Conventional technology at the limit
Until recently, attempts to improve the technology have been based on increasing the speed of the weaving process. The weft insertion rate has been developed over several hundred years from a few meters per minute to the current rate of more than 2,000 meters per minute. This made ever increasing demands on the mechanics and the yarn. Accelerating and braking stresses the thread to the very limits of its strength, making further improvements in performance next to impossible. Not so with Sulzer Textil‘s revolutionary multi-phase system. The multi-phase weaving machine uses compressed air to insert four weft yarns at the same time. The yarn is fed synchronized into the weaving cases at 1,250 meters per minute, an incredibly fast rate. The new technology increases capacity threefold compared to conventional machines and reduces production costs up to 30 percent.
Special glass for weft yarn processing
One of the machine‘s core functions is the weft processing. Here, high precision “Duran” special glass mini-tubes by SCHOTT are a central element. The order was handled by SCHOTT‘s Swiss sales company SCHOTT Schweiz.
“Duran” proved to be the ideal material because of its good surface structure. Tests were carried out to determine the precision accuracy of curvature and the glass ends required. Another benefit was the fact that SCHOTT is in a position to mass produce the items at a constant level of high quality. The glass mini-tubes are ideal for handling the yarn because, unlike metal or plastic, they have neither edges nor other irregularities which could interrupt the flow.
The threads are carried at high speed on a jet of air through the air channels and are inserted in the weft channels. It is easy to see that the interplay between material and technology is at the very highest level. Dreaded machine stoppages as a result of poor insertion have been minimized. Stoppage occurs only once per 500,000 insertions.