Karl Mayer introduces Cascade, an innovative energy recycling system

Energy consumption is a significant cost factor for textile companies, with finishing processes accounting for up to 15 per cent of turnover. In response, the Karl Mayer Group has developed Cascade, an innovative system designed to save energy in the drying processes of their Prosize sizing machines and Bluedye dyeing plants.

Cascade focuses on steam recycling within cylinder dryers. Steam, a costly energy medium, is reused to reduce overall energy consumption. By re-circulating process steam, Cascade significantly cuts energy costs and carbon dioxide emissions. For instance, in the Asian market, a dryer with 14 cylinders running for 7,000 hours can save up to $17,000 annually. Real-time data on steam circulation allows precise monitoring of savings and carbon dioxide reduction.

The system utilizes pressure drops across dryer zones, repurposing flash steam generated from hot condensate. This recycled steam is mixed with live steam to meet required process conditions, optimizing energy use.

Launched in January 2024 and showcased at ITM 2024 in Istanbul, Cascade will be standard in Prosize machines and integrated into other dryers, enhancing energy efficiency across the textile industry.