The CarpetCabler CarpetTwister carpet yarn machine was launched in 1982. With an average market share of 80%, we have become market leaders in all important markets such as the USA, Turkey, Benelux, Central and Eastern Europe and Asian countries within a short period of time.
This market position is the result of close cooperation with our customers, who successfully implement BCF industrial yarn processing in a demanding market environment. Our focus is on a high level of machine reliability and short response times to meet market requirements and fulfil customer wishes unerringly.
Energy efficiency, resource preservation and above all climate protection are at the heart of industrial processes. Furthermore, energy prices have become one of the most important cost factors in the manufacturing industry in recent years.
That is why our engineers are also focusing on using resources efficiently when developing new machines and systems. We are always continuing to develop our machines.
In our E³ philosophy, we have focused on customer benefit in particular and how to increase it by taking into account the three influencing factors of energy – economy – ergonomics.
E³ – Energy
The direct cabling process is mainly used for processing untwisted parallel filament fibre strands with multifilament. The two yarns are looped around each other on the cabling machine after being drawn off in the spindle area under the same initial tension, but are not twisted into each other.
The yarn structure that this creates provides an ideal degree of filling in the surface of the carpet. In this respect, producing carpet yarn is an energy-intensive process, as the outer yarn has to be guided around the inner yarn by rotation and results in yarn speeds of 300 to 420 km/h.
This is where the energy-saving new development comes in. The rotating mass of the spindle can be significantly reduced with a smaller size, and efficient drive technology as well as optimised bearings for spindles that rotate at high speeds further reduce the energy requirement.
Furthermore, the resulting path of the yarn balloon is determined by precise laser measurements, so the diameter of the yarn bobbins can be accurately adjusted. This results in considerable energy savings of up to 30%. Secondary electrical energy is also saved in a workplace with air conditioning.
The energy required for air conditioning is reduced because the cabling machine consumes less energy. For a single cabling machine with 160 spindles, this saves approx. 28 kilowatts per hour or approx. 15 kg of CO2 per hour, which adds up to an annual reduction in environmental pollution of approx. 100 tonnes of CO2. Our innovative technology has become the market standard. Our contribution to reducing energy consumption and conserving resources is in the design of machine elements which are optimized from all points of view.
E³ – Economy
The influencing factor of the economy starts right away when installing machines at the customer’s premises. The space required by the machine and the way it is installed is important here. We take both factors into account with space-saving design and ready-to-install machine sections.
In cabling and twisting, two physical movements must be combined or interlaid. The spindle rotation forms the yarn balloon and the take-up area pulls the strand through the spindle. At the same time, the finished package is wound up in the cradle of the take-up. Central drive units in the machine make these movements.
A drum shaft to evenly distribute the torque over the entire length of the machine is provided as standard to drive the spindle. We also offer optional motor spindles for processing polyester at higher spindle speeds of 7000-8500 rpm. The optimum yarn area to be processed results from the spindle size selected, so this selection is also very important in terms of economy. Of course, the spindles are equipped with high-strength ceramic components to guide the strand with as little friction as possible at high speeds. This means that all parameters are considered so that all common materials such as polypropylene, polyester and nylon can be processed without any issues.
Higher spindle speeds result in higher take-up speeds, which means higher stroke rates during yarn lay-ing. The CarpetCabler CarpetTwister can achieve take-up speeds of max. 120 m/min when using the mechanical gearbox or the optional electro-mechanical gearbox.
The computer-controlled machine has the option to monitor and optimise energy consumption and, in a corresponding expansion stage, also to process data of the central machine parameters.
E³ – Ergonomics
This area is concerned with the ease of operation of the machine and also considers aspects of occupational safety, as these two factors are inseparable.
The creel on the machine works with an effective spring system to reduce the force that needs to be applied. Optionally, the creel can also be operated pneumatically, resulting in a significant reduction of the operator’s workload.
All other controls are arranged so that the operator can reach them directly from the appropriate operating position. The creel-fed yarn is pneumatically guided through the threading tube into the spindle by the Creel-Jet, which saves a lot of time. It also results in particularly short changeover times when creating a new batch.
The machine elements ensure that it is easy to use and consider the safety of the machine operator to the highest degree. Covers in the take-up area as well as in the oscillating yarn laying area prevent the operator from reaching in.
The quality of the yarn that is produced is our core focus and forms the expectations and prerequisites of our customers around the world.
This is where the cycle of the customer benefit closes with measurable economic success in the production of BCF yarns. We are only satisfied with high-quality packages because we know that our customers trust us and expect it.
And there are even more highlights of our CarpetCabler CarpetTwister. Our global service network offers a quick and effective supply of original parts and our inspection service provides effective on-site advice for technical issues. This adds even more value to help our customers succeed.
We are always continuing to optimise our machines and applications. Our market success is confirmation that we reliably and precisely meet the expectations of our customers around the world. Although the Covid-19 pandemic has significantly limited face-to-face encounters in recent years, we are still cooperating directly with our clients. We are looking forward to meeting them again at trade fairs that we hope will take place again soon. We would be delighted to introduce you to our products.
Our comprehensive yarn processing solutions are a testament to our heritage, history and textile expertise which we are very proud of.
