A structured 6-step workflow to configure your factory, model your process, and generate actionable cost and sustainability reports.
Go to Factory Library in the sidebar. Click "➕ Add New Customer" to create a factory/dyehouse entry. This becomes your central record for all projects and operational data.
What you'll fill in: Company name is required and must be unique. Country is required for organizational reference (e.g., tracking which facilities are in which regions for reporting). Contact person, job title, phone, and email are optional reference fields—capture whoever manages the facility day-to-day.
Address, zip code, and city help with location tracking and regulatory filing. Notes is a free-form field for internal reminders (e.g., "Plant closed Aug 1–15" or "Special handling for dye lots").
After creation, your new factory appears in the list. To assign machines or configure utility prices, you'll return here and click Edit in step 2.
⚠️ Prerequisite: Complete step 1 first.
Open Plant Specific Inputs and select your factory from the dropdown. Click Edit to begin configuration.
Why these numbers matter: The prices you enter here—gas (€/m³), electricity (€/kWh), water (€/m³), and wastewater (€/m³)—flow directly into every cost calculation in your projects. If you enter gas at €0.40/m³ but your actual supplier charges €0.50, all your cost estimates will be €0.30 per kg too low.
Heating source determines whether you use gas-fired boilers or electric steam generation. Choose LC-Gas (low-calorific, ~10.3 kWh/m³) or HC-Gas (high-calorific, ~12.8 kWh/m³) if your facility burns natural gas. Choose Electricity if you use electrode boilers or electric immersion heating.
Labor model: Set your hourly wage, then enter the number of workers and machines per worker. If you have 2 workers managing 6 machines, enter "2 workers, 3 machines/worker." This scales labor cost allocation per machine.
Machines (optional): If you use batch dyeing, assign machines from your library here. You'll choose which specific machine to use when you create a project in step 4.
Before creating a project, decide which type of process your factory runs. This choice determines which configuration tool you use next—and you cannot mix batch and continuous logic within a single project.
Batch/Exhaust Dyeing (load → dye → unload): Fabric enters a machine, sits in liquor for a set time, then is drained and removed. Examples: jet dyeing, rotary drum, winch dyeing. If this is you, go to Machine Library and add each machine you own. For each, enter capacity (kg), total power (kW), efficiency (%), and optional specifications like circulation pump power and drain time.
Continuous Processing (fabric flows through modules): Fabric enters at one end and passes through multiple processing stages without stopping. Examples: singeing → desizing → padding → washing → drying. If this is you, go to Continuous Line Configuration and build your line by adding modules in sequence. Each module has its own settings (temperature, bath count, chemical recipe, etc.).
Key difference: Batch projects calculate costs per batch load. Continuous projects calculate costs per running meter (or per hour at a given speed). Choose carefully—your entire workflow depends on this decision.
Navigate to Applications and choose your process type.
Exhaust Application (Batch Dyeing): Go to Exhaust Application → Project. Select your factory and one of its assigned machines. Enter fabric weight in kg and liquor ratio (typically 6:1 to 8:1, meaning 1 kg fabric : 6–8 L liquor). Set power usage (% of machine capacity) and optionally your estimated monthly tonnage for scaling. Give your project a name and click Create. You'll then proceed to Steps to build your recipe.
Continuous Application (Flow Processing): Go to Continuous Application → Continuous Project. Select your factory and one of its configured lines. Enter fabric parameters: weight (g/m²), width (m), and line speed (m/min). The system auto-calculates fabric flow (m/h and kg/h). Give your project a name and click Save. You'll then proceed to Continuous Steps to configure each module.
What happens after save: Your project is now stored in the backend. All project data (steps, chemicals, settings, calculations) is saved as you work. You can return to edit your project anytime by selecting it from the project dropdown.
Exhaust Application (Steps): Build your recipe step by step. Click "➕ Add Step" to create each stage (e.g., "Pre-wash", "Dyeing", "Rinse 1", "Rinse 2", "Finish"). For each step, set the temperature profile: start temperature (°C), heating slope (°C/min), final temperature, dwell time (minutes at final temp), cooling slope, and cooling temperature. Mark the last step or any intermediate step as "drain" if fabric is removed from the machine. Then add chemicals: select each product from your library, enter dosage (g/L or % o.w.f.), and unit price. The system calculates total cost and chemical load. Use ↩️ Undo to revert any changes; you have a history of up to 25 changes.
Continuous Application (Continuous Steps): Configure each module in your line individually by expanding its section. Padders/Foulards: Set wet pick-up (%), bath temperature, and add your chemical recipe (g/kg fabric). Washing Units: Define number of baths, compartments per bath, fresh water inflow (L/kg fabric), and carry-over rates. Optionally add neutralization (acid dosing) with a target pH or manual setpoint. The system auto-calculates water quality (residual fraction Γ), heating demands (steam per bath), and OEKO-TEX® pH compliance in real-time. Dryers: Set dryer type (cylinder, stenter, flue), temperature, overfeed (%), and target moisture out. Other modules (Singeing, Desizing, Steaming): Set temperature and dwell time; cost calculations for these are not yet implemented.
Both workflows auto-save as you edit. Click Next → Report when your recipe is complete.
Click Report to see a complete analysis of your process. The report calculates cost per kg fabric, total CO₂ footprint by source, water consumption, chemical load (BOD₅ and COD), and—if you entered monthly tonnage—monthly scaled projections.
Cost Breakdown: See costs split by category (chemicals, water, heating, electricity, labor) in a bar chart and detailed table. The system shows cost per kg fabric, per m², and per kilometer (for continuous). Use this to identify which lever (e.g., reducing chemical price, lowering heating temp) has the biggest cost impact.
CO₂ Footprint: Total emissions are calculated from gas consumption and electricity use based on your plant parameters. This helps you benchmark against sustainability targets and identify opportunities (e.g., switching to a lower-carbon energy source).
Effluent Quality: BOD₅ and COD concentrations (mg/L) show your treatment burden. The BOD₅/COD ratio indicates biodegradability: ratios above 0.5 are easily treated; below 0.3 require advanced treatment. This guides decisions about pre-treatment chemicals or wastewater disposal routes.
Exhaust-specific: Temperature profile chart shows your full cycle with chemical dosing points marked. This is your visual recipe card—print or share it with operators.
Continuous-specific: Washing unit optimizer suggests optimal bath counts or fresh water flows to meet your quality targets (Γ limit, pH window) while minimizing water cost. Use this to decide whether to add/remove baths or adjust flow rates.
Export: Download a PDF or PowerPoint presentation with all charts, tables, and metadata. Use these for stakeholder presentations, compliance documentation, or customer inquiries.
Iterate on your recipe: adjust chemical dosages, temperatures, or settings based on cost and CO₂ insights, then re-run the report. Over time, you'll build a library of optimized recipes.
Open the app and start modeling your first project today.
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