Optipac VMC-15

Modular process control system

Optimizes finishing

The Orthopac VMC is a modular process control system for textile refinement. It optimises drying or fixing processes as well as the processes all about the stenter.

The system measures, logs and controls critical process parameters over the entire working width:

  • Temperature
  • Dwell time
  • Residual moisture
  • Exhaust air moisture
  • Thread density
  • Weight

This increases quality while saving 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.

The system can also be integrated into an Orthopac straightening system. It thereby combines the functionality of a weft straightener with that of a process control system in one compact device

Product highlights

  • Modular system architecture
  • Operator-friendly
  • Informative process visualisation
  • Online monitoring and control of all relevant parameters
  • Easy to retrofit

Customer benefits

  • Increased productivity
  • Optimised production security
  • Increased process reproducibility
  • Documentation and comparability of quality
  • Considerable energy savings
  • Short amortisation times

Eases challenges

Textile manufacturers and finishers fight with rising production and energy costs, declining profit margins, shorter production times as well as higher 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 textiles also play a major role.

The efficiency of the production plants can be drastically increased through suitable measuring and control technology from Mahlo. This means, at the same time, increased productivity with usually improved reproducible quality, optimised raw materials usage and work effort accompanied by clearly improved plant utilisation.

Regardless of the challenges of the textile industry – Mahlo has the right solutions ready. The broad range of applications for the textile industry by Mahlo is based on experience reaching back to the year 1945.

One stop solution

Improved product quality, saving of resources and energy as well as optimisation of the production processes in a single step: with the process control system Optipac VMC from Mahlo.

Area of application

  • At the stenter frame
  • In textile converting
  • In textile finishing

Sensors

The right tool for every application

Different intelligent sensors can be connected to the base unit via a bus connection.

Various process parameters can be measured, visualized, controlled and documented by means of special software packages, e.g. Printserver.

Opens internal link in current windowList of all sensors

Ecomat AML

Exhaust air humidity

Variants

  • Stand-alone device
  • Integrated in weft straightener Orthopac RVMC

Orthopac RVMC-15 / VMC-15, Pezzoli, Italy

Installations at Pezzoli Stamperia srl , Italy

Since 1976 Stamperia Pezzoli provides printing and finishing services for semi-finished textiles, operating according to the highest quality standards in every step of the manufacturing process and ensuring a highly competitive service in terms of technology and styling.

All pictures by courtesy of Opens external link in new windowStamperia Pezzoli

Mahlo weftstraightening and process control system at textile finishing
Stenter frame with weft straightener Orthopac RVMC-15 at the feed-end and scanning bridge Orthopac FMC-15 EP at the delivery end. Patcontrol PCS-15 scanning for pattern distortion at the feed- and delivery end. Residual moisture module Textometer RMS and exhaust air moisture module Ecomat AML control the drying processes.
Width measurement Wilot WMR in textile finishing
The width measurement by Mahlo measures and logs the product width. If the width of the fabric is too small or too large, an alarm can be issued.
Quality conrol at the outlet of a stenter frame
To log the quality of the fabric after the fixing process, a scanning bridge Orthopac FMC scans for web distortion, a Patcontrol PCS for printing pattern distortion, the Wilot WMR determines the product width and the Textometer RMS the residual moisture. An extensive quality report is generated.
Residual moisture measurement at the outlet of a stenter frame
The correct amount of residual moisture plays an important role in storage, shipping (mold growth!) or the further processing of textile. The residual moisture module Textometer RMS of the Optipac VMC process control system measures the fabric's electrical conductivity to determine the amount of moisture it retains. A Textometer RMS can be set to monitor and control almost 50.000 combinations of fibre, comprising up to 3 different kinds (from 12 basic types of fibre) in any percentage ratios you care to choose.
Three-channel measurement of residual moisture with Textometer RMS from Mahlo
To satisfy the most exacting requirements, an RMS can measure and control exceedingly low percentages of residual moisture – from 1.5 % upwards – when supplied with a specially designed electrode and matching electronics. Here with 3 electrodes to monitor residual at the left, centre and right for a cross-direction profile of the web.
Residual distortion and residual moisture at the stenter outlet
Nice to see on the front left: a measuring roll of the residual moisture measurement Textometer RMS and behind the fabric the counter roll. The electrical conductivity of the web provides the residual moisture. In the background, a headlight of an Orthopac FMC EP scanning bridge for residual distortion measurement subsequent to the fixing in the stenter.

Orthopac RVMC-15, Kinemat MMA Stamperia Olonia, Italy

Installations at Stamperia Olonia, Italy

The Italian textile printing company Stamperia Olonia was founded in 1969. Since the 90s it has been a fixture in the international decorative and home textiles sector.
The print shop with an annual output of approximately 30 million m² is located halfway between Milan and Lake Maggiore. The printing area with rotary, flat and digital printing machines up to a width of 320 cm includes a large finishing area, in which the Mahlo devices are also used.

All pictures by courtesy of Opens external link in new windowStamperia Olonia SRL

Weft straightening on an calendering line
Weft straightener Orthopac RVMC-15 with pull drive station module MMA-15 before the weft straightener. The pull drive ensures that the web is unrolled uniformly and with constant web tension from the batching roller.
Weft straightener Orthopac RVMC-15 on an calendering line
Before the calendering line the weft straightener corrects web distortions and ensures that the fabric reaches the calenders straight and according to the quality requirements.
Weft straightener with mounted pull drive station
Skew-roller and scanners of weft straightener Orthopac RVMC-15 with pull drive station module MMA-15 on top.
Weft straightening on an calendering line
Prior to calendering it is crucial, that the fabric is straight. The mahlo weft straightener Orthopac RVMC-15 (here with an upstream pull drive station module MMA-15) takes care of that.