Textile Technology section
Mahlo: transparency in process control for technical textiles
High-performance technical textiles have to fulfill their task to 100% in order to prevent damage and danger. The final product has to fully strictly meet requirements and gray areas are unacceptable. The processes have to be transparent, so that the user can recognize discrepancies at any time and can react to them.
A prerequisite for a working product, independent of further treatment, is a straight web.
The automatic weft straightener Orthopac RVMC-15 from the manufacturer of measuring, control and automation systems Mahlo GmbH & Co. KG, Saal a.d. Donau/Germany, detects and straightens 97% of all known webs. For s-shaped distortions and non-detectable fabric, the pin wheel straighteners only work only for non-elastic products, however.
This is different with the Orthomax RFMB-15, a fusion of pin wheel and roller straightener. Thanks to combining both technologies, the system minimizes distortions in web as well as elastic knitting. Many textiles made of elastic raschel knitted fabrics already benefit from these advantages.
The next step is monitoring the further processing. With the help of scanners and sensors, the quality control system Qualiscan QMS-12 makes important parameters visible and therefore controllable. By measuring basis weight before and after the coating, one can determine the weight of the single layers.
Mahlo: control of basis weight and material thickness
Weight and thickness greatly influence the functionality of nonwoven goods such as masks or protective gowns. The process control systems from the manufacturer of measuring, control and automation systems Mahlo GmbH & Co. KG, Saal a.d. Donau/Germany, are able to support manufacturers in monitoring and controlling important parameters during the production process. Different sensors are available depending on the application.
The Gravimat DFI sensor is part of the modular system Qualiscan QMS and measures the basis weight with the help of isotope radiation. The measurement is based on the attenuation of radioactive radiation by the substrate in the measuring gap. If the density is uniform, the basis weight measurement can also be used to draw direct conclusions about the thickness of the nonwovens.
As an alternative to the measuring technique with isotopes, Mahlo uses a measuring method with X-rays. The Gravimat FMX-T sensor is ideal for products that consist of only one component and determines basis weight and thickness reliably. It measures thin film, nonwovens and other fabrics with high resolution, measuring accuracy and absence of flaws.
VDMA: webtalk on automation and digitalization in textile dyeing and finishing
The VDMA technology webtalk on October 6, 2020 focused on automation and digitalization in textile dyeing and finishing.
The textile industry faces enormous challenges including fashion trends, flexible production, rising costs, reduced prices, sustainability requirements, etc. To cope with these challenges and make reliable decisions, customers need automated processes, control systems and digitized data.
Axel Pieper of Brückner Textile Technologies GmbH & Co. KG, Leonberg/Germany, discussed the topic of digitalization and how it opens up completely new possibilities for increasing productivity, reducing the use of resources and improving quality.
Using the example of a stenter frame, Thomas Höpfl from Mahlo GmbH & Co. KG, Saal a.d. Donau/Germany, showed the possible savings and optimization potentials of data-controlled production.
Manfred Mentges from Sedo Treepoint GmbH, Mengerskirchen/Germany, talked about highly integrated systems from ERP level, linking to the MES systems, to the machine floor. His company offers solutions for process management, color management, printing and energy management, establishing IoT/Industry4.0 systems.
After the presentations, the 3 experts were available to answer the participants' questions.
Mahlo: 75th anniversary
The manufacturer of measuring, control and automation systems Mahlo GmbH & Co. KG, Saal a.d. Donau/Germany, celebrated its 75th anniversary on August 5, 2020.
Founded in 1945 by Dr. Heinz Mahlo the company focused early on the development of measuring and control systems for the textile industry. At the end of the 1950s he applied for a patent for the 1st automatic weft straightener.
Mahlo weft straighteners and systems for process control for textile finishing can be found in all important markets. In the mid-1990s, the Qualiscan QMS quality control system was introduced to the market.
Mahlo is still family-owned today, and the cooperation between owner, management and staff plays a major role in its success. The company has branches in the USA, Italy, Belgium, Spain and China and cooperates with service stations and sales partners in more than 100 countries.
Photo: Company owners Ralph & Aura Greenwood-Mahlo at the desk of company founder Dr. Heinz Mahlo
Mahlo: next generation pattern control system
Large, artistic graphics, timeless glen check or exact pinstripes. This presents an increasing challenge for textile manufacturers to produce straight weft and straightened patterns. Here, the alignment according to the design often plays a greater role than the weft insertion. The manufacturer of measuring, control and automation systems Mahlo GmbH & Co. KG, Saal a.d. Donau/Germany, solves this problem with its improved Patcontrol PCS-20 system for pattern recognition and warp control. It straightens bow and skew distortions in technical textiles just as reliably as in terry cloth. Even goods that cannot be detected with conventional scanning systems do not pose a problem for pattern recognition.
The system uses camera technology to detect the position of the pattern and automatically and continuously determines the pattern repeat, measures the product width, and together with a straightener straightens the product distortion based on the print pattern.
New long-life LED lighting generates the maximum brightness on the market, thereby extending the scanning range for darker goods. Improved cameras allow brightness control by gain and exposure time. More than 2 cameras can also be connected per measuring point. This allows a higher resolution and even more accurate results. A Gigabit connection allows the transmission of large amounts of data. Using a mounting aid, the exact camera adjustment can be done easily and quickly. A compact interface box at the measuring point integrates the Patcontrol PCS-20 even more easily into the existing plant.
The system is also integrated into the mSmart digitalization concept. Users, machines and processes are networked with each other and meet all the requirements of Industry 4.0.
VDMA: technology webtalks for the textile industry
On June 22, 2020 the German Textile Machinery Association (VDMA), Frankfurt/Germany, started a series of Textile Machinery Webtalks. In the first edition experts from the companies Oerlikon Manmade Fibers, Mahlo and Nanoval presented technologies for the production of melt-blown nonwovens for respiratory protection masks (FFP masks and surgical masks). After the presentations, the experts were available to answer the participants' questions. Further technology webtalks on other topics are in preparation. Participation is free of charge. For further information: www.machines-for-textiles.com/webtalk
Mahlo: quality assurance of medical products
Manufacturers of medical goods are currently under pressure to deliver their goods as quickly as possible, but still with high quality. The manufacturer of measuring, control and automation systems Mahlo GmbH & Co. KG, Saal a.d. Donau/Germany, supports manufacturers in monitoring and controlling important parameters during the production process.
Weight and thickness have a great influence on the functionality of nonwovens. The Gravimat DFI sensor is part of the modular Qualiscan QMS quality measurement system and measures weight and material thickness using isotope radiation. The measurement is based on the attenuation of radioactivity by the substrate in the measuring gap. This weakening of the intensity is a measure of the basis weight of the goods. Mahlo works with different isotope variants in order to do justice to different material properties. Krypton-85 is used for goods with a weight between 10 and 1,400 g/m², strontium-90 is used for 100 – 6,000 g/m².
This method also solves problems faced by manufacturers of web-shaped goods such as hygiene fleece: measurement inaccuracies due to fabric flutter. Its sensor technology makes the Gravimat DFI immune to changes in the center of gravity. It measures precisely and is unaffected by any changes in degree of dryness, density or thickness.
Mahlo: Dr. Heike Wenzel new member at the advisory board
Effective April 1, 2020 Heike Wenzel is a new member of the advisory board of the manufacturer of measuring, control and automation systems Mahlo GmbH & Co. KG, Saal a.d. Donau/Germany. She succeeds Fritz P. Mayer, who is retiring from his position.
Wenzel acts as managing associate at the family-owned supplier of measurement technology Wenzel Group GmbH & Co. KG, Wiesthal/Germany. Furthermore she is the honorary vice president of the Industrie- und Handelskammer (IHK) in Aschaffenburg/Germany.
Mahlo: cooperation with universities in Bangladesh
As guest speakers at lectures at the Bangladesh University of Textiles (BUTEX), and the Northern University Bangladesh, both based in Dhaka, representatives of the manufacturer of measuring, control and automation systems Mahlo GmbH & Co. KG, Saal a.d. Donau/Germany, introduced the students to the requirements and solutions of modern textile production. In the future, the connection to one of the most important textile markets in the world is to be further strengthened.
Lectures covered how modular process control can be the answer to current challenges in the industry, such as rising costs for raw materials and personnel. In the age of
Industry 4.0, data-based production is indispensable and Mahlo has therefore developed the mSmart digitalization concept. Since all Mahlo machines are networked in the mSmart environment, the user receives all the essential data at a glance, anytime and anywhere. This enables a quick reaction based on the latest values. Process control thus not only helps to save resources, but also to make the machinery easier to handle.