Page 44 - October-November-2017

44 45

Corporate Highlights

Securely packaged

An online process for the non-stop

production of sacks on KARL MAYER’s
RDS 11 EL machine

Fig 2. The knitting elements on the RDS 11 EL

The batching unit produces rolls from the sack webs removed via a conveyor belt (Fig. 6).
elements comprising two compound needle bars, unlike its predecessor, the RSD 11 EL has been which, as “automatic sacks”, are fed fully
two knock-over comb bars, four ground guide bars equipped with a new feature, the EL pattern automatically to the filling machine. Alternatively, the
and seven pattern bars. With this configuration, the drive (Fig. 3). STMR process produces piles of individual sacks
RDS 11 EL works a combination of a pillar stitch and that are ready to be filled.
weft lapping. Two separate webs are produced, one
by ground guide bars, GB 4 and GB 5, on the rear In this case, the textile webs run via a roller feed unit to a
needle bar and one by GB 7 and GB 8 on the front thermal cutting unit on a swivel-mounted frame (Fig. 4).
needle bar. The two mesh webs are joined together
on one side in the working direction by pattern bar, Once the predetermined width of the sack has been
PB 6. The seam forms the base of the packaging reached, it is cut by a horizontal stroke of the cutting
sack. The opposite side is open to enable the sack to unit along the side seams. The RDS 11 EL incorporates
be filled. The openings in the horizontal direction are a marking thread (Fig. 5), so that sensor technology
also closed, by changing the lapping, to produce the can be used to detect the cutting points. The separated
side seams of the sack. sacks are then stacked using the swivel-mounted frame
Fig 1. The whole line with the FTL unit, the RDS 11 EL and the batching unit for automatic sacks until the set number has been reached. They are then
KARL MAYER has revamped its machine technology monoaxial flat film yarns. These yarns are delivered to The EL facility produces customised sacks
for producing packaging sacks. As before, this fully the Double-bar raschel machine, in depending of the The RDS 11 EL offers a number of options for the A machine that is ideally suited to the market
integrated system enables ready-to-use, high-quality demand. The needs-based delivery of the tape yarns efficient production of ready-to-use sacks, including Fig 3. The EL pattern drive on the RDS 11 EL Thanks to online process control and the high efficiency
products to be manufactured non-stop from film at is a decisive factor for online process control, just as the incorporation of sealing tapes, flaps for automatic of the RDS 11 EL, KARL MAYER’s line for producing
maximum efficiency. What is new, however, is the is the exact harmonisation of the machine technology filling, an adhesive strip for the subsequent This electronic system replaces the old, mechanical sacks operates at an extremely high production rate. At
machine’s level of flexibility. As the most important as a whole (Fig. 1). “With this non-stop sequence, application of labels, and contact yarns for NNC type. It does not use pattern chains or discs a speed of 900 courses/min, an average of about 900
element, the double-bar raschel machine has been everything must function perfectly and all the subsequent process control. Above all, the and enables the pattern to be changed easily. The sacks per hour can be produced – depending on the
equipped with an EL pattern drive, which enables components have to be in perfect harmony, rather dimensions of the product can be varied. For repeat lengths can also be changed easily to adjust dimensions selected and the stitch density.
variable sack lengths and lappings to be worked. like an orchestra,” says Rainer Baier, a product example, the opening widths of the nets can be the size of the sacks. The RDS 11 EL has also been
developer, at the machine presentation. varied via the stitch density, i.e. via the take-down, newly equipped with the tried-and-tested The market is extremely impressed by this high
Five blades per inch produce tape yarns from film and by the lapping. The depth of the sack can also KAMCOS®-system, so that its extensive potential productivity and flexibility. The first complete line with
An FTL unit is located at the beginning of the A tried-and-tested basic design be changed via the threading arrangement of the can be easily exploited. FTL unit and batching unit for automatic sacks left
processing chain for producing sacks. This element An RDS 11 EL is used to knit (Fig. 2) the tape yarns guide bars as a function of the number of webs KARL MAYER’s headquarters in Obertshausen in
in the production line has a cutting bar for cutting a to produce complete sacks. The machine is supplied produced in parallel. The width of the sacks can Stacks or rolls – both types of take-up are possible September 2016. This delivery was the result of two
double-layered, primary polyolefin film into tape yams with a width of 193", a gauge of E 6, a threading also be varied as required. The width is determined Two systems are available for taking-up the years of successful development work.
and drawing them in a heating zone to produce arrangement of 1 in, 2 out, and a set of warp knitting by the repeat length, which can be freely selected warp-knitted sacks, i.e. the 26/6 batching unit and
and changed easily. The reason for this is that, the STMR sack separating machine.

October/November 2017 October/November 2017