A textile equipment manufacturer in Zhejiang, specializing in supplying dyeing and finishing production lines, faced serious challenges due to insufficient cooling for its calendering and setting rollers.
- Product quality issues: Excessive roller temperatures caused fabric scorch marks and significant color differences within batches, resulting in a high defect rate.
- Low production efficiency: Operators frequently stopped production to manually adjust roller temperatures, disrupting workflow and reducing output.
- Equipment wear and customer complaints: Prolonged high temperatures accelerated bearing wear, increased maintenance costs, and led to recurring quality complaints from downstream clients, damaging the company’s reputation and sales.
KANSA designed customized cooling systems for different production scales:
- ICW-10 water-cooled chiller (33kW cooling capacity) for medium-sized dyeing and finishing lines.
- ICW-20 water-cooled chiller (66kW cooling capacity) for high-load, large-capacity lines.
Both water-cooled chillers feature indirect cooling and PID intelligent temperature control, integrating spiral cooling coils inside the rollers with thermally conductive silicone to enhance heat exchange. The system automatically monitors and adjusts temperatures in real time. Additional upgrades, such as dust filters and 304 stainless steel water tanks, ensure stable operation in humid, lint-filled factory environments.
After implementation, roller temperature fluctuations were significantly reduced, eliminating scorch marks and color variation while cutting defect rates dramatically. Manual adjustments were no longer needed, downtime dropped sharply, and production efficiency improved considerably. Roller bearings now last nearly twice as long, lowering maintenance costs. With these results, the client placed large-scale orders for KANSA chillers, and the stable temperature control helped its dyeing and finishing lines earn greater trust and increased demand from downstream customers.
