Tekstil Teknik Dergisi Tekstil Haberleri, Tekstil Sektörü, Tekstil Teknik
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Present since 1955 on a wide range of markets, Calemard® has focused its activities on highly technical cutting applications.
Calemard® has therefore gained strong market positions on textiles, technical textiles and nonwovens, in particular when the market or the material request quality slitting and/or rewinding. On standard usual textile market, machinery by Calemard performs on different applications like sun protection, labels, interlining, ribbons, flags and etc. Nowadays, Technical Textiles are becoming one of the main converting applications for Calemard® machinery, and are typically based on filtration fabrics, conveying belts, dipped fabrics, rubberized fabrics, automotive.
Originally focused on narrow web slitting, the company has expanded its knowledge in spooling technology. This experience enables Calemard® to position itself as a leader, not only in narrow web slitting and rewinding/spooling, but also for delicate product conversion such as nonwovens. Calemard® has been present for more than fifteen years in the hygiene business, with high performance and very sensitive equipment to handle this delicate material. Calemard® launched several years ago dedicated spooling lines. These highly technical and productive narrow slitting lines perform jumbo spools of fragile nonwoven hygiene products used in the manufacturing of baby diapers, feminine protection and adult incontinence.
With around 200 spooling heads delivered worldwide, Calemard® brand is now recognized as a leader in providing proven and efficient solutions for spooling sensitive nonwovens. Calemard®’s Pegase spooling line has been developed to produce jumbo spools. Calemard®’s spooling technology has been engineered to respond to the baby diapers and femcare producers to maximize their productivity on their production lines with the use of high capacity spools of very sensitive material. These jumbo spools hold 12 to 40 km of material which means at least a strip 10 times longer than slit pancakes/reels and high savings for diaper and femcare producers: less diaper to reject, less manpower for material handling, higher productivity! Calemard® self-traverse technology guarantees to produce at high speed (600 m/min) spools of a strip with no stress, no tension, no elongation and no twist. This third generation of Pegase uses state of the art technical solutions: accurate web regulation tension, very precise web guiding and strip conveying, double shaft unwinder for mother rolls loading in down time, ergonomic ultrasonic splicing unit and various solutions for production quality and productivity improvement such as metal detector, strip width measurement, data collection, dust collection, fast cutter positioning. Calemard® also proposes new solutions to increase by 28%* your productivity, to ease handling operations and reduce costs. Calemard® also provided wide slitters to process bulky and/or fragile large rolls. The development of new products has pushed new developments of higher capacity slitter or very specialized one for ‘niche’ markets (doctor machines, laminating and etc.). Calemard® supplied a lot of equipment to commission slitter companies to process various nonwoven like for roofing, filtration, garments, flooring, automotive, medical applications…
Decoup+®, the specialist of continuous ultrasonic cutting and sealing
Spoolex’s ultrasonic area, Decoup+® brand proposes different cutting and welding equipment, applicable at any stage of the textile production and converting process. From handheld devices for final make-up operations, to module to be integrated on weaving looms, stenters or off-line machines, the industrial range of proven solutions is specifically adapted to continuous operations. For cutting on looms Decoup+® proposes compact and easy to install devices on any type of loom, producing stable and consistent edges, whilst maintaining fabric properties. Reliable and affordable, this equipment is the solution to avoid hot cutting drawbacks.
Cost-effective ultrasonic cutting and sealing solutions for PP-Tapes
Each day, the company’s team of technical experts works in close collaboration with major machine manufacturers. Thanks to this partnership Decoup+® have now gained strong market position notably in FIBC industries. FIBC industries are constantly requiring resistant, hygienic, eco-friendly and new solutions for PP fabrics cutting-sealing purposes. Because it performs clean and strong, ultrasonic cutting technology has been used for many years now and is today well introduced in all steps of big bag manufacturing process mainly for cutting, sealing operations. The company’s famous and well-known STAR devices have been used worldwide for more than 30 years for PP ultrasonic welding and cutting on flat or circular weaving loom. Also the standard Star devices are designed to work at loom speed, to perform clean, resistant but smooth edges allowing an easy handling and immediate use of the fabric without any risk of problems in finishing operations (contamination, needle breakage, unusable fabric due to overthickness, yellowing, burns…). The process on loom is a two-steps operation: The first step consists in a creation of an ultrasonic welded track on the fabric (maximum 27mm width). The second step is a mechanical cut in the middle of the welded track. Moreover, Decoup+® offers high-tech reference equipment to the best market price.
Up to now, continuous ultrasonic cutting/ sealing was only available on weaving loom for low or medium speed (adapted to weaving loom speed). But as an expert of ultra sonic technology and thanks to their complete mastering of ultrasonic equipment, Decoup+® have developed a new solution. Decoup+® is now able to offer the ultrasonic solution to reach higher speeds (off line) as one of the main requirements is to gain productivity while keeping the same quality. Thanks to newest development and an adapted range of tools, Decoup+® proposes a solution to cut fabrics from 70 to 250 gsm at high speed on your off-line machines. Based on their usual combined cutting technology, this process is still a 2 steps operation, but, consisting in both ultrasonic welding and ultrasonic cutting. This solution grants the same benefits in terms of edge resistance, cleanliness and softness than with the standard Star technology, but allows working up to 50 m/min (depending on fabric gsm).
Decoup+® has also a strong experience in splicing benches. Installed at the exit of nonwovens production lines, splicing benches are used to join two bobbins together or to eliminate defects during control processes. Decoup+®‘s ultrasonic splicing technology performs strong join without overthickness while maintaining the original properties of the product, and so, eliminates the risk during finishing operations, to stop the lines to scrap the neck and overthickness resulting from a hot wire splicing. Then, for final make-up operations Decoup+® proposes a manual range of equipment: autonomous workstation to perform high quality cutting, sealing or welding operations only with tool changes, and handheld cutters for straight or profile cutting adapted to multi-purposed operations.
Roll Concept® not supply simple roller
For more than 20 years now, Roll Concept® designs and manufactures the patented ALVEOTUBE® product line. This eco-solution is the best aluminum compromise on the market between bending resistance and low inertia, and allows decreasing electrical power need and consumption during line speed-up phases. Specially engineered to improve process performance and increase line speed on web handling and converting industry, the lightweight precision rollers and cores ensure to users easy installation, easy handling and durability. The range includes simple profile but also ready to run solutions with a large choice of finishing and coatings:
Industrial rollers: Idler rolls guide and transfer the web at different steps of the production run: they keep a constant tension on the webs thanks to reduced friction and perfect rotation. Their lightweight and the unique alveolar structure enable to combine bending strength and resistance to corrosion. Customized in different diameters and lengths, these rolls are ready to be installed!
Universal core adpator Corexal® to transform in few seconds a 3’’ expanding shaft into a 6’’ one. Air or mechanical shafts which support cardboard winding cores during winding operations have usually an internal diameter of 3˝ (76.2 mm). But generally it’s necessary to rewind on 6˝ internal diameter winding cores (152.4mm). Air shafts today solutions need adaptation, pneumatic supply; they are heavy and fragile… Roll Concept® has developed a universal core adaptor: this mechanical solution allows to wind on a 6˝ winding core while using a 3˝ shaft, without any electrical, air, water, mounting, tools or internal diameter modification. When the 3’’ shaft is inflated, it opens the adaptor allowing supporting the 6’’ cardboard winding cores. After air shaft deflating, a spring allows to remove the cardboard winding core. Such as all Roll Concept’s product range, Corexal® could be provided in various lengths, with different surface finishes to fulfil customer’s needs.
Thermal rollers: Alveolar structure is perfectly adapted to fluid circulation. Thanks to their design the ALVEOTUBE® profiles can be used to have cold fluid (air or water) passing through the alveolus. There is no standard roller version. Applications are always specific and adapted to customer’s needs, but the advantages are always the same: excellent thermal transfer thanks to the thin skin and aluminum structure, 50% less weight compared with a double casing steel roller and low inertia when full.
