Energy costs, constituting up to 15 per cent of turnover for textile finishing companies, are a significant economic burden. To address this, Karl Mayer Group has introduced Cascade, an innovative system designed to slash energy consumption in the drying processes of its Prosize sizing machines and Bluedye dyeing systems.

Cascade leverages steam as a heating medium in cylinder dryers, offering substantial energy savings and reduced carbon dioxide emissions. By recirculating process steam within the machine, Cascade significantly lowers the need for fresh steam. According to Karl-Heinz Vaassen, Head of Textile Drying at Karl Mayer, this approach enables "genuine, efficient energy recycling."

The financial benefits are notable. A 14-cylinder dryer running 7,000 hours annually in the Asian market can save up to $17,000 per year. The system's dashboard provides real-time data on steam circulation, allowing precise tracking of energy and carbon dioxide savings.

Cascade operates by utilizing the pressure drop across the dryer sections. The highest pressure in the first section condenses steam without temperature loss, and the hot condensate is fed into a flash tank, generating vapor exhaust through pressure reduction. Instead of being wasted, this "freshly recycled steam" is used to heat the second cylinder section after mixing with live steam.

This patented system, integrated into Prosize machines from January 2024, debuted at ITM 2024 in Istanbul to great acclaim. The first upgraded machine will be delivered to a European manufacturer in the second quarter of 2024. Future plans include extending Cascade to other dryer types and the Bluedye system.