Advantages of yarn intermingling for weaving and warp knitting

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    Heberlein, the leading supplier of air interlacing and air texturing jets, has also applied its expertise to develop a unique air-saving solution for a smooth and efficient weaving process. The Heberlein WarpJet-KV needs up to 38% less compressed air compared with other jets. First-hand information is available at the upcoming ITMA Asia (Hall 8.1, Stand A43) – and the key details are presented here.

    High-speed weaving and warp knitting processes demand yarns with smooth surfaces for efficient processing. Special procedures to achieve the required yarn quality include air interlacing and sizing. Sizing is less favored with sustainability in mind because it requires removing the sizing agent after weaving using water, which creates high pollution loads.

    The art of air interlacing

    In order to develop a novel interlacing system, Karl Mayer, the leading manufacturer of preparation systems for warp knitting and weaving, turned to Heberlein. Given Heberlein’s reputation in filament yarn processes and its competencies in air jets, it was considered an ideal partner. This collaboration, which began in 2015, initiated the innovation of a completely new air interlacing system that offers considerable economic advantages in warp preparation and the subsequent fabric production sequences.

    A process creating reliable intermingling points has several benefits, as the weaving machine no longer stops through shedding issues with filament openings or friction from broken filaments. So, the weaving process operates at higher speeds, also enabling the reduction of size application.

    When the process requires maximum efficiency and yarn strength, you can use Heberlein’s high-precision components. The WarpJet-KV can increase the intermingling points to 60 to 90 per metre – about triple the usual number, to suit individual requirements in the weaving process. Common speeds from 4,500 to 5,000 m/min in the spinning process usually allow 15/30 nips per metre, which might be sufficient for a smooth weaving process. However, many mills prefer to be on the safe side, especially when using yarns of ≤ 75 denier and DPF ≤ 1.0 – so they opt to install the Heberlein intermingling device.

    Advantages of yarn intermingling for weaving and warp knitting
    WarpJet-KV

    Less air, more profit

    The other key aspect is that we require the air pressure to ensure an increased number of intermingling points, assuring filament cohesion, especially with fine yarns. During air interlacing, an air blast physically intermingles the individual filaments of a multi-filament yarn with one another.

    Saving compressed air in the air interlacing process results in reduced energy costs. Furthermore, this fact is substantiated by the performance of the Heberlein WarpJet-KV. During tests on the same machine with 1,536 threads, and while maintaining the same level of air pressure, it is evident that the WarpJet-KV enables savings of 307 and 491 m3/h in comparison to a standard jet. When comparing the air pressure required for the same quantity of intermingling points (FP/m), these savings accumulate to an impressive 38%. Thanks to advanced technology by Heberlein, the diameter of the jet’s air orifice is smaller and requires less air while producing the same number of knots.

    Never too early for profitable investment

    In warp knitting, the demands are stringent and complex. Uncompromised yarn quality with highest production efficiency at lowest cost – with the premise of sustainable production – is fundamental. That makes it an ideal time for a retrofit with a proven solution: the Heberlein WarpJet-KV. The figures show interlacing performance up to 10 to 30% higher than competitor jets, based on the same air consumption and stability requirement of intermingling points. Air consumption can be 13 to 40% lower for the same number of intermingling points.

    Compatibility with Karl Mayer Machines

    You can retrofit Karl Mayer machines to install Heberlein’s WarpJet-KV by modifying the main air connection. Additionally, the modular design of the jets permits a single unit to interlace up to 64 yarns. Depending on the application, customers can benefit from the easy exchange of the JetPack, and, typically with Heberlein jets, maintenance, cleaning, and replacement are straightforward.

    Source: Heberlein

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