During the last ITMA exhibition, held in Barcelona on September 2011, Pentek introduced DreamAIR, a new tumbling technology dedicated to the physical and chemical treatment of fabrics in continuous. With the aim of giving the highest added value to any fabrics, DreamAIR blends the creative and versatile content of discontinuous processes together with the repeatability and control of the continuous processes.

Thanks to the experience gained in the years through the design and manufacturing of EnAIRgy (continuous tumbler) and PentAIR (discontinuous tumbler) it has been possible to reach such a challenging target. The movement of the fabrics comes from the experience of EnAIRgy continuous tumbler, featuring frequent mechanical crushes against treatment grids and continuous fabrics advancement

Fabric transportation in rope form and a variety of chemical processes is the heritage of PenAIR, which has been the base for further studies. After two years of continuous research and development inside a well-known dye-house in Prato, italy, Pentek has introduced DreamAIR in the final version as shown at ITMA.

Among the reasons that have motivated Pentek in investing in this new technology it is worth to mention the following:

1. The need of its existing client and end-user to offer an even better product, with more quality and with innovative finishing and tumbling effects.
2. The need of introducing a versatile technology, able to process both woven and knitted fabrics, before and after dyeing, coating, printing, etc.
3. The need of a continuous process, with repeatability of result and process control.
4. The need of introducing an eco-sustainable process, with incredible reduction of consumptions and following reduction of production cost.

These reasons are coming from the fact that many chemical treatments in textile finishing are still made on machinery born for different purpose (jet/ flow/airflow/various tumblers, etc,) or on smaller drum tumblers with all the related problems in controls and efficiency, higher running and operation costs,

DreamAIR compensates the lack of specific equipment and it positions as a unique process technology in continuous process. For matching high production requirements and flexibility on the various treatments, Pentek has chosen a module concept

DreamAIR's main module consists of two treatment channels. Each channel is composed by two-fabric accumulation vats, which are linked together by a shooting tunnel, where the airflows are injected for the transportation of the fabric. The fabric is fed into the machine by a transportation reel, going through a washing and treatment overflow (patented systems), which also determines the inversion movement of the fabrics inside the channel.

In order to standardise the time of process, Pentek has patented a synchronisation system, which allows the automatic fabric storage by controlling the fabric inversion time and by over/under feed of the transportation reels.

The fabric will move to the second treatment channel, where it keeps the treatment and eventually going (by overflow transportation) to an additional washing and neutralisation module for intensive cleaning. At the exit, the fabric will accumulate to a j-box for an optional rope opener, for opening up the fabric and plaiter or batch-rolling disposition.

The airflows that are generated for fabrics transportation are sucked behind the treatment grids (patented System) and recirculated inside the machine, by going through an air/water separator. This device allows keeping chemical elements in the machine and not being exhausted outside.

Thought as a workhorse for the treatment of fabrics with high residual element (enzymes, waxes, various coating and pigments, etc,), DreamAIR is equipped with fully extractable vats for easy access and cleaning. The water enters from the forth accumulation vats and it is distributed all over the machine by counter current flow. Each treatment vat reticulates the water through a specific pump, passing through a filter before being fed into the washing and treatment overflows. The water quality is controlled by specific software, which regulates the automatic feeding of the chemicals, used for every recipe.

Technologies processes: During the research and development time and the first installation, Pentek had the chance to test the new technology on several fabrics' types with different treatments:

• Enzyme washing of cotton and blends, before ad after dyeing;
• Soda and enzyme washing of Tencel and blends;
• Soda and enzyme washing of cupro and blends;
• Sand wash of silk;
• Washing of coated/pigment dyed fabrics;
• Washing of waxed fabrics;
• Treatment of woollen knits and blends for the desired tumbling effects;
• Washing and enzyme treatments of denim fabrics;
• Progressive steaming and tumbling of polar fleece;
• Various physical and chemical treatments as preparation for dyeing.