While drum tumbler systems present consistency challenges through random fabric movement, leading fleece manufacturers have adopted air transport technology that delivers uniform lambskin and sherpa effects across thousands of meters, without fabric tangling or batch variations.
The difference lies in how fabric moves during finishing.
Understanding drum tumbler limitations
Drum tumbler systems-where fabric falls and tumbles inside rotating drums-face inherent design characteristics that affect consistency and reproducibility:
Random fabric movement
Fabric moves unpredictably inside rotating drums, with some areas receiving excessive mechanical action while others barely move. This variability makes uniform pile development challenging across entire fabric widths.
Manual intervention requirements
Fabric loaded piece by piece can tangle during processing. Manual repositioning between cycles introduces operator variables that affect batch-to-batch consistency across shifts and production runs.
Batch-specific processing conditions
Each drum cycle operates with slightly different temperature, timing, and loading parameters. These variations compound across production runs, making industrial-scale reproducibility challenging when brands demand identical results across thousands of meters.
The air transport alternative: controlled movement for consistent results
Air transport systems address drum tumbler limitations through controlled fabric movement. Instead of random tumbling, fabric moves through precisely calibrated airflows that deliver uniform treatment across every centimeter.
Predictable fabric movement
Continuous, gentle, powerful airflows move fabric with complete control. Every fiber receives identical mechanical action, heat, and steam exposure. Result: perfect uniformity from edge to edge, meter after meter.
Elimination of manual repositioning
Fabric never requires untangling or repositioning. Operator variables disappear. Production becomes fully reproducible regardless of shift or personnel.
Industrial-scale reproducibility
Consistent processing parameters across all production runs ensure identical results from first meter to last. When brands specify uniform lambskin or sherpa effects, air transport provides the required consistency.
AIRO® air transport systems: two complementary configurations
Biancalani’s AIRO® technology implements controlled air-only transport in two production configurations:
A batch processing system using air transport in rope configuration. Ideal for special lots, premium articles, and intensive treatments requiring maximum lambskin or sherpa effect development. Steam application where needed enables precise effect control.
AIRO®24 continuous open-width system
A continuous processing system using air transport in open-width configuration. Perfect for high-volume industrial production requiring consistent results across thousands of meters. Combines fabric drying with steam for uniform lambskin effects.
Both systems share the core advantage of controlled air transport: fabric never tangles, operators never reposition, results remain identical batch after batch.
How air, heat, and steam build perfect effects
Achieving lambskin, sherpa, or rice-grain effects requires precise coordination of mechanical action, temperature, and steam application. AIRO® air transport systems orchestrate all three:
✔ Air transport moves fabric gently yet powerfully, preventing tangling while ensuring uniform mechanical action.
✔ Controlled heat opens pile structure and stabilizes three-dimensional volume, creating the foundation for permanent effects.
✔ Calibrated steam develops a defined curl structure for lambskin and sherpa effects, or creates the fine, compact texture for rice-grain finishes.
This combination physically constructs permanent softness into fabric structure-no chemical additives required. Results resist countless wash cycles without degradation.
Proven results across industrial production
Manufacturers adopting AIRO® air transport technology achieve:
✔ Consistent quality enabling premium pricing across production runs
✔ 30% reduction in processing cycles through elimination of retreatments
✔ Reproducible results across millions of meters processed
✔ Zero operator variability regardless of shift changes
✔ Contract continuity through consistent brand quality compliance
Leading outdoor, sportswear, and fashion brands demand absolute consistency from their suppliers because brand reputation depends on uniform quality. When premium collections span global production runs, even minor variations in lambskin or sherpa effects become unacceptable. Manufacturers serving these markets know that consistency determines contract continuity.
Versatility across fleece applications
AIRO® air transport technology delivers consistent finishing across diverse applications:
Technical polar fleece
High-performance fabrics for outdoor and sportswear, where weight-to-warmth ratio and moisture management determine product success. Permanent softness and natural breathability maintain performance through extended use.
Sherpa effects
High-pile surfaces with natural lambskin appearance for fashion and homewear markets. Air transport guarantees uniform density and curl definition across entire fabric widths.
Lambskin effects
Raised pile with three-dimensional relief structure requiring precise volume control. Air transport achieves consistent texture from selvage to selvage while maintaining fabric softness.
Rice-grain effects
Fine, compact surfaces with elegant granular texture and uniform appearance.
Join leading manufacturers achieving consistent quality
The difference between variable and reproducible fleece finishing lies in how fabric moves. While drum tumblers create consistency challenges, air transport technology delivers the uniformity that leading brands require.
AIRO® systems have processed millions of meters for manufacturers worldwide, delivering consistent results that meet demanding brand specifications.
Next Steps:
→ Request technical specifications
Review detailed performance data and system configurations
→ Schedule a fabric trial
Process your fabrics and experience AIRO® air transport results firsthand
→ Explore performance benefits
Discover how consistent quality strengthens customer relationships
Contact Biancalani to discuss how AIRO® air transport technology can enhance your fleece finishing operations.
Source: Biancalani