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Textile Systems: Productivity Improvements on Mayer Double-Plush Raschel Machines

Client

Malden Mills, Inc. Plant in Mountainside, N.J.

Problem

Large "RASCHEL" machines of the double-plush type had low productivity, although the quality was excellent. Market demands increased and new machines could not be obtained soon enough. Present machines had to be modified and their production increased somehow without losing quality.

Solution

Machines were running at 350 RPM. Any increase in speed caused large amplitude vibrations and quality was affected. The machines were instrumented and the source of vibrations located. Linkages wer reduced in weight and some were modified; machine frames were reinforced; and the base mountings were redesigned. Speed was increased to 500 RPM; but then fabric losses increased. It became necessary to monitor yarn tension and breakage. Existing broken yarn detectors were not suitable and a new system had to be designed. Rethreading of the yarn sheets and installing gravity drop-wires at the pile sheets improved performance and allowed the speed to increase to 600 RPM without losssss of performance.

Picture of the Mayer Double-Plush Raschel Machines shows one side of the machine where improvements were made. Drive linkages are seen below. Machines measure 25' X 30' X 15' feet and are provided with catwalks and cranes above. Six machines were in use.

Later on, compact yarn control and detection devices were developed for these machines by Universal Textile Machine Corporation.