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Flat bed printing & Rotary printing
Stamperia Pezzoli offers printing and finishing services for textiles for more than 35 years, maintaining the highest quality standards in every step of the manufacturing process and ensuring a highly competitive service in terms of technology and styling. Stamperia Pezzoli's finished textiles are used worldwide mainly for furniture and linen in households, hotels and hospitals. They are also used in the shipping industry and in the outdoor sector.
Pezzoli relies on Mahlo technology for straight-thread fabrics as well as process control and quality control during the finishing processes on the stenter frame. In the installation shown, a combination of Orthopac weft straighteners at the inlet and outlet of the stenter frame ensures perfect straightening results. For the best printing results, the Patcontrol system also monitors the pattern repeat and pattern distortion. The parameters in the stenter frame - dwell time, exhaust air moisture, residual moisture, fabric width - are monitored by the Optipac process control system.
Images courtesy of Stamperia Pezzoli, Italy
Stenter frame with Orthopac weft straightener at the inlet and outlet. A Patcontrol PCS also scans pattern distortions. The Optipac process control controls the dwell time, exhaust air and residual moisture.
A Patcontrol PCS scans for pattern distortions at the inlet and sends control commands to the weft straightener.
At the inlet, the Orthopac RVMC automatic weft straightener supplies the stenter frame with straight fabric.
The Ortopac RVMC uses skew rollers and bow rollers to correct skew and bow distortions in the fabric.
Exhaust air humidity sensors in the Optipac VMC measure and control the exhaust air humidity in the stenter frame. Excess moisture escapes, leaving the energy required for drying or fixing.
Hidden in the stenter frame, Optipac VMC sensors measure the surface temperature of the fabric and control the dwell time / fixing time.
Sensors at the stenter frame outlet measure the residual moisture of the fabric and adjust the system if the value is too high or too low.
The Wilot WMR width measuring system from Mahlo records the fabric width as it passes through the stenter frame.
An Orthopac FMC logs the residual distortion values at the outlet of the stenter frame and sends control pulses to the straightening machine in the infeed if necessary.
The pattern distortion at the stenter frame outlet is also logged with the Patcontrol PCS and, if necessary, control pulses are sent to the straightening machine in the infeed.
Orthopac RVMC-15
Classic optical weft straightener
Classic universal weft straightener - optionally with integrated process control system Optipac VMC-15
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Weft straightening the way it should be ...
The Orthopac RVMC is the universally employable straightening system from Mahlo for the correction of fabric distortions for nearly all applications. Available with hydraulic or electrical straightening roller adjustment.
The modular construction of the weft straightener allows the system to be configured to meet the demands of changing conditions and requirements.
Product Highlights
- Modular system architecture
- Easy to retrofit
- Operator-friendly
- Informative process visualization
Customer benefits
- Online monitoring and regulation of all relevant parameters
- Increased productivity
- High production reliability
- Optimised process repeatability
- Documentation of quality
- Providing a comparative basis for the quality standard
- Considerable energy savings
- Short amortisation times
Sensors
Sensors for the detection of distortion in textiles
The precise and correct determination of distortion on running textile webs is the basis for successful weft straightening. Mahlo offers a wide range of sensors for this task. Thus, all conceivable applications and requirements can be covered.
Modular process control system for the textile industry
Textile manufacturers and textile outfitters are fighting with increasing production and energy costs, declining profit margins, shorter production times as well as greater requirements on quality and flexibility. Cost-efficient and quality-focused textile outfitting thus becomes increasingly important. Sustained production and the trend to higher-quality, technically sophisticated fabrics also play a major role.
Regardless of the challenges of the textile industry – Mahlo has the right solutions ready. The broad range of applications for textile production by Mahlo is based on experience reaching back to the year 1945.
Orthopac is a modular straightening and process control system available throughout the entire process of textile outfitting. It combines the functionality of a weft straightener with that of a process control system in one compact device. It automatically 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 modular design of the system allows its flexible adaptation to all applications. Both, standard requirements and highly customized demands are thus met.
- At the feed end of a stenter
- At the feed end of a levelling stenter
- On decatisers
- Ahead of a printing machine
- Between an open width washing machine and drum dryer
- On coating ranges ahead of the coater at the feed end of a
flame laminator - At the feed end of wide compactors for knitgoods
- etc.
The touchscreen of the system displays the measurements. Individually modifiable displays of the measured values facilitate easy monitoring of the complete process by the user. Various software packages (FULL or BASE) allow adjusting visualization and operating concept to different demands on detectability and user convenience.
- The FMC full version offers all setting capabilities and options to the entire depth. The full potential of the straightening system can thus be utilized.
- The FMC Base version focuses on the essential functions of the system and offers a compact and simple overview for thecontrol of the processes.
The weft straightener Orthopac with integrated web distortion detection forms the basis of the modular design. Additional intelligent sensors can be connected to the control system via a bus connection. The following process parameters can be measured, visualized, controlled and documented by means of special software packages (mLog):
- Weft thread or course skew / skew and bow rollers of the weft straightener Orthopac
- High moisture / squeezing pressure
- Thread or course density / over-feed
- Exhaust air humidity / fan speed / flap opening
- Surface temperature / product web speed and dwell time
- Basis weight / over-feed
- Residual moisture / product web speed
- Stretch and Shrinkage / over-feed
- Product width
Orthopac RMM Straightener: Manual straightening machine without optical scanning system and control
| Weft straightener | Orthopac RVMC |
|---|---|
| Mechanical straighter | 3 skew rollers, 2 bow rollers (optional 3) |
| Nominal product width, maximal | 3400 mm |
| Power connection | 3 x 400 VAC ±10 %, 50/60 Hz, transformer station available for special voltages |
| Power consumption, maximal | 4 kVA |
