The Open Width Compactor are the ability to improve the hand and appearance while achieving the natural relaxed state of the knit loop in a continuous process. Residual shrinkage results in knit fabric by tumble drying testing methods if 1% are possible. With the compaction system, accurate repeatability of desired finishing results are obtainable. Has evolved into a new era of performance improvement and appearance for open width knit fabrics with the Open Width Compactor. The final step of processing for high quality outerwear and apparel knit fabrics will give softer hand, superior shrinkage control, width control, and yield control.
Benefits of Open Width Compactor
Uniform compression
An open-width compactor machine applies pressure uniformly across the fabric, ensuring that it is compressed evenly and consistently.
Improved fabric hand
The compaction process can improve the hand of the fabric, making it feel softer and more comfortable to wear.
Reduced shrinkage
By compressing the fabric, an open-width compactor can reduce its tendency to shrink during subsequent washings or other treatments.
Increased fabric stability
The compaction process can improve the dimensional stability of the fabric, reducing the risk of distortion or warping.
High production efficiency
An open-width compactor can process large quantities of fabric quickly and efficiently, making it a valuable tool for textile manufacturers.
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Treat all kinds of open width knitted fabric, 100% cotton jersey, interlock, viscose, blended etc.....
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Customer service
We firmly believe that we offer THE BEST customer support in the industry and it is our ongoing goal to continually improve on our services. As an independently owned and operated business, we are able to provide the most accommodating service possible.
Advanced equipment
We take great measures to ensure that we work with the industry' s highest quality equipment and that our equipment is regularly and meticulously maintained.
Competitive prices
We offer our products at competitive prices, making them affordable for our customers. We believe that high-quality products should not come at a premium, and we strive to make our products accessible to all.
Efficient and convenient
The company has established marketing networks around the world to provide high-quality services to customers in an efficient and convenient manner.
High quality products
We always put customer needs and expectations in the first place, refine on, continuous improvement, to seek every opportunity to do better, to provide customers with their expectations of quality products, to provide customers with the most satisfactory service at anytime.
Professional team
We have a team of skilled and experienced professionals who are well-versed in the latest technology and industry standards. Our team is dedicated to ensuring that our customers get the best service and support possible.
Checking Parameters of Compactor Machine
Shade Check
Shade of the compacting fabric is checked in the delivery side of the machine. The operator collects the fabric and compare the shade of the fabric with the buyer's approved swatch.
Width Check
Operator measures the width of the fabric with the measuring tape and compares it with the buyer's requirement.
Weight Check
Weight of the fabric is determined by GSM check. Operator checks the GSM of the fabric by GSM cutter and electric balance.
Edge Line Checking
Two edges of the fabric is check in delivery side. If any fix line is identified, which normally occurs from the expander it should be connected.
Design and Slanting
Operator checks design and slanting of the fabric in the delivery side of the machine.
Fabric Faults
Various types of fabric quality are measured in the delivery side of the fabric.
Cloth feeding function
Into the cloth rack:
The main structure is: The transmission roller driven by the transmission motor, and its function is to make the cloth enter the equipment smoothly.
Storer:
The main structure is: J-shaped cloth stacking trough, tension adjustment device, edge suction device.
Its function is: To store the fabric, to ensure the smooth conversion of processing varieties without stopping the machine. At the same time, it can measure the measuring point before the shrinkage rate of the fabric for the variety of the incoming fabric package.
The function of the tension adjustment device is mainly to adjust the tension of the cloth under the condition of cloth storage and non-storage, so that the cloth can run smoothly, and the edge suction device makes the cloth not deviate from the cloth storage device.
Wetting and cloth feeding functions
The main structure is: Tension adjustment roller, transmission roller driven by transmission motor, water spraying wet device, air jet drying cylinder.
The function of the device is: The tension adjustment roller adjusts the tension change caused by the overfeeding of the cloth; the main drive roller makes the cloth run, and can be adjusted to produce overfeeding at the same time; the water spraying device is driven by a group of linked nozzles and Consists of a water inlet pressure regulator, the amount of sprayed water can be adjusted through the water inlet pressure regulator, and the cylinder surface of the air jet dryer has a small hollow structure. The steam is ejected from small holes, and the cylinder body is wrapped with chemical fiber, its function is to make the fabric wet fully and reasonably.
An open-width compactor is a machine used in textile finishing to compress and smooth out fabrics. Here are some of the applications and advantages of using an open-width compactor.
Textile finishing
An open-width compactor is used to compress and smooth out fabrics after they have been dyed or printed, giving them a more finished and polished appearance.
Improving fabric quality
The compaction process can improve the quality of the fabric by reducing shrinkage and improving the fabric's dimensional stability.
Reducing fabric waste
By compressing the fabric, an open-width compactor can reduce the amount of fabric that is wasted during the finishing process.
Working Principle of Open Width Compactor
The working principle of an open-width compactor involves a series of rollers that compress and smooth out fabrics. Here are the basic steps involved in the working principle of an open-width compactor.
Loading the fabric
The fabric is loaded onto the machine's entry section, where it is fed into the compactor.
Pre-treatment
The fabric may be pre-treated with moisture or steam to prepare it for the compaction process.
Compressing the fabric
The fabric is passed through a series of rollers that apply pressure to compress and smooth out the fabric.
Heat treatment
The compressed fabric is passed through a heating section, where it is exposed to high temperatures to set the compressed shape.
Cooling
The fabric is then passed through a cooling section, where it is cooled to set the compressed shape.
Unloading the fabric
The finished fabric is unloaded from the machine's exit section, where it is ready for further processing or shipping.
Knitting Open-Width Preshrinking Machines in Textile Production
Open-width processing of fabrics
The knitted open-width pre-shrinking machine can open the knitted fabrics, that is, stretch the fabric from a narrow width to the required width to meet the needs of subsequent processing technology.
Pre-shrinking and dimensional stability processing
Through preset parameters such as tension, temperature and speed, the knitting open-width pre-shrinking machine can pre-shrink the fabric, reduce the shrinkage rate of the fabric during subsequent processing, and ensure that the fabric Dimensional stability.
Improve the texture of the fabric
While processing the fabric, the knitting open-width pre-shrinking machine can also improve the texture of the fabric, making it softer and more comfortable, and improving wearing comfort.
Reduce losses in subsequent processing links
The size of the fabric processed by the knitting open-width preshrinking machine is more stable, which can reduce the scrap rate in subsequent processing links and save costs.
Quality Check of Open Width Compactor
Shade Check
Though there are very less chances of shade variation to occur in this tubular compactor machine as fabric goes through a compaction process, the backside operator should check the shade visually by comparing the before and after effect of compaction process. If the extent of shade variation is found to be high, the responsible shift officer is informed immediately who takes the necessary action to overcome the problem.
Fault Check
The operator checks for Knitting faults (i.e double yarn, yarn contamination, fly yarn, etc.), Spinning faults (i.e thick & thin yarn, barre mark, etc.) and other Dyeing or Finishing faults (like dye stain, band line, chemical spots, meter to meter shade variation, torn & hole, fabric structure and crease mark, etc.) during the processing.
Width Check
Measure the fabric width using a measuring tape and compare it with the required finished width, which is specified in the program by the shift officer based on the customer requirement with a tolerance limit of exact or +1″.
Weight Check
Cut a piece of fabric in relax condition to check the GSM by di-cutter and then check in electronic measuring scale. Weight should be always ± 5 g/m2 than the required.
Design and Slanting Check
Check the design and slanting of fabric at the delivery side. If any abnormality is found adjust the machine.
Edge-line Checking
Check the two edges of fabric at the delivery side. If any fix-line is identified, which normally occurs from the expreader wheel, it should be corrected.
Sample Tests
After finishing, one-meter sample is cut from each batch of fabric in relaxed condition. Then it is sent to QC lab where the fabric sample is tested for different specifications as specified by the customer like dimensional stability, washing fastness, water fastness, light fastness, rubbing (wet/dry), pilling etc.
Temperature Detection of Pre-Shrinking Machine
On-line monitoring of the temperature of the steaming and wet drying cylinder
The steam supply and humidity drying cylinder is mainly composed of a cylinder body, an outer steam chamber and a steam inlet head. The specific monitoring scheme is: use a platinum thermal resistance to detect the internal temperature of the steam supply to the wet drying cylinder. When the temperature reaches the set temperature, the PLC controls the solenoid valve on the steam pipeline leading to the outer steam chamber to open to steam, so as to ensure the humidity. After the steam enters the outer layer steam chamber, it can be completely vaporized on the drying surface, so that the fabric can be evenly moistened without dripping water. In the past, the operators used their personal experience to operate the steam valve. Often, the time was short, or the quality of the steam was not good, and the heating temperature of the drying rack was not enough, which caused serious water dripping on the surface of the drying drum, which dripped onto the fabric and produced defective products.
On-line monitoring of fabric humidity before shrinking
There are three types of spray humidification devices used in the previous humidification unit: siphon gas-water nozzle, water suction pump and integrated nozzle combination, and booster pump and integrated nozzle combination. The water mist sprayed by these three types has a small amount of water droplets. The uniformity of the water mist is not very ideal for high-grade fabrics, and the spray volume cannot be adjusted according to the type of fabric. The humidity of the fabric depends entirely on the operator.
Online monitoring of fabric tension
There is a close relationship between the tension of the fabric and the shrinkage rate, especially between the wet unit and the rubber blanket. Users often adjust the fabric tension between the two units too high in order to eliminate the creases on both sides of the fabric, which affects the pre-shrinking effect, and also makes the wet-feeding motor in the state of power generation, which makes the inverter very easy to damage. In order to keep the tension constant, a tension detection roller is installed between the wet supply unit and the rubber blanket pre-shrinking unit, and the speed of the wet supply motor is controlled through the tension sensor.
When debugging on-site, firstly correct the zero point of the cloth guide roller; secondly, check whether the change in tension is consistent with the speed; thirdly, the display of tension must be consistent with the weighing unit used for zero point calibration; fourthly, frequency conversion The output voltage of the device is +/-lOV; finally, the PID control is realized by programming the PLC, and the appropriate PID parameters must be set, namely: PID sampling time 0.3s; PID gain 0.85; PID integration time 3s.
In the actual operation according to the above steps, when the zero point is corrected (that is, the zero point elbow is in a tension-free state, and the corresponding output voltage is OV), the cloth is passed into the cloth guide roller, and the zero point is detected. It is found that the zero point drifts, that is, the zero point is always An output voltage of -0·3V appears, corresponding to the displayed tension of -3kgf. In order to eliminate this phenomenon, the threading route can be flexibly changed on site, so that the zero drift can be solved. In addition, due to the different ways of feeding the fabric and the difference in dryness and wetness of the fabric, it is easy to cause a large change in tension. In this way, the original 25kgf tension corresponds to the output voltage of 1V, and 50kgf tension corresponds to the output voltage of 5V. Therefore, the online detection and control of the fabric achieves the desired effect.
Our Factory
Hans Industries (Wuxi) Co., Ltd is a specialist manufacturer in Textile Finishing Machinery. We major produce: Automatic Fabric Slitting Machine, Rope opener, Tube Sewing machine, Automatic Weft Straightener etc.
FAQ
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