Textile Technology section
TMAS: 2 new members with Industry 4.0 technology
The Textile Machinery Association of Sweden (TMAS), Stockholm/Sweden, welcomes 2 new companies – both at the forefront of sustainable and Industry 4.0-enabled technologies – to its membership.
The first is Coloreel AB, Jönköping/Sweden, the developer of a thread coloring unit which enables the instant and high-quality coloring, fixation, washing and lubrication of thread to take place simultaneously to the actual embroidering of a fabric, representing an entirely new approach to this traditional field.
The advanced colorization software and instant thread coloring technology allows a single needle to carry out what previously required multiples of them, and with much more consistent stitch quality. Designed to work with any existing industrial embroidery machine without modification, the stand-alone Coloreel unit allows set-up and lead times to be reduced as well as significant flexibility in production schedules, while eliminating the need for large thread inventories. The unit can also reduce the total production time required for complex designs by up to 80%, as well as instant reaction to the specific color requirements of customers.
The second new TMAS member, imogo AB, Limhamn/Sweden, has the patent-pending FlexDyer process which provides opportunities for major savings in water, energy, chemicals and dyes by as much as 90% compared to conventional jet dyeing systems, as well as in lowering maintenance and labor costs. Imogo’s Mini-Max spray test unit is also available for the achievement of offline ‘right first time’ results for the company’s industrial scale Dye-Max.
The savings in treatment water the Dye-Max achieves are due to the extremely low liquor ratio of 0.3-0.8 l/kg of fabric and at the same time, the low liquor ratio and the spray process require considerably less auxiliary chemicals to start with. The low liquid content in the fabric also minimizes the energy required for fixation. The Dye-Max has a working speed of up to 50 m/min with the practical speed determined by the fabric weight and application volume. The Spray Applicator can also be incorporated in existing lines to replace a padder, both for dyeing and applying finishing chemistry, in order to increase their productivity and reduce the environmental footprint of existing processes.
Dilo: new needlefelt line for Scavone
With 126 years of existence S/A Fabril Scavone, Itatiba/Brazil, is a South American textile company that is steeped in tradition. Since its entry into the technical textiles sector in 1993, the portfolio has expanded to filtration, shoes, geotextile, acoustic, furniture and automotive which until now have been produced on 4 nonwovens production lines.
Scavone is now increasing its production capacity with the new needlefelt line from the nonwovens machinery manufacturer DiloGroup, Eberbach/Germany.
The DiloGroup plant consists of fiber preparation, MultiCard and lap drafter, as well as crosslapper and needlelooms. It is used to process PET, PP and Bico fibers into needlefelt especially for geotextile and automotive applications. The implementation of Dilo Line 4.0 software offers an optimum process control and monitoring.
Autefa: nonwovens solutions at Techtextil India
During Techtextil India from November 20-22, 2019, the manufacturer of textile machinery, Autefa Solutions Germany GmbH, Friedberg/Germany, will present its portfolio of carded-crosslapped needlepunch lines, aerodynamic web forming technology, spunlace, and thermobonding lines for producing nonwovens which cater to wide range of applications such as filtration, geotextile, automotive, carpets, technical felts, waddings, insulations, wipes, hygiene etc.
With the introduction of the new hydro-entanglement machine V- Jet Futura, Autefa now offers the entire line for spunlace producers. The V-Jet injector for spunlace machines and the Square Drum Dryer SQ-V, both are innovative contributions to energy savings and reduced manufacturing costs. The aerodynamic web forming machine Airlay Futura is based on the successful Airlay K 12.
Solutions from Autefa ensure lower energy cost, lower maintenance cost combined with higher rate of production and superior quality. The company also offers the service of a customized needle board pattern. The i-Point needling simulation tool increases the capacity and the quality of needlepunched fabrics. The software makes development of new needle patterns and the evaluation of surface quality much more effective and economic. It creates a layout of stripper and bed plate including the elliptic needling (Variliptic). This customized design of needle pattern, which also takes draft and shrinkage into consideration, reduces the process optimization time on customer site. The needlepunch lines produce an even and homogenous fabric with very good technical performance in terms of tensile strength and evenness (MD/CD ratio).
Lectra: fabric zero-buffer cutting solution for automotive interiors
New solutions for the mass production of fabric car seats and interiors have been launched by the supplier of integrated technology solutions for textile and flexible materials Lectra SA, Paris/France.
The latest additions to the already-extensive Vector Automotive fabric cutting machine range, the iP6 and iP9, combine cutting equipment innovation with an optimized software application and specially designed consumables to enable automotive suppliers to achieve zero-buffer cutting on a very wide variety of automotive materials.
Constant, real-time control of the cutting equipment is integral to Vector Automotive iP6 and iP9’s ultraprecise cutting. Sensors on the cutting-head camera detect stress and instantly adapt cutting parameters. The new algorithm, an add-on to the equipment software pilot, manages common lines in real time for the greatest possible accuracy while cutting parameters are continually adjusted to the blade’s dimensions.
In addition to substantially reducing material consumption, there are also lower consumable replacement costs and increased cutting time. Just as with materials, the new solutions enable an equivalent gain in paper and plastic films for each 1 mm reduction in buffer. Improvements in the bristle block, sharpening band and blade lifespans reduce maintenance time by half, thereby drastically increasing machine availability. Both solutions come with Vector Dashboard, a cloud-based application to monitor the equipment through daily key performance indicators.
Saurer: efficient twister for staple fiber yarn
At the international textile industry exhibition ShanghaiTex from November 25-28, 2019, in Shanghai/China, Saurer Technologies GmbH & Co. KG Twisting Solutions, Krefeld/Germany, will focus on the very efficient FusionTwister for staple fiber yarns. The cost-effective production of 2-for-1 twisted staple fiber yarns is achieved by taking into account the 3 main factors of energy, economics and ergonomics.
The machines’ reliably low energy consumption is achieved by means of an optimized spindle drive as well as a great variety of spindle and feeding sizes for all kinds of applications. The machine’s short set-up times, fast air threading and easy handling were key considerations with regard to optimizing ergonomics.
The computer-controlled servo drive system offers a high degree of flexibility to wind the yarn onto cross-wound packages with a large variation in shapes and density. Other features adding to the FusionTwister’s versatility are the software upgrade and newly designed computer panel. This results in better readability and more flexibility, while creating the base for the Saurer mill management system Senses.
Gerber: fully connected, end-to-end platform
By effectively streamlining the workflow, the newly released AccuMark 12.2 platform from the supplier of integrated software solutions Gerber Technology, Tolland, CT/USA, increases productivity, identifies fit issues, and decreases the lead time from an average of 57 weeks to as little as a few days. The single platform fully connects the supply chain from design to production leveraging 2D/3D CAD, PLM and Industry 4.0 enabled smart machines. This covers not only the area of digital product development but also the connection to both mass automated and on-demand production.
AccuMark 12.2 has been designed to enhance Gerber’s end-to-end platform through an improved digital print workflow, several new 3D capabilities that will improve fit assessment, and offer better communication among partners and team members. AccuMark 3D 12.2 also includes major improvements in 3D simulations.
The latest installment of the CAD solution will also feature major updates to their cut planning software. AccuPlan 12.2 not only makes it simple to get a precise cut but, when combined with Gerber’s powerful nesting software, AccuNest, is able to reduce costs and material waste.
Users will be able to reduce time spent grading by 50% with the ability to grade proportionally, double productivity when adding notches by using the Double Notch and Notch All Positioned functions and increase the development speed up to 5 times faster and see a 15% fabric savings when using the AccuMark digital print development workflow.
Dornbirn-GFC with GFC Startup Days
Circular Economy, digitalization, technical textiles, nonwovens and the 1st Startup days were the hot topics of the 58th Dornbirn Global Fiber Congress (Dornbirn GFC) in Dornbirn/Austria. With over 700 visitors from 30 countries, interest especially came from companies from Asia and Turkey.
Sustainable resource management has become a core element for our future. Plenary lecutres on the subject of sustainability were held by Robert van de Kerkhof (Lenzing AG) and Uday Gill (Indorama Ventures) from the perspective of the fiber industry.
How can software industry support sustainable industry? – This question was outlined by interesting examples from Robert Rosellen (Microsoft) and Stefan Achleitner (Palo Alto Networks).
From September 11-12, 2019 the 1st Dornbirn GFC Startup Days took place under the motto “Come and see where Startups meet Industry, Research and Brands”. Supported by PricewaterhouseCoopers (PwC) about 20 international startups presented their innovations in the event tent. The 3 best projects were presented with the Startup Award.
Furthermore, there were over 100 expert lectures on the following subjects: fiber innovations, circular economy and sustainability, digitalization and smart textiles, surface modification and additives, sports and leisure wear, nonwovens and technical textiles.
Autoneum: new digital acoustic management of vehicles
The automotive supplier Autoneum Management AG, Winterthur/Switzerland, has launched an online configurator for the acoustic management of vehicles. The Acoustic Garage offers a comprehensive information and product experience on all aspects of noise protection in cars. In addition, users can customize various acoustic components according to their individual requirements. In this way, Autoneum supports vehicle manufacturers in ensuring optimal acoustics in future models. The new configurator allows interested parties – whether customers, science representatives or end consumers – to design a customized noise protection package. Acoustic Garage is based on the company’s simulation expertise: internally developed software calculates the acoustic performance of selected components and vehicle setups in real time and generates a detailed analysis that can be shared, saved and categorized.
natific: digital color solutions
The supplier of color production and management process technology and color accreditations, natific AG, Aesch/Switzerland, will showcase natific digital color solutions at the Performance Days in Munich/Germany from November 13-14, 2019.
The B2B software solution ColorWarehouse ensures high precision and reproducible color results. All color data from the supply chain are transferred to a cloud-based system for central information management. Designers no longer need to send physical color samples or make visual assessments. Dye houses actually self-approve colors when they are within tolerance. Key performance indicators can be benchmarked across different mills, services tracked and monitored, and quality issues minimized. Development cycles are shortened by an average of 4-6 weeks while color quality is elevated.
Beyond production monitoring functionalities, the system enables strategic supply chain management. Solid indicators help identify key performers and facilitate decision-making that supports supply chain optimization.
The new B2B platform ASAP can tell customers very clearly how accurately a supplier can produce a given color for a given material before going into production. In contrast to traditional platforms that solely provide digital color data to suppliers, ASAP works by enabling a 2-way interactive exchange between brands and their suppliers. The platform’s ability to seamlessly integrate into existing IT infrastructures, such as Product Lifecycle Management (PLM) or Enterprise Resource Planning (ERP), ensures smooth communication.
Stoll: new showroom in Italy
Stoll Italia Srl, Barletta/Italy, a subsidiary of the manufacturer of flat knitting machines H. Stoll AG & Co. KG, Reutlingen/Germany, opened a "Centro di Programmazione" in Barletta.
In addition to a new showroom with Stoll machines and knitting patterns, the new establishment offers support for programming and repair work along with a spare parts store for local Stoll customers. There is also a training room for both software and machine training.