Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                
SlideShare a Scribd company logo

Compactor

•Download as PPTX, PDF•
•
Md. Mazadul Hasan Shishir
Md. Mazadul Hasan Shishir

The document provides information about a compactor machine used to control fabric shrinkage. It summarizes the machine's functions, operating parameters, and components. Key points include: 1. The compactor machine compacts fabric in the lengthwise direction and provides overfeed to control shrinkage during processing with steam. 2. It lists the machine's functions such as improving hand feel, reducing thickness, and controlling shrinkage. 3. It describes the machine components and operating parameters like temperature, speed, and overfeed percentage for different fabric types. 4. Diagrams show the mechanism and fabric path through a blanket and tube compactor machine.

1 of 68
Compactor
Prepared By : Mazadul Hasan sheshir ID: 2010000400008 13th Batch (session 2009-2013) Department : Wet Processing Technology Email: mazadulhasan@yahoo.com Blog : www. Textilelab.blogspot.com (visit) Southeast University Department Of Textile Engineering I/A 251,252 Tejgaon Dhaka Bangladesh Prepared By :
The compactor machine is a tubular fabric shrinkage control machine which can compact the fabric in length wise direction, to provide over feed to the fabric while processing in presence of steam, and able to control the shrinkage. In other words, this is a process of compacting the fabric in length ways direction.
Compactor
 Upgrade the fabric hand feel and import a smooth, silky touch to the fabric.  Compress the fabric and reduce its thickness.  Improve the opacity of the fabric.  Import different degree of luster to the fabric.  Reduce the yarn slippage.
1. Shrinkage control 2. GSM control 3. Width control 4. Ironing the fabrics 5. To compact the fabric 6. To control the shrinkage 7. To maintain proper width and G.S.M
Machine Operating Rules & Regulation for Compacting Machine: • Machine should be kept always clean. • Knot & very much course stitch containing fabrics should not be feed to the machine. • Machine should not be stopped until the temperature decrease at 65ºC • Teflon should be cleaned minimum two times in a day. • Load value of load cell should be check. • Machine inlet steam should be between 4 – 6 bars. • Electric component should be safe from water during machine cleaning. • If any problem is observed in dyeing machine, the information should be sent to maintenance department as soon as possible. Operator must not be accessed electric control panel in any condition.
Compactor
Shrinkage Tolerance of Different Fabric: Fabric Type Length (%) Width (%) S/J -5.50 -5.50 Lycra S/J -6.00 -6.00 Single Lacoste -7.00 -7.00 Lycra Single Lacoste -7.00 -7.00 1X1 Rib -7.00 -7.00 Lycra 1X1 Rib -7.00 -7.00 2X2 Rib -8.00 -8.00 Lycra 2X2 Rib -8.00 -8.00 Interlock -7.00 -7.00 Terry Fleece -5.00 -5.00
Mechanism of Blanket Type Compactor
Compactor
Compactor
Fabric Path of Tube Compactor
Compactor
FUNCTION ONAL SELECTION LEGEND 1 – Fabric Brake 13 – Felt Centering Rollers 2 – Fabric Feeding roller 14 – Felt Tensioning Rollers 3 – Beater 15 – Heated Roller 4 – Safety Photocell indicating Lack of Fabric 16 – Felt Drawing Rollers Covered with Rubber 5 – Fabric Conveyor Belt 17 – Rollers with Loading Cell for automatic Fabric Tension Control 6 – Photocell Loop Control 18 – Exit Belt Drawing Roller 7 – Operator Platform 19 – Fabric Conveyor Belt 8 – Re – directing Roller 20 – Movable Arms 9 – Automatic Spreader Mod. AL-BATROS 21 – Fabric Conveyance Hopper 10 – Steaming Chamber 22 – Plaiting Roller 11 – Motorized Adjustable Rollers 23 – Fold Pressing Device 12 – Felt Re – directing Adjustable Rollers 24 – Plaiting Platform OPTION: A – Ring Spreader for Tubular Fabric C – Cardboard Positioning Device B – Cooling Chamber at Exit D – Cutting Device
Machine Parameter Set Up Value Steam Pressure 2 bar. Air Pressure 4 bar. Temperature 100-120 C. Machine Speed 15-50 m/min Over Feed 35 m/min 
Compactor
Compactor
Brand name : Fabcon Manufacturing country : U.S.A Year of manufacturing : 2006 Maximum speed : 60 m/min Minimum speed : 10 m/min Production/day : 8 tons/day Maximum Temperature : 70˚C Tube compactor Machine
Compactor
Machine specification: Brand name: HELIOT International Type/model no: HC2000GL Company: France No of motor: 08 Over feed = m/min Machine speed range: 13-22m/min Termperature(0C) range: 100-1400C Maximum width 86 Minimum width 36 Applied for: Open fabric Left over feed: -20% +20% Right over feed: -20% +60% High production: -20% +60% Front over feeding cylinder: -20% +60% Middle belt: -20% +60% Open fabric Compactor
Check point: I)Check steam & air line pressure II)adjust felt temperature III)Blanket pressure:3.5-4.0-4.5 Some instructions for optimum performance: 1. Center the felt blankets on the cylinder. Ensure that all cylinders are running parallel relative to each other. Adjust the limit switch against the edge of the felt. 2. Place the felt under tension. Upper felts tension-2 bar, Lower felt tension-1 bar. 3. raise the heated drum working temperature to 200 f| & set the speed to 11-22 yd/min(10-20 m/min) 4. Open the humidification ramp in order that felts are in a steam atmosphere. 5. As soon as these conditions are reached, let the felt run for 2.5 m
Machine specification: Brand name: FERRARO Type/model no: COMPTEX-RE 2800. Company: ITALY. No of motor: 17 Over feed = Max + 35%, Min -35%. Machine speed = Max 32m/min, Min 4m/min. Termperature range: 100-2000C Maximum width =240cm Minimum width =100cm Applied for: Open fabric Left over feed: -20% +20% Right over feed: -20% +60% High production: -20% +60% Front over feeding cylinder: -20% +60% Middle belt: -20% +60% Open compactor
Heating system: Steam Main parts of the machine: 1. Heating chamber 2. Blower (2, one at the entry chain zone for uncurling and another at the entry of compacting zone) 3. Synthetic blanket as a conveyor, 4. Folder 5. Exhaust fan 6. Unpinning cylinder (-40% +40%) 7. Belt cylinder (-40% +40%) 8. Uncurling device at entry of compacting zone. 9. sensor 10. brush roller
Additional attachment: •Selvedge cutting •Selvedge safety •Pinning safety •Selvedge unrolling •Selvedge drying •Steam zone heating
Controlling points: •Water pressure 2.5 lb •Air pressure 4 lb •Steam pressure 6 lb Manpower Required: Worker: 06 Production: Capacity: 5 tones/shif Actual production: 4 tones/shif Utility: Steam Electricity, Compressed air.
Compactor
Overfeed % Up Setup for Lafer compacting Machine: Overfeed % Up for Lycra Single Jersey : 60 Overfeed % Up for Single Jersey : 35/40. Overfeed % Up for Lacost fabric : 35/40 Overfeed % Up for Rib fabric : 20/22 Overfeed % Up for CVC fabric : 45
Main Parts: (Lafer Compacting Machine) Heat Padder: Control Motor Speed. Heat Chamber: Three. 1. Lower Padder 2. Stenter 3. Compactor Main Power Blanket: For finishing Cloth. Guide Roller Clip: Straighten the fabric Wheel raising Steam Box: soften the fabric Load Cell: Keep the delivery Roller for perfect tension. Temperature: 1500C (Highest) Speed: 50 M/Min Overfeed % Up: More the Overfeed % Up More the GSM. Steam Pressure: Up to 10 Kg
In Tube-tex compactor m/c fabric spread range:
Compactor
Compactor
Compactor
Compactor
Compactor
Compactor
Compactor
Compactor
Compactor
Compactor
Compactor
Compactor
Fabric dia (inch) Maximum spreading (inch) 14” 17” 16” 19” 17” 20” 19” 25” 22.25” 28.25” 26” 36.38” 34.75” 47” 45” 57” 48.25” 60”
For different type of fabric speed and compaction (TUBE TEX): Fabric Type Speed ( r.p.m ) Compaction S/J 20 8-9 % Lycra S/J 25 7-10 % 1*1 Rib 30 8 -11 % Single lacoste 30 10 -14 % 2×2 Rib 30 -35 6-7 % Double lacost 30 -35 12 % Pk. Fabric 30 10 -12 % Interlock 30-35 9 – 12%
Technical description of the basic compacting machine:
Support Structure: It consists of sturdy body sides made of painted steel, supporting the cylinders, the mechanical part and the plant system; they are connected by means of longitudinal and transversal cross-section. The body sides are provided with special safety locks. Inlet Tightener: The inlet tightner is designed to drag the fabric to the machine with an adequate tension. Its effect can be varied by turning the hand wheel provided. Fabric Draw Roller: The draw rollers receive their movement from a variable speed motor. They deter-mine the speed of fabric. 1. The rollers are normally covered with rubber and it is most important that the surface of the covering is always in good condition so ass to avoid slipping of the fabric. Should this not be so then it is necessary to replace the covering. 2. The processing of fabrics treated with chemical against might involve a rapid deterioration of the drag rolls coating.
Idle Cylinders: The idle cylinders are designed to change the route of the fabric to convey it in the right position for subsequent working. Dancing Roller Synchronizer: The dancing roller is constituted by a cylinder mounted on oscillating arm, connected to a rheostat for the synchronization of the various group. Inlet fabric Guide: It consists of shoulders supporting a couple of adjustable spreader rollers operated by an independent motor, and a pneumatically operated fabric centering unit with move-able staves, controlled by border guard photocells. Steaming Tank : It consist of no. 1 steam delivery chamber on the fabric, made of inox steel and complete with metering valve and on-off solenoid valve.
•Compacting units: They are the real compacting units. Each unit consists of: 1. A steam heated cylinder, diameter 500 mm., made of chromium plated and ground steel; it is complete with a rotary joint for steam feeding, a thermocouple feeler to feel the temperature, and an effective system for the condensate drainage. The cylinder temperature can be adjusted with the utmost (+/-2˚C) directly from the keyboard placed on the control board, and is shown on the display. 2. A thick Nomex – Polyester compacting felt. The double action felt centering de- vice ensures perfect felt alignment during running. The computer controlled felt control mechanisms automatically releases felt tension after a machine stop. 3. An adjustable position counter-roller for the fabric shrinkage control during inlet in the compacting group. 4. An inlet element in a special non-adherent fibre (shoe) equipped with a device for adjusting both angle of incidence and insertion length.
Spreader Roller It is a spreader roller, for the selvedge unwinding and the inlet of the fabric perfectly spread in the machine. Scroll Roll Unit The adjustable spreading scrolls at entry are used for open width knits and for all fabrics that have lengthwise creases. Consists of two adjustable spiral scroll roll driven by an independent motor. Device for Fabric Tension Check It consists of a cylinder combined with a special load cell sensor. It allows synchronizing the speed between the upper and lower compacting unit, and adjusting the fabric tension between them with the utmost precision. The adjustment is performed directly from the keyboard placed on the control board and is shown on the display.
Cooling Unit It consists of a steel structure including a conveyer belt, the drag and tension cylinders Of the latter, a suction chamber with a net plane for a perfect distribution of the cooling air. The chamber is connected to a high-efficiency centrifugal electric fan. Checking Table: The inspection table is composed by a steel structure that supports a table that accompanies the fabric falling from the cooling band. In this phase the operator placed in the rolling up unit zone can carry out a check on the quality of the worked fabric and notice possible defects. Fabric Storage Chute for the System Non-Stop: It consists of a j-plate for the fabric storage during the phase of roll change. It allows removing the finished roll, and starting a new roll without stopping the system.
Rolling Unit It consists of a bearing structure and a moveable trolley which supports the rolling cylinders. The trolley sides on two rails in order to allow the perfect alignment of a selvedge on the roll of fabric. The movement is automatically controlled and is operated by an electromechanical actuator. The reading of the selvedge border is performed by two photocells, whose position can be adjusted by means of a hand wheel. The rolling cylinders are covered with vulcanized rubber for a perfect adhesion. The roll compactedness can be adjusted by a pneumatically operated device. The rolling unit is complete with a spreader roller, operated by an independent motor, placed immediately before the rolling cylinders. Steam System It is installed in the machine. It includes a filter, an on-off valve, a pressure gauge for displaying the line pressure and a condensate separator. It is provided with a series of servo-operated solenoid valves to feed the different elements of the machine and wit automatic steam traps complete with by-pass for manual drainage. Controls The main controls are located on the left side at the machine entry; they include a “Touch Screen” interface and a set of buttons. The auxiliary controls are placed on the panel at the machine exit. The emergency stop buttons are located on the sides of the machine.
S) Electric Board: The electric board is installed in the machine. It includes the electromechanical instal- lation, electronic cards, a set of inverters and the PLC controlling the machine. It is also equipped with protection devices, and cooling devices. All operation func-tion is shown in the “Touch Screen” on the main control board. The machine is equipped with a direct grounding of all the electric components and of the metal frame. The preventive measures to ensure immunity in the presence of electromagnetic dis- turbances have been adopted, and have been taken the necessary precautions to atte- nuate the disturbances of an electromagnetic nature produced by the electric/ electronic system of the machine T) Pneumatic System It includes an on-off valve, a filter-lubrication unit, a pressure regulator and a series of solenoid valves for the operation of the pneumatic actuators.
Monforts Compactor Machine:
Maximum Speed : 40 m/min Minimum Speed : 7 m/min Steam Pressure : 4 - 4.5 MaximumOver feed (%) : 22% MinimumOver feed (%) : 18% Pressure Type : Cylinder + Rubber Belt Monforts Compactor Machine:
Compactor
Type: Blade Compactor Machine Types of Roller: 4 (Anti Roll, Expander Roll, Retard Roll, Pad Roll) Compaction depends on Retard Roller. Shade depends on Shoe Depth. Feed Roll Temperature is automatically set by the machine. Shoe Pressure: 2.5 - 3 Maximum Fabric Passing Speed: 40 m/min Minimum Fabric Passing Speed: 20 m/min Maximum Over feed (Bilateral Slat) %: 98% Minimum Over feed (Bilateral Slat) %: 90% Maximum Temperature: 80oC ( Blade Types Compactor Machine )
Ferraro Compactor Machine:
Type: Blanket Compactor Machine No. of Steam Chamber: 2 Steam Temperature: 100oC Maximum Fabric Dia Capacity: 225-228 cm Minimum Fabric Dia Capacity: 100 cm GSM Control: 7-8 Maximum Fabric Passing Speed: 20 m/min Minimum Fabric Passing Speed: 10 m/min Maximum Over feed (%): 35% Minimum Over feed (%): 0% ( Blanket type Compactor Machine )
Santex Compactor Machine (Tubular Knitted Fabric Compactor):
Type: Blanket Compactor Machine Minimum Fabric Dia Capacity: 126 cm Maximum Fabric Dia Capacity: 28 cm Steam Temperature: 120oC Maximum Overfeed (%): 40% Minimum Overfeed (%): -10% No. of Cylinder: 2 Padder Pressure: 6-7 (Tubular Knitted Fabric Compactor)
Fabric type Colour Speed (m/min) Over Feed (%) Temperature (degree C) Blanket Pressure Teflon Pressure Stretch (%) Single jersey White Colour 15-18 15-18 25-30 25-30 90-110 110-120 1.5-2bar 36psi As required Pique (s/j,d/j) White Colour 15-18 15-18 30-35 30-35 100 110-120 1.5-2bar 36psi As required Lycra s/j White Colour 12-16 12-16 Full over feed 100-110 100-120 1.5-2bar 36psi As required 1x1 Rib White Colour 15-20 15-20 20-30 20-30 100 110- 120 1.5-2bar 36psi As required 2x2 Rib White Colour 12-15 12-15 25-30 25-30 100 110- 120 1.5-2bar 36psi As required Interlock White Colour 12-16 12-16 Full over feed 100 110- 120 1.5-2bar 36psi As required
Teflon speed (+) – More compaction Teflon speed (-) – Less compaction, G.S.M because overfeed is less.
Utilities used: •Electricity •Steam •Compressed air Control Point : - Water pressure - Air pressure - Steam pressure
1. Shade Check: In delivery side operator checks the shade of fabric with customer approved swatch. 2. With Check: Operator measures fabric width by using measuring tape and compared with required width. 3. Wight Check: Operator checks the weight by using GSM cutter and electronic bal-ance& compares with the required finished width. 4. Fault Check: As mentioned before 5. Design & Slanting: Operator checks design and slanting at delivery side. 6. Edge line checking: check two edges of fabric at delivery side.
Compactor
Belt Principle for Imparting Mechanical Shrinkage for Knits
Compactor
1. Yarn Manufacturing Technology Link:http://www.facebook.com/pages/Yarn-Manufacturing-Technology/485014954866808 2. Fabric Manufacturing Technology Link:http://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605 3. Garments Manufacturing Technology Link:http://www.facebook.com/pages/Garments-Manufacturing-Technology/472364799463126 3. Wet processing Technology Link:http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-/468645219825404 4. Fashion-Design-and-Technology Link:http://www.facebook.com/pages/Fashion-Design-and- Technology/587655294583875?ref=ts&fref=ts My Facebook Textile related Pages http://www.textilelab.blogspot.com

More Related Content

Compactor

  • 2. Prepared By : Mazadul Hasan sheshir ID: 2010000400008 13th Batch (session 2009-2013) Department : Wet Processing Technology Email: mazadulhasan@yahoo.com Blog : www. Textilelab.blogspot.com (visit) Southeast University Department Of Textile Engineering I/A 251,252 Tejgaon Dhaka Bangladesh Prepared By :
  • 3. The compactor machine is a tubular fabric shrinkage control machine which can compact the fabric in length wise direction, to provide over feed to the fabric while processing in presence of steam, and able to control the shrinkage. In other words, this is a process of compacting the fabric in length ways direction.
  • 5.  Upgrade the fabric hand feel and import a smooth, silky touch to the fabric.  Compress the fabric and reduce its thickness.  Improve the opacity of the fabric.  Import different degree of luster to the fabric.  Reduce the yarn slippage.
  • 6. 1. Shrinkage control 2. GSM control 3. Width control 4. Ironing the fabrics 5. To compact the fabric 6. To control the shrinkage 7. To maintain proper width and G.S.M
  • 7. Machine Operating Rules & Regulation for Compacting Machine: • Machine should be kept always clean. • Knot & very much course stitch containing fabrics should not be feed to the machine. • Machine should not be stopped until the temperature decrease at 65ºC • Teflon should be cleaned minimum two times in a day. • Load value of load cell should be check. • Machine inlet steam should be between 4 – 6 bars. • Electric component should be safe from water during machine cleaning. • If any problem is observed in dyeing machine, the information should be sent to maintenance department as soon as possible. Operator must not be accessed electric control panel in any condition.
  • 9. Shrinkage Tolerance of Different Fabric: Fabric Type Length (%) Width (%) S/J -5.50 -5.50 Lycra S/J -6.00 -6.00 Single Lacoste -7.00 -7.00 Lycra Single Lacoste -7.00 -7.00 1X1 Rib -7.00 -7.00 Lycra 1X1 Rib -7.00 -7.00 2X2 Rib -8.00 -8.00 Lycra 2X2 Rib -8.00 -8.00 Interlock -7.00 -7.00 Terry Fleece -5.00 -5.00
  • 10. Mechanism of Blanket Type Compactor
  • 13. Fabric Path of Tube Compactor
  • 15. FUNCTION ONAL SELECTION LEGEND 1 – Fabric Brake 13 – Felt Centering Rollers 2 – Fabric Feeding roller 14 – Felt Tensioning Rollers 3 – Beater 15 – Heated Roller 4 – Safety Photocell indicating Lack of Fabric 16 – Felt Drawing Rollers Covered with Rubber 5 – Fabric Conveyor Belt 17 – Rollers with Loading Cell for automatic Fabric Tension Control 6 – Photocell Loop Control 18 – Exit Belt Drawing Roller 7 – Operator Platform 19 – Fabric Conveyor Belt 8 – Re – directing Roller 20 – Movable Arms 9 – Automatic Spreader Mod. AL-BATROS 21 – Fabric Conveyance Hopper 10 – Steaming Chamber 22 – Plaiting Roller 11 – Motorized Adjustable Rollers 23 – Fold Pressing Device 12 – Felt Re – directing Adjustable Rollers 24 – Plaiting Platform OPTION: A – Ring Spreader for Tubular Fabric C – Cardboard Positioning Device B – Cooling Chamber at Exit D – Cutting Device
  • 16. Machine Parameter Set Up Value Steam Pressure 2 bar. Air Pressure 4 bar. Temperature 100-120 C. Machine Speed 15-50 m/min Over Feed 35 m/min 
  • 19. Brand name : Fabcon Manufacturing country : U.S.A Year of manufacturing : 2006 Maximum speed : 60 m/min Minimum speed : 10 m/min Production/day : 8 tons/day Maximum Temperature : 70˚C Tube compactor Machine
  • 21. Machine specification: Brand name: HELIOT International Type/model no: HC2000GL Company: France No of motor: 08 Over feed = m/min Machine speed range: 13-22m/min Termperature(0C) range: 100-1400C Maximum width 86 Minimum width 36 Applied for: Open fabric Left over feed: -20% +20% Right over feed: -20% +60% High production: -20% +60% Front over feeding cylinder: -20% +60% Middle belt: -20% +60% Open fabric Compactor
  • 22. Check point: I)Check steam & air line pressure II)adjust felt temperature III)Blanket pressure:3.5-4.0-4.5 Some instructions for optimum performance: 1. Center the felt blankets on the cylinder. Ensure that all cylinders are running parallel relative to each other. Adjust the limit switch against the edge of the felt. 2. Place the felt under tension. Upper felts tension-2 bar, Lower felt tension-1 bar. 3. raise the heated drum working temperature to 200 f| & set the speed to 11-22 yd/min(10-20 m/min) 4. Open the humidification ramp in order that felts are in a steam atmosphere. 5. As soon as these conditions are reached, let the felt run for 2.5 m
  • 23. Machine specification: Brand name: FERRARO Type/model no: COMPTEX-RE 2800. Company: ITALY. No of motor: 17 Over feed = Max + 35%, Min -35%. Machine speed = Max 32m/min, Min 4m/min. Termperature range: 100-2000C Maximum width =240cm Minimum width =100cm Applied for: Open fabric Left over feed: -20% +20% Right over feed: -20% +60% High production: -20% +60% Front over feeding cylinder: -20% +60% Middle belt: -20% +60% Open compactor
  • 24. Heating system: Steam Main parts of the machine: 1. Heating chamber 2. Blower (2, one at the entry chain zone for uncurling and another at the entry of compacting zone) 3. Synthetic blanket as a conveyor, 4. Folder 5. Exhaust fan 6. Unpinning cylinder (-40% +40%) 7. Belt cylinder (-40% +40%) 8. Uncurling device at entry of compacting zone. 9. sensor 10. brush roller
  • 25. Additional attachment: •Selvedge cutting •Selvedge safety •Pinning safety •Selvedge unrolling •Selvedge drying •Steam zone heating
  • 26. Controlling points: •Water pressure 2.5 lb •Air pressure 4 lb •Steam pressure 6 lb Manpower Required: Worker: 06 Production: Capacity: 5 tones/shif Actual production: 4 tones/shif Utility: Steam Electricity, Compressed air.
  • 28. Overfeed % Up Setup for Lafer compacting Machine: Overfeed % Up for Lycra Single Jersey : 60 Overfeed % Up for Single Jersey : 35/40. Overfeed % Up for Lacost fabric : 35/40 Overfeed % Up for Rib fabric : 20/22 Overfeed % Up for CVC fabric : 45
  • 29. Main Parts: (Lafer Compacting Machine) Heat Padder: Control Motor Speed. Heat Chamber: Three. 1. Lower Padder 2. Stenter 3. Compactor Main Power Blanket: For finishing Cloth. Guide Roller Clip: Straighten the fabric Wheel raising Steam Box: soften the fabric Load Cell: Keep the delivery Roller for perfect tension. Temperature: 1500C (Highest) Speed: 50 M/Min Overfeed % Up: More the Overfeed % Up More the GSM. Steam Pressure: Up to 10 Kg
  • 30. In Tube-tex compactor m/c fabric spread range:
  • 43. Fabric dia (inch) Maximum spreading (inch) 14” 17” 16” 19” 17” 20” 19” 25” 22.25” 28.25” 26” 36.38” 34.75” 47” 45” 57” 48.25” 60”
  • 44. For different type of fabric speed and compaction (TUBE TEX): Fabric Type Speed ( r.p.m ) Compaction S/J 20 8-9 % Lycra S/J 25 7-10 % 1*1 Rib 30 8 -11 % Single lacoste 30 10 -14 % 2×2 Rib 30 -35 6-7 % Double lacost 30 -35 12 % Pk. Fabric 30 10 -12 % Interlock 30-35 9 – 12%
  • 45. Technical description of the basic compacting machine:
  • 46. Support Structure: It consists of sturdy body sides made of painted steel, supporting the cylinders, the mechanical part and the plant system; they are connected by means of longitudinal and transversal cross-section. The body sides are provided with special safety locks. Inlet Tightener: The inlet tightner is designed to drag the fabric to the machine with an adequate tension. Its effect can be varied by turning the hand wheel provided. Fabric Draw Roller: The draw rollers receive their movement from a variable speed motor. They deter-mine the speed of fabric. 1. The rollers are normally covered with rubber and it is most important that the surface of the covering is always in good condition so ass to avoid slipping of the fabric. Should this not be so then it is necessary to replace the covering. 2. The processing of fabrics treated with chemical against might involve a rapid deterioration of the drag rolls coating.
  • 47. Idle Cylinders: The idle cylinders are designed to change the route of the fabric to convey it in the right position for subsequent working. Dancing Roller Synchronizer: The dancing roller is constituted by a cylinder mounted on oscillating arm, connected to a rheostat for the synchronization of the various group. Inlet fabric Guide: It consists of shoulders supporting a couple of adjustable spreader rollers operated by an independent motor, and a pneumatically operated fabric centering unit with move-able staves, controlled by border guard photocells. Steaming Tank : It consist of no. 1 steam delivery chamber on the fabric, made of inox steel and complete with metering valve and on-off solenoid valve.
  • 48. •Compacting units: They are the real compacting units. Each unit consists of: 1. A steam heated cylinder, diameter 500 mm., made of chromium plated and ground steel; it is complete with a rotary joint for steam feeding, a thermocouple feeler to feel the temperature, and an effective system for the condensate drainage. The cylinder temperature can be adjusted with the utmost (+/-2˚C) directly from the keyboard placed on the control board, and is shown on the display. 2. A thick Nomex – Polyester compacting felt. The double action felt centering de- vice ensures perfect felt alignment during running. The computer controlled felt control mechanisms automatically releases felt tension after a machine stop. 3. An adjustable position counter-roller for the fabric shrinkage control during inlet in the compacting group. 4. An inlet element in a special non-adherent fibre (shoe) equipped with a device for adjusting both angle of incidence and insertion length.
  • 49. Spreader Roller It is a spreader roller, for the selvedge unwinding and the inlet of the fabric perfectly spread in the machine. Scroll Roll Unit The adjustable spreading scrolls at entry are used for open width knits and for all fabrics that have lengthwise creases. Consists of two adjustable spiral scroll roll driven by an independent motor. Device for Fabric Tension Check It consists of a cylinder combined with a special load cell sensor. It allows synchronizing the speed between the upper and lower compacting unit, and adjusting the fabric tension between them with the utmost precision. The adjustment is performed directly from the keyboard placed on the control board and is shown on the display.
  • 50. Cooling Unit It consists of a steel structure including a conveyer belt, the drag and tension cylinders Of the latter, a suction chamber with a net plane for a perfect distribution of the cooling air. The chamber is connected to a high-efficiency centrifugal electric fan. Checking Table: The inspection table is composed by a steel structure that supports a table that accompanies the fabric falling from the cooling band. In this phase the operator placed in the rolling up unit zone can carry out a check on the quality of the worked fabric and notice possible defects. Fabric Storage Chute for the System Non-Stop: It consists of a j-plate for the fabric storage during the phase of roll change. It allows removing the finished roll, and starting a new roll without stopping the system.
  • 51. Rolling Unit It consists of a bearing structure and a moveable trolley which supports the rolling cylinders. The trolley sides on two rails in order to allow the perfect alignment of a selvedge on the roll of fabric. The movement is automatically controlled and is operated by an electromechanical actuator. The reading of the selvedge border is performed by two photocells, whose position can be adjusted by means of a hand wheel. The rolling cylinders are covered with vulcanized rubber for a perfect adhesion. The roll compactedness can be adjusted by a pneumatically operated device. The rolling unit is complete with a spreader roller, operated by an independent motor, placed immediately before the rolling cylinders. Steam System It is installed in the machine. It includes a filter, an on-off valve, a pressure gauge for displaying the line pressure and a condensate separator. It is provided with a series of servo-operated solenoid valves to feed the different elements of the machine and wit automatic steam traps complete with by-pass for manual drainage. Controls The main controls are located on the left side at the machine entry; they include a “Touch Screen” interface and a set of buttons. The auxiliary controls are placed on the panel at the machine exit. The emergency stop buttons are located on the sides of the machine.
  • 52. S) Electric Board: The electric board is installed in the machine. It includes the electromechanical instal- lation, electronic cards, a set of inverters and the PLC controlling the machine. It is also equipped with protection devices, and cooling devices. All operation func-tion is shown in the “Touch Screen” on the main control board. The machine is equipped with a direct grounding of all the electric components and of the metal frame. The preventive measures to ensure immunity in the presence of electromagnetic dis- turbances have been adopted, and have been taken the necessary precautions to atte- nuate the disturbances of an electromagnetic nature produced by the electric/ electronic system of the machine T) Pneumatic System It includes an on-off valve, a filter-lubrication unit, a pressure regulator and a series of solenoid valves for the operation of the pneumatic actuators.
  • 54. Maximum Speed : 40 m/min Minimum Speed : 7 m/min Steam Pressure : 4 - 4.5 MaximumOver feed (%) : 22% MinimumOver feed (%) : 18% Pressure Type : Cylinder + Rubber Belt Monforts Compactor Machine:
  • 56. Type: Blade Compactor Machine Types of Roller: 4 (Anti Roll, Expander Roll, Retard Roll, Pad Roll) Compaction depends on Retard Roller. Shade depends on Shoe Depth. Feed Roll Temperature is automatically set by the machine. Shoe Pressure: 2.5 - 3 Maximum Fabric Passing Speed: 40 m/min Minimum Fabric Passing Speed: 20 m/min Maximum Over feed (Bilateral Slat) %: 98% Minimum Over feed (Bilateral Slat) %: 90% Maximum Temperature: 80oC ( Blade Types Compactor Machine )
  • 58. Type: Blanket Compactor Machine No. of Steam Chamber: 2 Steam Temperature: 100oC Maximum Fabric Dia Capacity: 225-228 cm Minimum Fabric Dia Capacity: 100 cm GSM Control: 7-8 Maximum Fabric Passing Speed: 20 m/min Minimum Fabric Passing Speed: 10 m/min Maximum Over feed (%): 35% Minimum Over feed (%): 0% ( Blanket type Compactor Machine )
  • 59. Santex Compactor Machine (Tubular Knitted Fabric Compactor):
  • 60. Type: Blanket Compactor Machine Minimum Fabric Dia Capacity: 126 cm Maximum Fabric Dia Capacity: 28 cm Steam Temperature: 120oC Maximum Overfeed (%): 40% Minimum Overfeed (%): -10% No. of Cylinder: 2 Padder Pressure: 6-7 (Tubular Knitted Fabric Compactor)
  • 61. Fabric type Colour Speed (m/min) Over Feed (%) Temperature (degree C) Blanket Pressure Teflon Pressure Stretch (%) Single jersey White Colour 15-18 15-18 25-30 25-30 90-110 110-120 1.5-2bar 36psi As required Pique (s/j,d/j) White Colour 15-18 15-18 30-35 30-35 100 110-120 1.5-2bar 36psi As required Lycra s/j White Colour 12-16 12-16 Full over feed 100-110 100-120 1.5-2bar 36psi As required 1x1 Rib White Colour 15-20 15-20 20-30 20-30 100 110- 120 1.5-2bar 36psi As required 2x2 Rib White Colour 12-15 12-15 25-30 25-30 100 110- 120 1.5-2bar 36psi As required Interlock White Colour 12-16 12-16 Full over feed 100 110- 120 1.5-2bar 36psi As required
  • 62. Teflon speed (+) – More compaction Teflon speed (-) – Less compaction, G.S.M because overfeed is less.
  • 63. Utilities used: •Electricity •Steam •Compressed air Control Point : - Water pressure - Air pressure - Steam pressure
  • 64. 1. Shade Check: In delivery side operator checks the shade of fabric with customer approved swatch. 2. With Check: Operator measures fabric width by using measuring tape and compared with required width. 3. Wight Check: Operator checks the weight by using GSM cutter and electronic bal-ance& compares with the required finished width. 4. Fault Check: As mentioned before 5. Design & Slanting: Operator checks design and slanting at delivery side. 6. Edge line checking: check two edges of fabric at delivery side.
  • 66. Belt Principle for Imparting Mechanical Shrinkage for Knits
  • 68. 1. Yarn Manufacturing Technology Link:http://www.facebook.com/pages/Yarn-Manufacturing-Technology/485014954866808 2. Fabric Manufacturing Technology Link:http://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605 3. Garments Manufacturing Technology Link:http://www.facebook.com/pages/Garments-Manufacturing-Technology/472364799463126 3. Wet processing Technology Link:http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-/468645219825404 4. Fashion-Design-and-Technology Link:http://www.facebook.com/pages/Fashion-Design-and- Technology/587655294583875?ref=ts&fref=ts My Facebook Textile related Pages http://www.textilelab.blogspot.com