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Tonello High speed warp knitting machine

presents the with double needle bed

laser, the new

innovative, This is a remarkable decline. The reasons for this can goal is to achieve a 1.3-fold total draft using a break

draft of 1.15, then only a draft of 1.13 remains for the
be manifold and may be related to cotton cultivation
revolutionary and harvesting methods. However, a crucial aspect main draft (1.15*1.13 = 1.3). This means that the
is that the economic pressure on spinning mills and
levelling dynamic is limited to 13 percent. This is
Laser Line their production costs is increasing, leading to the much too low to respond to short-wave fluctuations.
use of ever shorter fibers.
For comparison: With the autoleveller draw frame,
Development history of the IDF at Truetzschler the main draft and thus the levelling range often
exceeds 400 percent.
It takes time for optimised processes to establish
The big turning point that the denim world has been the speed Double needle bed machine 2bars knitting area themselves on the market. This is because process
waiting for has finally arrived: after a long period of
shortening initially presents a challenge in the
Italian Review destined to represent the new benchmark for the work area, it is easy to use and allows you to operate Italian Review parameters such as strength, elasticity or By eliminating the break draft in the IDF 2, the entire
THE Laser Table: is the new Tonello proposal for table
spinning mill. It must be ensured that the same yarn
research, refinement, and fine tuning, Tonello is
work.Compact in its total volume, but with a larger
quality is achieved in terms of processing
launching THE Laser on the market, the range that is
appearance. In the mid-nineties, at the beginning of
entire sector.
either on the entire surface of the table, or alternating
processes in two distinct areas. This allows fast,
the IDF development, it was unimaginable that yarn
The laser, the absolute laser. A new software, a
could be produced from 100 percent noils, but today
flexible, and alternating production of the garments.
totally reinvented process
this is certainly the case. This is also a way for large
Design and quality finally together, to offer more
combing mills to include their own waste in the value
THE Laser Table & Mannequin: radically changes the
productivity, flexibility, speed, accuracy, and repeata-
chain and selling it with added value. Truetzschler
approach to “table + mannequin” technology. It
bility. Overall dimensions reduced by as much as a
Ear loops face-mask
third; possibility of working a continuous cycle, 24
implemented the IDF system in 1999, based on
levelling range is fully utilised. Fluctuations are ideally
with the new oblique mannequin, which reduces the
hours a day, 7 days a week; incredible software
Spanish market requirements for the card TC 11. In
compensated this way. If two parameters must be
overall dimensions of the machine and allows for
performance and uncompromising quality: for integrates the innovative features of the Laser Table The ideal machine for mass production of simple Sportswear accessories has significantly advanced this development and drafting takes place in one drafting zone. Thus the
The DNB/600-2B machine enables very high
the following years, it was continuously developed
optimised simultaneously, it is much more difficult to
improved performance of the fully automatic and
combining technology and creativity, and pushing super-rapid change between the two working modes. articles, such as sportswear accessories and bands productivity, thanks to its operating speed and the and improved. find the technologically better setting. This is
them beyond every limit. The mannequin can also be marked at a full 360 for technical articles. low stitch density value required by fabrics produced. because break draft and main draft must be varied
degrees. Its compact design and reduced working width allow In 2013 Truetzschler presented a fundamental and constantly adapted to material changes. The IDF
THE Laser is much more than a new line of Beside the innovations on our electronical knitting fast article change overs, in both small and long revision: The Integrated Draw Frame IDF 2. The 2 is thus not only the better technological solution,
machines: it is another (R)evolution signed Tonello, a THE Laser Conveyor: machine for continuous machines, COMEZ continued in the study and production runs. special feature was the reduction of two drafting but also simplifies handling. This is a particular
radical paradigm shift that will result in a better and processing on conveyor belt or traditional fixed table. development of numerous machines models with zones to one. Thus, the IDF 2 responds to the advantage, since nowadays many spinning mills
more efficient way of working. In other words, Tonello It allows non-stop laser processing and garment mechanical control to improve their efficiency, Users of COMEZ machines are in a position to obtain increasingly urgent demands of our customers for have to deal with the problem of having hardly any
has reinvented the Laser, changed the rules of the unloading. Ideal for T-shirts and knitwear, it is also productivity and easy operations. high quality products in large quantities. They can production cost reduction on the one hand and a qualified personnel available to technologically
game, and nothing will ever be the same again. particularly flexible for laser cutting jeans. Co-stars of therefore count on continuous production high quality standard despite poor raw material evaluate settings of this kind.
the range are the absolute latest developments The result of this ongoing research is the new (overcoming changes in fashion tastes and market qualities on the other. This is because only the
The laser, the range CREA and B.O.P. DNB/600-2B, a high speed mechanical warp knitting trends), enabling them to also be competitive in new High yarn quality is becoming less and less heavily occupy the minds of our customers. For one, 1-zone drafting system allows particularly low drafts, When using a normal-width drafting system, larger
Lab, Table, Table & Mannequin, Conveyor: these are machine with double needle bed, suitable for the market segments. dependent on the presence and experience of the shortening of processes means lower staff which are the decisive guarantee of success for the masses are accelerated and decelerated again
the magnificent 4 components of the most complete CREA is a software conceived and developed by mass production of simple articles, such as bands employees in a spinning mill. Nowadays, it is numbers are possible, whilst the IDF also provides a processing of particularly short fibers. during levelling, which can lead to increased energy
Laser range ever, to meet all production, creative, designers for designers, smart, intuitive, and for sportswear. Notable features of the DNB/600-2B: significantly influenced by futuristic plant solutions solution for tackling the increasing demand for consumption. For this reason the width of the bottom
and logistic needs. user-friendly. Its infinite creative tools allow to easily • high efficiency and operating speeds and intelligent machine systems. In the world of spinning high-grade yarns from inferior raw material. The main difference between IDF 1 and IDF 2 lies in and top rollers of the IDF 2 has been reduced to the
modify a design in an instant, directly “on the The machine is equipped with 2 mechanically • simple structure spinning, options for shortening processes, and thus the drafting system itself. Experience has shown that width of a sliver. This also allowed the introduction of
THE Laser Lab: the most compact, smart, and cool machine”, and to go directly to production. B.O.P. or controlled guide bars and can process any type of • easy operation and maintenance reducing outlay in production, are becoming more For years, Truetzschler has been watching the trend low total drafts are the key to success – especially the clever solution of rotating top rollers, which has
laser in the range. It is characterized not only by its Be On Point, is a “one touch” automatic positioning yarn, both synthetic and natural, according to the and more relevant. One example is the IDF that fiber lengths used in the rotor yarn sector in with short-staple cotton, which is usually used in led to a doubling of the service life before grinding.
compactness, but also by its easy installation, system for design, which does not require particular machine gauge. In addition, the two needle beds and The primary application sectors for articles produced integrated draw frame from Truetzschler which so far particular are becoming shorter and shorter. In 2003, rotor spinning. However, dividing this small draft into
maintenance, and handling, as well as by the options operator precision. This increases the quality and guide bars allow the production of double face fabric on this warp knitting machine are sportswear is superior to all competitor solutions. It can be used the average fiber length for our customers’ rotor yarn break draft and main draft results in more The IDF 2 also introduced the sliver loop storage.
for it being placed in either shops or in production repeatability of marking, while significantly reducing structures. accessories and technical articles. to combine two important aspects which currently installations was 28.5 mm, today it is only 26 mm. disadvantages than advantages. For instance, if the This driven deflection roller levels the sliver loop by
contexts, depending on the power and, therefore, execution times.
November/December 2020 November/December 2020

means of an integrated light barrier, resulting in actual tension being applied. (IDF 1 break draft 1.0).
perfect synchronisation between card and IDF. The The second diagram illustrates that IDF 2 and IDF 1
levelled loop permits high change speeds. This both have the same trend, i.e. that the yarn strength
ensures a higher efficiency at the card, especially decreases with increasing total draft. Compared to
when using small rotor cans. IDF 1, IDF 2 shows overall strength at a higher level.
This confirms the statement that the use of only one
drafting zone has a positive effect on the yarn
properties.
Development of the IDF 2
The IDF 2 has been established on the market for
seven years. The advantages of the system are now
recognised by the entire professional community,
competitors and customers. Initially, the shortened
process was only used with 100 percent cotton –
preferably from the recycling sector – but today it is

The combination of Truetzschler cards with IDF 2
gives customers an advantage, because they
produce a thin, stable web which is perfectly suited
to be drawn directly to the desired sliver count – at
highest production rates and lowest drafts. If cards
produce a heavier web, the use of low drafts is not
possible at all, as, for example, from 12 ktex to 5 ktex
a draft of 2.4 is applied.

One versus two drafting zones – technological no longer limited to this. The system is successfully
advantages applied in the processing of 100 percent raw cotton
In order to show the influence of the distribution of and other materials. It thus offers an answer to the
drafts on main draft and break draft as opposed to requirements of our customers with regard to
only one draft zone, a yarn of 100 percent raw cotton increasing and necessary flexibility in the production
(Mato Grosso) with Ne27 was spun in the direct process.
spinning process with a card production of 170kg/h.
With IDF 1, break drafts of 1.0, 1.05 and 1.16 with The handling of the IDF has also been improved. For
different main drafts were combined. The IDF 2 was example, there is now a retention lock that prevents
run with drafts of 1.2 to 1.95. The tests showed the the cover of the IDF from always having to be
trend across all parameters that IDF 2 with its 1-zone opened completely during the piecing process.
drafting system has clear advantages over IDF 1. Similarly, the use of maintenance-free deep groove
ball bearings entirely eliminates the need for
The first diagram shows the influence on yarn relubrication at the delivery rollers: The number of
evenness for a total draft of 1.7. There is clear lubrication points is thus reduced to four. The
evidence that the break draft in the IDF has a
negative influence on yarn parameters. It is self-adjusting lap monitoring of the top rollers,
noteworthy that for all quality parameters, the already known from the draw frames, has now also
presence of the first drafting zone in the IDF 1 alone found its way to the IDF. There is no need to readjust
has a negative effect on the results, without any after grinding intervals and changed settings.