Customer’s request

The customer requested us to develop a solution for the infeed and outfeed of a backing line for tufted carpet and artificial grass. The line had to meet the following specifications:

  • Carpet for processing is delivered in rolls or folded in trolleys
  • Ergonomic removal of tubes from the cradle
  • Handling of fabric from 70 g/m² (infeed) to 5300 g/m² (outfeed)
  • Carpet thickness from 5 to 65 mm
  • Integration of customer-specific requirements for the various methods of latex application
  • Faultless web control for varying fabric widths and strongly varying products (due to the effect of the pile)
  • Realisation within existing building with reduced dimensions
  • Rolls of artificial grass wound very compactly with straight roll edges and minimal loss
  • Easy product changes and operation
  • High line speed
  • Option for cut optimisation during inspection (maximisation of first grade fabric qualities)
  • Backing line
  • Backing line
  • Backing line
  • Backing line
  • Backing line
  • Backing line
  • Backing line
  • Backing line
  • Backing line
  • Backing line
  • Backing line
  • Backing line

Our realisation

The installation we delivered at Condor includes the following features:

  • Feed table and cradle are electrically movable to create space for trolleys
  • Tubes are automatically removed from the cradle after unwinding by means of specially developed lifting arms
  • We managed to control fabric tension for both light and heavy fabrics by using strategically placed load cells and working with recipes
  • When designing the 3 latex applicators (lick roller, press nip and double backing), we took the experiences and wishes of the (expert) customer into account
  • We integrated roller frames and centre controls at various points in the line that always automatically direct the centre of the fabric to the centre of the line. This ensures that the fabric always keeps running properly in case of fabric width variations, without the need for operator intervention
  • In order to integrate the machine line within the existing limited production space, some machine parts were given a double function, such as a bridge that simultaneously serves as a roller frame. We placed the puncture roller on a platform above the oven outlet so that it would not take up any space on the ground.
  • The winding unit is the icing on the cake in this beautiful line:
    • Edge-controlled for nice straight roll edges
    • Adjustable pretension by means of an additional brake roller shortly before the winding unit
    • Servo-controlled centre drive of the tube to properly tension the artificial grass around the tube
    • Our unique system for attaching the carpet to the tube can staple artificial grass to the tube fully automatically at 1-2 cm from the edge of the carpet
    • By electrifying the winding bridge and the positioning of the centre drive, among other things, the winding unit can handle high line speeds and is also more energy-efficient and safe
  • The last accumulator before the winding unit can remain permanently filled with carpet, which allows the operator or the cut optimisation system to decide (based on sufficient length) where to cut transversely and what becomes first or second grade

We are happy to help you

Do you have a customised project and would you like to discuss it? Don't hesitate to contact us!

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