In the competivtive world of textile manufacturing, efficiency and precision is key. For Pincroft maintaining a cutting-edge production line is essential to meet the demands of its diverse clientele. However, after years of operation, the extisting infrastructure began to show signs of inefficiency and outdated technology, posing challenges to productivity.

The challenge of aging

Since its installation in 2007, Pincroft´s “Thermex” continous dyeing, condensing, and thermosoling range at the Adlington dyehouse in Lancashire, UK, had served them well. Yet, as the industry evolved, the limitations of their aging equipment became apparent. Manual operation, limited control capabilities, and energy inefficiencies hindered Pincroft´s ability to meet the stringent requirements of their clientele, particularly in sectors such as military-grade camouflage and flame-retardant fabrics. Coming up with a solution

Recognizing the need for a comprehensive modernization, Pincroft turned to Monforts, a trusted partner with a reputation for innovation and reliability. The decision to upgrade their “Thermex” line proved pivotal in revitalizing Pincroft´s operations. The modernization project, meticulouly executed by Monforts experts, included the installation of state-of-the-art automation features. New control cabinets, gear motors for the fabric transport drives and PC, PLC control, touch panels and frequency inverters were seamlessly integrated, providing machine operators with unprecedented control over the entire production process. Additionally, Pincroft demonstrated its commitment to sustainability by investing in a new combined heat and power (CHP) plant on-site. This strategic initiative not only reduced their dependence on external energy sources but also enabled them to produce 67% of their electricity needs internally, while recovering heat for use across their textile operations.

Impact of the modernization

The tranformative effects of Monfort´s automation on Pincroft´s operations were immediate and profound. The upgraded “Thermex” system at Pincroft´s Adlington plant now achieves unrivalled reliability even at maximum fabric speeds, for cost-effectiveness when dyeing both large and small batches of woven fabrics. Achim Gesser, Monforts Area Sales Manager and Head of Spare Parts, outlines: “Textile companies making major capital investments in new manufacturing lines rely on durability from the company´s production ranges, and it´s for this reason that there are currently an estimated 2,000 Monforts machines in operation worldwide – some of which were first installed over 30 years ago. This doesn’t mean, however, that they can’t benefit from many of the advances in performance and automation we have subsequently made. The retrofitting of specific modules with new control and drive technology – going far beyond the basic replacement of spare parts – can have a significant impact on the performance of an existing line and especially maximising energy savings.”

In conlusion, the integration of advanced technology at has paved the way for significant energy savings, further bolstering Pincroft´s sustainabilty efforts. By embracing cutting-edge automation and sustainable practices, Pincroft has not only overcome existing challenges but has also positioned itself in the industry, ready to meet the demands oft the future head-on.