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Photo: Sellers Textile Engineers
Hybrid Shearing Cylinder
10.10.2022

The Hybrid Shear by Sellers Textile Engineers

BTMA member Sellers Textile Engineers is marking its 110th anniversary this year with the introduction of a new concept in carpet shearing, as the essential final step in ensuring tuft uniformity and ‘just new’ freshness in finished carpet rolls.

The company has for many years offered two options in the construction of its shearing cylinders – the first, namely the ‘strap-on’, incorporates spiral blades bolted to the cylinder body and the second, known as the ‘caulked-in’, includes spirals which are fixed very securely in a machined groove within the machine.

The new Sellers’ Hybrid Shearing Cylinder combines the benefits of both, resulting in an improved cut and finer finish, in addition to longer repeatable finishing and increased rigidity.

BTMA member Sellers Textile Engineers is marking its 110th anniversary this year with the introduction of a new concept in carpet shearing, as the essential final step in ensuring tuft uniformity and ‘just new’ freshness in finished carpet rolls.

The company has for many years offered two options in the construction of its shearing cylinders – the first, namely the ‘strap-on’, incorporates spiral blades bolted to the cylinder body and the second, known as the ‘caulked-in’, includes spirals which are fixed very securely in a machined groove within the machine.

The new Sellers’ Hybrid Shearing Cylinder combines the benefits of both, resulting in an improved cut and finer finish, in addition to longer repeatable finishing and increased rigidity.

“The Hybrid Shearing Cylinder has all the advantages of the ‘strap-on’ spiral blade to provide a sharper and cleaner cut, along with enhanced rigidity which significantly lengthens the intervals between the necessary regrinding of the blade,” explains Sellers Director Neil Miller. “We currently have six Hybrid Shearing Cylinders operating in the field and the earliest, which has been installed in both No1 Head position, where the majority of the shearing operation and heaviest cut is performed, and also in No3 Head, where the sharper cutting angle has resulted in a much improved surface quality.”

Sellers shearing machines have led the field in carpet finishing for many decades, enabling the leading manufacturers to stay competitive by enabling the highest quality of finish to be achieved economically and efficiently.

The latest advanced features of these machines include a load cell tension control drive system, an automated touchscreen for easy operator control and fault diagnosis, an enhanced cleaning system including cylinder and blade separation and fully controllable pivoting beds. Further options include thickness monitoring, seam detection and metal detection systems.

“The Hybrid Shearing Cylinder will become standard on our latest machines and also be made available for retrofitting, to provide significant benefits to our existing users,” says Miller. “All of our equipment is designed, manufactured, assembled and tested at our plant in the UK, and as one of the few remaining European engineering companies to make all of our components in-house – with now over a century of accumulated know-how – flexibility in design allows our finishing solutions to be targeted to specific customers and their product requirements. Aligned to this is a lead in process control systems which ensure the accurate control, reliability and repeatability of the processing parameters on all of our machines.”

Sellers remains committed to providing complete finishing solutions for all carpet, tile and artificial grass products. Its range includes machines for tufted secondary backing, both conventional, powder and extrusion lamination, Wilton and Axminster products, artificial grass and foam lines, coating lines for bitumen, PVC, PU and other polymers, as well as shearing for all carpet products.

Ongoing developments on the company’s coating and drying lines have resulted in improved guiding and product tension control as well as dryer efficiency, reducing heat loss and optimising energy use. These include a re-design of the fan pressure boxes and impingement nozzles to increase airflow efficiency, modulating gas burners and introducing easy clean, accessible filters.

In addition, the proven dual zone system has been enhanced, giving a temperature differential of up to 80°C between top and bottom zones. Dryers can be heated by either gas or steam and operation and access have been simplified with controls via touchscreen and PLC.

An extensive range of ancillary equipment is available to provide maximum flexibility to cover product requirements, for both new processing lines and as upgrades to existing equipment.

“Carpet manufacturing is now based on well-established, tried and trusted processes and it’s rare for new innovations to be introduced into this sector,” says Jason Kent, CEO of the British Textile Machinery Association. “The new Sellers Hybrid Shearing Cylinder can provide a competitive edge for manufacturers which is currently being proven in the field. It’s one of a number of new innovations the company is planning to showcase at next year’s ITMA exhibition in Milan.”

08.08.2022

Mahlo at Febratex

Brazil hosts all industries needed for textile and garment production - from fiber to final production. This is why Mahlo, with its diverse solutions on straightening technology and process control, will exhibit at Febratex, held on August 23-26 in Blumenau.

"No matter what products they make, all producers have the same goals at the end of the day," says Area Sales Manager Miguel Lessel. "High-quality goods without distortion and optimized processes that combine quality and economy.

The automatic straightening system of the world market leader ensures thread-straight fabric in almost all applications. The modular system can be adapted to individual production conditions. To optimize the processes around the stenter frame, Mahlo offers various process control systems. These can be used, for example, to measure and control critical parameters such as dwell time, thread density or residual moisture. These systems not only help to improve the quality of the textiles, but also to save raw materials and reduce energy costs.

Brazil hosts all industries needed for textile and garment production - from fiber to final production. This is why Mahlo, with its diverse solutions on straightening technology and process control, will exhibit at Febratex, held on August 23-26 in Blumenau.

"No matter what products they make, all producers have the same goals at the end of the day," says Area Sales Manager Miguel Lessel. "High-quality goods without distortion and optimized processes that combine quality and economy.

The automatic straightening system of the world market leader ensures thread-straight fabric in almost all applications. The modular system can be adapted to individual production conditions. To optimize the processes around the stenter frame, Mahlo offers various process control systems. These can be used, for example, to measure and control critical parameters such as dwell time, thread density or residual moisture. These systems not only help to improve the quality of the textiles, but also to save raw materials and reduce energy costs.

Source:

Mahlo GmbH + Co. KG

Photo: Mahlo
26.07.2022

Mahlo at Indo Intertex 2022

  • Focus on straightening technology and process control

At Indo Intertex, held from 10 to 13 August in Jakarta, visitors get to see the Mahlo-way for process control in textile production. The German machine manufacturer and its partner agency Agansa Primatama will be available to show everyone its leading straightening technology as well as energy saving concepts around the stenter frames. INDO INTERTEX is South East Asia’s largest trade show on the textile and garment industries, bringing together leaders to experience world-class manufacture, technology and solutions.

Indonesia is one of the ten biggest textile producers in the world. Especially the USA, the European Union and Japan import a majority of their requirements from the Southeast Asian Island state. In order to fulfill the increasing demands and the call for high quality goods, producers invest in machinery, equipment and technology.

  • Focus on straightening technology and process control

At Indo Intertex, held from 10 to 13 August in Jakarta, visitors get to see the Mahlo-way for process control in textile production. The German machine manufacturer and its partner agency Agansa Primatama will be available to show everyone its leading straightening technology as well as energy saving concepts around the stenter frames. INDO INTERTEX is South East Asia’s largest trade show on the textile and garment industries, bringing together leaders to experience world-class manufacture, technology and solutions.

Indonesia is one of the ten biggest textile producers in the world. Especially the USA, the European Union and Japan import a majority of their requirements from the Southeast Asian Island state. In order to fulfill the increasing demands and the call for high quality goods, producers invest in machinery, equipment and technology.

At IndoIntertex, Mahlo informs about its straightening machine Orthopac RVMC-15, among other. Based on experience reaching back to over 75 years, the machine offers the latest technology for correcting distortions. The modular straightening and process control system ensures a straight-thread product before and after the drying or fixing process and optimises the processes all around the stenter. This increases quality and saves resources and energy. The process control system Optipac VMC-15 measures and controls critical parameters such as dwell time, thread density or residual moisture.

Source:

Mahlo GmbH + Co. KG

Process control with Qualiscan QMS (c) Mahlo. Process control with Qualiscan QMS.
17.05.2022

Mahlo at Techtextil 2022

At Techtextil from 21-24 June in Frankfurt, Mahlo will be demonstrating how manufacturers of technical textiles can optimise their production even further using measuring and control technology.

Special straightening technology for technical textiles
Mahlo's range also includes solutions for straightening distorted goods. Best suited for technical textiles are, for example, the symbol of the straightening machine, the Orthopac RVMC-15 and the reinforced version Orthopac GRVMC-15. Frame, bearings, and rollers are designed for high loads and allow large working widths of up to 5,400 mm. As the latest development from Mahlo, the experts present the Orthopac CRVMC-15 automatic straightener, which is particularly interesting for the glass & carbon fabric industry and some special applications.

At Techtextil from 21-24 June in Frankfurt, Mahlo will be demonstrating how manufacturers of technical textiles can optimise their production even further using measuring and control technology.

Special straightening technology for technical textiles
Mahlo's range also includes solutions for straightening distorted goods. Best suited for technical textiles are, for example, the symbol of the straightening machine, the Orthopac RVMC-15 and the reinforced version Orthopac GRVMC-15. Frame, bearings, and rollers are designed for high loads and allow large working widths of up to 5,400 mm. As the latest development from Mahlo, the experts present the Orthopac CRVMC-15 automatic straightener, which is particularly interesting for the glass & carbon fabric industry and some special applications.

The Mahlo team will present the wide portfolio of intelligent scanners and sensors that record product and process parameters, such as distortion, fabric temperature, dwell time, basis weight, coating weight, thickness, moisture content, residual moisture, exhaust moisture, air permeability, etc. online. Among other things, visitors can expect to see the Famacont PMC-15 weft density measurement system in live operation. The system measures the weft or course density on the running web and compares it with the target value stored in the recipe data management system. The detected deviation from the target value is used to fully automatically control the overfeed during the needling process at the stenter frame and to ensure a constant weft/course density over the full width of the product.

Source:

Mahlo GmbH + Co. KG

Folding / Plating (© 2021, Maag Brothers)
16.12.2021

Swiss Textile Machinery: Changes and opportunities through automation

For most textiles, finishing processes are not actually the last stage. Products often need an extra touch of expertise to make them perfectly ready for the customer. At this point in the value chain, that usually means manual tasks – but now there are technical solutions and intelligent systems which can handle complex operations better, while adding extra value and assured quality.
Automation brings reliability and efficiency, ultimately saving costs to produce the right quality every time. Swiss companies are specialized in many of these disciplines, with machinery for fabric inspection and presentation, labelling and tracking, folding and packaging. They have the technology to inspire a new vision at the post-production segment of the textile manufacturing processes. Optimization of workflows, with bottleneck management, is an obvious potential benefit. And it delivers measurable returns on investment. The wider picture with automation will prepare companies for the IoT and Industry 4.0.

For most textiles, finishing processes are not actually the last stage. Products often need an extra touch of expertise to make them perfectly ready for the customer. At this point in the value chain, that usually means manual tasks – but now there are technical solutions and intelligent systems which can handle complex operations better, while adding extra value and assured quality.
Automation brings reliability and efficiency, ultimately saving costs to produce the right quality every time. Swiss companies are specialized in many of these disciplines, with machinery for fabric inspection and presentation, labelling and tracking, folding and packaging. They have the technology to inspire a new vision at the post-production segment of the textile manufacturing processes. Optimization of workflows, with bottleneck management, is an obvious potential benefit. And it delivers measurable returns on investment. The wider picture with automation will prepare companies for the IoT and Industry 4.0.

New business models
The advantages of automation in mills with high-volume production are obvious: consistent quality, increased efficiency, waste reduction in some cases, as well as significant medium-term cost reductions in every case.
That description focuses on the aims of modern mills in low-cost markets. But producers in Europe and USA could reach out for more. For them, automation could be a game-changer, offering unique new opportunities.
Reshoring is a growing trend now. It shows great potential and is definitely driven by sustainability and changes in consumer mindsets. “We believe that the time is right – the machines and solutions certainly are – to push automation also to the very end of the production line, replacing intensive manual work and take the chance for reshoring. The current situation is kind of a transition time which is expected to last for a couple more years in the textile industry,” says Rueedi. He adds that any investments in these prime markets pay off much faster because of higher labour costs.
Innovation transformed through automation can do much more than simply replacing the nimble fingers of humans. It also enables new business models, guaranteeing prosperous future business, alongside greater job security.

Digital workflow and process control
The Swiss company Maag Brothers is a leading supplier of high-end machines for quality assurance in the final make-up processes, specifically fabric inspection, plating/folding, selvedge printing and packaging. Maag reports on a practical example from a mill in India which recognized the potential of automation.
An analysis at the customer’s mill identified the main goals as modernization of the workflow at quality control and packing processes. Maag’s new system covers tasks from fabric inspection to dispatch, and offers transparent and easily adjustable processes with real-time process control. It’s a digital solution, resulting in a slim organization, paperless, and the basis for further optimization towards Industry 4.0 to exploit its full potential. The customer’s own calculation showed a ROI for the installation at less than three years – along with a reduction in manpower and savings in fabric costs for shade samples.

Perfectly labelled, efficient data...
Smooth processes start with a label. Swiss company Norsel is an expert in grey fabric labelling systems, for piece tracking through all textile processes. High-quality label printing and proper sealing on all kind of fabrics ensure readability and sustainability after dyehouse processes such as mercerizing, high temperature dyeing and even hot calendering. No roll mix-up during dyeing, easy sorting of fabric rolls and rapid delivery make processes in the mill much more efficient. Using RFID codes lifts fabric inventory control to the highest level, with all information readily transferred to a database and integrated through any ERP software.
It’s a foolproof way to avoid the risk of human errors from hand-written notes on grey fabrics and article sheets, by opting for reliable, secure and forward-looking solutions.

Sample collections – the silent salesmen
First impressions count, so fabric producers like to present their collection perfectly – and that’s only possible with automated solutions. Swiss producer Polytex continuously refines its solutions, underlining its leading position in sample making equipment. Fully-automatic high-performance sample production lines are designed to satisfy the highest expectations. Fully-automatic lines or robotic machines set the standards for quality and performance. Even the most demanding clients can achieve their goals with impeccable samples, quickly and efficiently made, for flawless collections that are sure to impress.

Automation drives buying
First impressions are also the trigger for quick purchase decisions. The proof is there on every store shelf. Customers of Espritech are also well aware of it. They trust this Swiss producer of automated folding machinery to provide the final touch of class to home textiles and apparel products before they go on display. The folding systems are generally large mechatronic devices, loaded with latest technologies in mechanics, electronics, sensors and pneumatics. “Textile producers are amazed how folding machines solve the tricky task of reliably handling chaotically behaving materials. They see process optimization potential and the impact. We observe a slow but continuous change of mindset installing sophisticated technology even in the last steps of textile finishing,” says Philipp Rueedi, CFO at Espritech.

TexCoat G4 non-contact precision spray fabric-finishing system (c) Baldwin Technology Company Inc.
02.08.2021

Baldwin at Techtextil North America

  • Introducing TexCoat G4 to US textile industry
  • Non-contact precision spray fabric-finishing system enhances sustainability and process control

Baldwin Technology Company Inc. will be showcasing its TexCoat G4 non-contact precision spray fabric-finishing system at the Techtextil North America trade show, held Aug. 23 to 25, in Raleigh, North Carolina.

With extensive sustainability benefits, unprecedented tracking and process control, and Industry 4.0 integration, the TexCoat G4 provides consistently high-quality fabric finishing, with no chemistry waste, and significantly reduced water and energy consumption.

Baldwin’s innovative non-contact spray technology eliminates chemistry dilution in wet-on-wet processes. The TexCoat G4 consistently and uniformly sprays chemistry across the fabric surface and applies it only where needed, on one or both sides.

  • Introducing TexCoat G4 to US textile industry
  • Non-contact precision spray fabric-finishing system enhances sustainability and process control

Baldwin Technology Company Inc. will be showcasing its TexCoat G4 non-contact precision spray fabric-finishing system at the Techtextil North America trade show, held Aug. 23 to 25, in Raleigh, North Carolina.

With extensive sustainability benefits, unprecedented tracking and process control, and Industry 4.0 integration, the TexCoat G4 provides consistently high-quality fabric finishing, with no chemistry waste, and significantly reduced water and energy consumption.

Baldwin’s innovative non-contact spray technology eliminates chemistry dilution in wet-on-wet processes. The TexCoat G4 consistently and uniformly sprays chemistry across the fabric surface and applies it only where needed, on one or both sides.

Customers can expect no bath contamination during the finishing process, as well as minimal downtime during changeovers, which are made easy with recipe management that includes automated chemistry and coverage selection. The TexCoat G4 also enhances sustainability by wasting no chemistry during color, fabric or chemistry changeovers, and because only the required chemistry volume is applied to the fabric, wet pick-up levels can be reduced by up to 50 percent—leading to 50 percent less water and energy consumption.

Furthermore, in single-side applications, drying steps can be eliminated for various textiles, including those that are back-coated and laminated, thereby streamlining and simplifying the production process.

Source:

Baldwin Technology Company Inc.