A REVOLUTIONARY TWISTING SYSTEM FOR BCF CARPETYARNS
A REVOLUTIONARY TWISTING SYSTEM FOR BCF CARPETYARNS
This document introduces a revolutionary twisting system for BCF carpet yarns, focusing on yarn winding and processing machines. The system aims to enhance efficiency and reduce operational steps in yarn processing.
Smart Process vs. Conventional Process
The Smart Process integrates extrusion, SmarTwist, and heatsetting in a streamlined manner, offering a payback period of less than 1.5 years. In contrast, the conventional process involves multiple steps including extrusion, cabling, storage, relaxation, and heatsetting.
SmartTwisting System
The SmartTwisting system performs twisting in one operation without singles twist, maximizing bulk and ensuring good tip definition. It allows for multi-purpose twisting, producing 2 ends of 2 or 3 ply yarn in a single step, and supports alternate twist directions with small tack points.
Inline Twisting for Heatsetting
The system features inline twisting for heatsetting with components like capstan feeders, closed-loop tensioners, and accumulators. It supports high-speed twisting directly from extrusion packages, eliminating the need for intermediate storage.
Working Principle and Features
The system requires a larger heatsetting creel but eliminates the need for cablers. It reduces the take-up winder and tufting creel requirements by half, minimizing yarn waste and length differences. The system allows easy switching between 2 and 3 ply yarns and uses RFID in twist jets for proper jet use.
Machine and Process Control
The Hyperion and Orion systems control vital parameters such as speed, air pressure, and yarn tension. They monitor production parameters and store them in adjustable recipes. The systems offer secure access with password protection.
Technical Specifications
The system processes PP, PA, and PES BCF yarns with a count range of 600 to 20,000 dTex. It supports twisting speeds up to 450 m/min and twist levels from 50 to 250 tpm. The electrical supply is 3x400V or 3x480V+PE, with a total connected load of 2.5 kVA per module. Air consumption is 14 Nm3/h per module, requiring clean, dry, and oil-free air.
Contact Information
For more information, contact Gilbos NV in Belgium or Gilbos of America, Inc. in the USA.
Catalog excerpts
A REVOLUTIONARY TWISTING SYSTEM FOR BCF CARPETYARNS YARN WINDING & PROCESSING MACHINES
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CONVENTIONAL PROCESS SMART PROCESS Storage - Relaxation Tufting - Weaving Tufting - Weaving
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INLINE TWISTING FOR HEATSETTING CONVENTIONAL TWISTING AND HEATSETTING 2 operations NO singles twist Maximum Bulk Good Tip Definition 1 operation NO singles twist Maximum Bulk Good Tip Definition Multi-purpose twisting system for carpet BCF yarns; each module produces 2 ends of 2 ply or 2 ends of 3 ply yarn in 1 single step. Alternate twist direction S/Z with small tack point between the twisted zones. High speed twisting with maximum bulk and no singles twist. Twisting directly from extrusion packages, thereby avoiding intermediate storage and handling. Endless styling possibilities
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WORKING PRINCIPLE Tension - measurement Stage 2 Heatsetting Power-Heat-Set® Superba® Closed loop tensioners SmarTwist Accumulator > 25 min. capacity Closed loop tensioners 1st & 2nd end Tension - measurement Stage 1
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FEATURES EASY SWITCH FROM 2 TO 3 PLY YARNS RFID IN TWISTJETS TO GUARANTEE PROPER JET USE AND EASY CHANGE OF TWIST JETS CHARACTERISTICS OF THE SMARTWIST PROCESS Larger heatsetting creel, but no space for cablers required. 2 ends per finished package, so only half the take-up winder required. 2 ends per finished package, so 2 ends in each tufting needle. 2 ends in each tufting needle, so only half the tufting creel required. 2 ends per finished package, so no length differences and no yarn waste. No intermediate storage of cabled yar
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MACHINE AND PROCESS CONTROL BY MEANS OF THE HYPERION AND ORION SYSTEM 72 ENDS = 36 SMARTWIST MODULES SUPERBA® LAYOUT
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Human Interface Gilbos Machines The Gilbos Hyperion control system controls all the vital entanglement parameters such as speed, air pressure and yarn tension. Also the production parameters such as length, number of packages, production and efficiency are monitored by the Hyperion control system. All the parameters are stored on the Hyperion control system in easily adjustable recipes. Transferring recipes and adjusting machine configurations can be done within a matter of seconds. Access to the Hyperion control system is protected by passwords with different security levels. 48 ENDS = 24 SMARTWIST...
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TECHNICAL SPECIFICATIONS Count range Layout gauge Twisting speed Electrical supply Total connected load Machine and process control Hyperion and Orion control system GILBOS nv Grote Baan 10 BE-9310 Herdersem - Aalst Belgium Tel. +32 53 78 18 78 Fax +32 53 78 24 70 [email protected] www. gilbos.com GILBOS of AMERICA, Inc. 1812 Antioch Road Dalton GA 30720 USA Tel. +1 706 529 3600 Fax +1 706 529 3595 [email protected] www. gilbos.com All technical details, descriptions, illustrations, dimensions and other particulars in this brochure are given in good faith, and can be subject to change without notice....
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MULTIPURPOSE TAKE-UP WINDER4 Pages
