machine is automatically controlled and can run the entire process, including pre-dyeing and post-dyeing treatments in a completely autonomous way.
• Package delivery: the machine is pre-assembled in our workshop including complete pipelines, realized with the best and most reliable components.  This solution is drastically reducing erection and start up time, assuring the best realization.

Production capacity

• Production capacity is directly depending on the number of steps of the performed process.
• Considering a standard process, including:
  • 1 step for pre-treatment (wetting-scouring-etc.)
  • 1 step dyeing
  • 2 steps post-dyeing treatment (washing-fixing-etc.) It is possible to produce up to 2.500.000 m/year, increasing to 3.250.000 in case of no pre-treatment step (dyeing on dry fabric or external wetting).

• In case of higher production volumes required, it is also possible to install Bingo in combination with existing washing lines.

Advantages and technical strengths

• Contemporary dyeing of warp and weft with enormous economical savings.
• Consistent dyeing results not affected by external influences.
• The best diffusion and fixation of indigo and sulphur dyes on fibres.
• High color brilliancy and dyes efficiency (+40% with sulphur dyes).
• Processing of big ready-for-dyeing fabric rolls, both on wet or dry.
• No nitrogen consumption except for initial filling.
• Drastic reduction of sulphites and sulfates in effluents.
• Easy integration with existing continuous washing lines.
• Processes and working conditions according to the most updated concepts of sustainability and environment protection.

Operational flexibility

• Possibility to dye fabrics with extremely wide range of weight.
• Suitable for fabric overdyeing and/or color adjustments.
• Possibility of Multiple-step dyeing working with low concentrations for intense and high fastness colors.
• Possibility of high concentration/high temperature dyeing processes for exclusive results un-matchable with traditional machines.

Dyeing results

As above mentioned, process flexibility  has  been  one of  the targets pursued when designing Bingo.

Thanks to innovating technology and engineering, all the dyeing parameters can be adjusted according to needs:

• Color intensity
• Fixation degree
• Color penetration
• Dyeing bath volumes
• Dipping time
• Reaction/Diffusion time

All these possibilities have been tested during several trials on our IndigoLab.

Tests where conducted by Denisol Pure Indigo and Diresul dyes by Archroma -       (*) "indicates values based on standard process"

The dyeing technology under Nitrogen

It is a special technology that is ecological and economical, particularly suitable and very advantageous for the dyeing with indigo and other reduction dyes.

MASTER is the only manufacturer that, having a R&D department with laboratory and pilot machine, has studied and tested this system, which has been used on several types of continuous dyeing machines for warp, which are patented and successful.

In its 55 years experience on design and manufacturing of only dyeing machine, the last 15 years have been dedicated mostly to this particular technology, on which acquired exceptional and exclusive know-how.

Interpreting the new requirements of the textile market, MASTER transferred this particular know-how to the field of fabric dyeing, designing “BINGO” (Pat.), the first multi-functional machine, with automatic operative cycle, for the dyeing of fabric with indigo and sulphur colors, into inert environment (under Nitrogen).

Practically, to the classic indigo dyeing method, common to all traditional machines, primarily made up of three operational stages that are repeated several time: impregnation of the fabric with leuco dye, squeezing out of the excess dye bath and oxidation by exposing the dyed fabric to air, BINGO® has added a fourth operational stage, that is the diffusion/fixation of the leuco dye into inert environment, where also the dipping and squeezing of the fabric occur.

Into inert environment, the indigo chemical reduction is full and perfect and the leuco dye is separated at nanometer sized particles; its dyeing power makes it penetrate and fix to the fiber better than a traditional system, which in some cases also allows eliminating the fixing agent even though working with a higher concentration of dye in the bath.

This original working condition, into inert environment and closed circuit allows eliminating some problems of the classic system, compared to which it has the advantages not only to drastically reduce the consumption of caustic soda and sodium hydrosulphite but also to considerably save washing water thanks to a better fixation of the dye to the fabric.

Advantages

• Consistent dyeing results, not affected by external influences.
• The best diffusion and fixation of indigo and sulphur dyes on fibres.
• High color brilliancy and dyes efficiency (+40% with sulphur dyes).
• Reduction of the soda and hydrosulphite consumption.
• Reduction of the washing water consumption.
• Reduction of sulphites and sulfates in effluents.
• Reduction of production costs.
• Processes and working conditions according to the most sustainability.
• Increase in the operational flexibility thanks to the possibility of working with concentrated baths/high temperature for exclusive results un-matchable with traditional machines.