Weaving technology for narrow width fabrics and high strength belts
Narrow width fabrics, mostly for industrial use, are further categorised into high performance narrow width fabrics and general purpose narrow width fabrics. Narrow width looms are being used to manufacture high strength belts and webbings. Pradeep, Dharmendra, Hemant, CK Nakum, and Nishika analyse the weaving technologies used to manufacture narrow width fabrics.
The technology used for weaving narrow width fabrics is carried on narrow width looms called needle or tape looms. Today, developments under conventional as well as technical textiles with various weaving technology for narrow width fabrics is rapidly increasing and potentially high demand for such products can be anticipated. Entrepreneurs can leverage this technology to launch innovative products with high unique selling proposition (USP).
Modern narrow machines are equipped with Computer Aided Design (CAD), jacquard, pattern creation and programming software for creating contemporary fabrics. Narrow fabrics using materials such as polypropylene, polyester, cotton, nylon, carbon, dyneema, aramid are more suitable for a wide range of applications such as garments, bags, shoelaces, fancy ribbons, sandals, wrist bands, safety belts, waist belts, and industrial belts.
Narrow fabric weaving is a fundamental textile technology.
Before the 17Th century, there was no difference between broad and narrow fabric weaving because on the hand loom it was only possible to weave one fabric at a time so that the width of the fabric was of no importance.
The situation changed in the 17Th century with the invention of a special demand of narrow fabrics for various applications, in this way several splits of fabric can be woven simultaneously.
Shedding and weft insertion were optimised so that by the middle of the 20Th century highly efficient narrow fabric looms with dobby and jacquard shedding were on the market. These narrow looms with direct warping machine were versatile to run a range of yarns for innovative product developments.
Fabrics that are not more than 45 cm in width, having two selvedges (Uncut edge on both the sides) can be termed as narrow fabric.
Application of Narrow Weaving Machines:
1. Itema America Inc. Narrow Weaving Machine for Sample Development:
We can weave many designs of fabric from different yarns to finalise the fabric for particular use. After meeting required parameters up to satisfactory level, decision of weaving on broad loom with exact width can be taken. This facility will prevent more consumption of costly yarns during sampling as well as we have opportunity to generate many prototypes economically up to finished products because of minimum quantity of material required.
We are taking an example of Evergreen Narrow sample loom equipped with modern weaving technology as follows:
1. Weaving Width: 20 inches (maximum)
2. Speed: 75 picks per minute, if full width utilised
3. Weft Insertion System: Single Pick insertion by Rapier weaving technology for Eight Weft with different Counts and colours can be inserted.
4. Shedding: 24 Heald frames including Leno Selvedges frame.
5. Beat - Up: Beat up is controlled by Servo Motor, suitable for heavy fabric also.
6. Take Up: Weft density can be changed freely within the same weave by electronic controller.
7. Warp Let-off: Positive electronically controlled. Digital display of warp tension. Optional second beam assembly available.
8. Loom Stop Motions: Loom stops at warp or weft breakage.
9. Design: Special software for innovative fabric designs.
10. Power: 220V Single phase, 50-60Hz
Manufacturer of Sample Machine: ITEMA America Inc.
2. Jakob Muller Multi Width Narrow Stripes / Woven Belts Needle Machine:
Multi Width Narrow Loom Direct Warping & Belt Weaving
i. Labels: Small pieces of cloth are attached to identify its country, owner, usages, size, important information at a glance on fabric, packed material, bottles, etc are called labels. These are woven small fabrics on narrow looms with needle, tap and rapier technology having multi widths simultaneously. There are mainly two types of labels traditionally marketable as mentioned below: PVC Rubber Label - Used in handbags and apparels Leather Labels - Used as stylish effect in jackets and jeans
ii. Reflective Taps: They are used in creating logos for apparels, handbags and footwear.
iii. Elastics: They are generally used in making gloves, sportswear, straps for under garments, socks, and swimwear.
Methodology:
To decide specification of belts with pre-planned material: Warp count x weft count x ends per inch x picks per inch x width x weave x thickness.
a) Rewinding of yarn from big package to smaller packages on winding machine.
b) To put rewound spools on creel of Muller Direct Warping Machine.
c) To take warp sheet into reed dents according to design.
d) To prepare number of beams so that addition of all warp ends can give required width of belt.
e) To apply lease on beams so ends can be separated as required.
f) To keep these beams on Jakob Muller loom creel.
g) To bring all ends forward together from drop pins (Close type).
h) To draw all ends in heald shaft according to weave.
i) To draw ends from reed.
j) To take forward warp sheet and insert in guide rollers (take up motion)
k) To keep weight for beam tension in adequate manner.
l) To insert weft yarn in needle.
m) Start the machine with required settings.
n) To wind woven belt on batching roller
Jacob Muller Belt Weaving Machine - Tensile Properties Test
Specimen #
|
Thickness
[mm]
|
Width
[mm]
|
Maximum Load
[kN]
|
Specimen
|
1
|
2.50
|
82.00
|
30.43
|
High Tenacity Polyester Belt
|
2
|
2.50
|
50.00
|
50.50
|
Polyester Glass Belt
|
3
|
3.00
|
50.00
|
25.24
|
100 per cent Polyester Belt
|
Application of carbon belt for construction:
Application of CF for beaming in construction
Further, for increasing the mechanical properties like tensile strength, high temperature resistance etc Lacom or Lamination and Coating Machine can be used.
Aramid and high tenacity polyester belt under coating on Lacom
HKO Heat Protection
Since Asbestos fibres are highly toxic, fibre glass and aramid belt are the replacement for high temperature range from 350°C to around 1600°C. Belts of satin weave with 650 to 1250 GSM and 1.3 mm thick are being used in the industry for thermal insulation, reducing heat loss and protecting sensitive human organs. High temperature belts are very useful for rescue operation during fire fighting. To make it possible with foolproof confidence, FR testing is required by deciding distance from fire place and duration of stay in affected area.
3. MAGEBA narrow weaving machines:
With the range of MAGEBA weaving machines we are able to produce light, elastic and non-elastic tapes, as well as heavy, elastic and non-elastic belts, but also technical narrow fabrics.
MAGEBA provides reliable and common needle looms as well as traditional but highly modified shuttle looms.
Special narrow fabrics machines builder MAGEBA had launched a high productivity shuttle loom for complex, multidimensional narrow fabrics in ITMA 2011 in Barcelona.
MAGEBA narrow jacquard loom & shuttle loom
4. Prashant make needle narrow loom:
Piezo Technology (Patented Bi-Morph-Actuator).No hooks, no solenoid hence, no heat.
Innovative close module design for defect free production.Simple & user friendly touch screen controller.Knot & Loop free harness with spring pull down.Design input in controller by pen drive. Prashant Group's narrow looms are indigeneous and economic in cost with direct warping machine.
Needle Narrow Loom
Results & Discussion
1. Samples of various weaves like plain, twill, satin, combination, and elaborate jacquard designs in a very cost effective manner have been developed in the industry on narrow looms with minimum use of expensive yarns before deciding wider width on various Looms.
2. With very costly yarns like aramid, carbon and dyneema prototype are being made as demand of technical fabric has been increased in market. Narrow width prototypes can be tested and modified for exact applications.
3. Sampling on narrow weaving machine saves cost as well as time.
4. We can weave high strength belts in one or more split together with tensile strength 50 KN even more depends upon material and width of belts.
5. Woven belts can be finished by coating on auxiliary machines to enhance mechanical properties.
6. Customer preference keeps changing all the time. Innovations will help in the future growth of the industries; around 3,000 varieties of elastic fabrics are manufactured on narrow width looms. ICRA Management Consulting Services Limited (IMaCS) analysis shows the market size of narrow fabrics in India as follows:
Narrow Fabrics Consumption
|
2007 - 08
|
2012 - 13
|
2014 - 15
|
Quantity in Million Meters
|
830
|
1110
|
1337
|
Value in Indian Rupee (Crores)
|
365
|
625
|
785
|
7. Earlier, metallic chains were used as safety belts but now, high strength woven belts are also used. Radical changes in the textile sector have fuelled the narrow fabric industry to become more successful because these are easy to handle and uncomplicated to mount.
8. High temperature fabrics/belts are being used in FR blankets and ballistic uniforms.
Conclusion:
Demand shows that investment in narrow fabric industry for an entrepreneur is an evergreen business. New establishments can break even very soon as machine installation cost is low while demand of product is high with easily procurable materials. Machines are simple to operate.
We can weave a variety of samples in a very cost effective manner on narrow looms with limited consumption of expensive yarns.
This technology is very important to produce specified application products like high strength belts, car seat belts and conveyor belts.
Reference:
1. Narrow Fabric Weaving - Hans Walter Kipp.
2. Narrow Fabrics Conference - Jakob Muller Institute.
3. Needle Weaving Technology in Narrow Fabrics. - Erich Essig.
4. ICRA Management Consulting Services Limited (IMaCS).
5. Textileworld.com
6. www.prashantgroup.com
8. www.mageba.com
9. www.itemagroup.com
