Orthopac RVMC-15

Quick and accurate straightening

Weft straightening the way it should be

The Orthopac RVMC is the universally employable straightening system from Mahlo for the correction of web distortions for nearly all applications. Available with hydraulic or electrical straightening roller adjustment.

The modular construction 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

Textile process excellence

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 textiles 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 the textile industry 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.

Weft straightening and process control united

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 (Print Server).

  • Weft thread or course skew / skew and bow rollers of the straightener Orthopac RVMC
  • 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
  • Grammage / over-feed
  • Residual moisture / product web speed
  • Stretch and Shrinkage / over-feed
  • Product width


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.

Area of application

  • 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.

Variants

  • RMM Straightener: Manual straightening machine without optical scanning system and control

Technical data

  • Power connection: 3 x 400 VAC ±10 %, 50/60 Hz; transformer station available for special voltages
  • Max. power consumption:  4 kVA
  • Ambient temperature: 5 – 45 °C (without A/C unit), 5 – 50 °C (with A/C unit)

Orthopac RVMC-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.
Mahlo's automatic weft straightener Orthopac RVMC-15 at a stenter frame in textile finishing
The Orthopac RVMC is the universally employable straightening system from Mahlo for the correction of web distortions for nearly all applications. Available with hydraulic or electrical straightening roller adjustment. The modular construction allows the system to be configured to meet the demands of changing conditions and requirements.
Mahlo's automatic weft straightener Orthopac RVMC-15 at the feed-end of a stenter
Prior to fixing the fabric in the tenter, the weft straightener from Mahlo ensures that the fabric enters the tenter straight and without distortion.
Pattern control system Patcontrol PCS
Pattern distortion control: The system uses cameras to automatically detect the position of the pattern and – together with a weft straightener – aligns the product distortion based on the print pattern. Thus, the fabric comes out correct even when it was printed oblique or skewed.
View into the weft straightener Orthopac RVMC-15
The skew rollers (green, top front) sit in a frame and are pivoted together. Behind in red the bow rollers (up to 3 possible). In the lower part the scanning bridge for distortion detection, here with 6 scanners.
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.
Residual distortion detection with Orthopac FMC
Here the back of the fabric with the scanner for distortion detection. The headlights (transmitted light) sit on the opposite side of the web. The Orthopac FMC at the stenter outlet is often used additionally to a weft straightener on the inlet for quality control and logging. Here a version with manual scanner positioning (recognizable by the snap-in holes on the underside of the guide rail)
Patcontrol PCS at the delivery-end of a stenter
In addition to the residual distortion measurement with an Orthopac FMC, the Patcontrol PCS checks and logs whether the printed patterns are still straight after fixing in the stenter frame.

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.
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Tel.: +49-9441-601-0 • info@mahlo.com