where technologies and experience converge albany for textile... · 2014. 4. 1. · calator ruck...

Albany International Italia S.r.l. – Socio UnicoVia Stazione, 80 - 30035 Ballò di Mirano (VENEZIA) Italy - Tel. +39 041 5135211 - Fax +39 041 5135222

Codice Fiscale e Registro Imprese di Venezia n. 12887730153 – Partita IVA n. 03340790272 – Capitale Sociale € 104.000 i.v.

Wheretechnologiesand experienceconverge

ALBANY INTERNATIONALIndustrial Products Technologies



Felt has a name

Where

technologies

And experience

converge

Albany International ItaliaIndustrial Products Technologies



FELTS FOR TEXTILE FINISHING PROCESS

CONTINUOUS DECATIZING

NONWOVEN MANUFACTURING

TRANSFERT PRINT

FABRICS SHRINKAGE CONTINUOUS BOILING

KNITTED FABRIC COMPACTION



FELTS FOR TEXTILE INDUSTRY

A long experience in the field of industrial fabrics and a steady commitment specifically aimed at the textile finishing has allowed Albany International

Italia S.p.A., Marghera - Venice, to produce a wide range of felts for fabrics’ finishing process.

Our production meets all manufacturing demands by offering a wide range of products specially designed for each type of process.

All our products are manufactured with high quality raw materials and modern manufacturing facilities in order to always supply our customers

with safe and reliable products.



AMONG OUR ESTEEMED CUSTOMERS:

ALBRECTH

BISIO

CALATOR RUCK

CIBITEX

FERRARO

GESSNER

KLIEVERIK STORK

LAFER

LEMAIRE

MONTI ANTONIO

MUZZI

PAGANINI

SPEROTTO RIMAR



WHAT IS A FELT?

The first felts were woollen felts and their production was based on the wool’s possibility to felt because of a mechanical process (milling) in presence of humidity and

heat.

Since long ago and nowadays, most textile mills have been using needled felts made from polyester, polyamide and mixed acrylic/wool fibers.

A long experience in the field of industrial fabric s and a steady commitment specifically aimed at the textile finishing allowed Albany International to produce

a wide range of felts for each type of process.

All our products are manufactured with high quality materials and modern manufacturing technologies in order to supply our v alued customers with safe

and reliable products.



Needled felts made with synthetic fibers

These felts are manufactured according to the “sandwich” technical process, i.e.needled batt – base fabric – batt, to obtain a strong, resilient and stable structure.

The choice of the materials, design and mafufacturing parameters depends on:� application / use

� cost� machinery

The woven base fabric

The needling process is made on a base fabric previously woven.This base fabric allows a good mechanical strength.

The base fabric can be tubular or open.

The needling machine

Downward oriented needles featuring several spurs are fixed upon a board (5000to 6doo needles per board).

The up and down motion of the board makes the needles penetrate into a pre-combed layer, thus bringing the fibres through a woven base which is the felt core.

In this case, fibers are linked one with each other and to the base fabric by themechanical action of needles.

The quality of needled felts depends on several factors:

a) the quality of the woven base makes the strength and the stability of the felt.This is why every felt manufacturer designs its own weave.

b) The quality of needled fibersIt is possible to needle any kind of fibres (poliamide, poliester), from recycled fibres

to high-tech ones like NOMEX.



In synthetic felts, a bit of natural fiber can be included.

Wool with a good mechanical strength is anyway limited to 30% of it in the blend.According to our experience, if higher percentage of wool is used, a large part of it is

broken by the needles strokes.

The tuning of the needling machine -forward speed of layers, penetrating depth of needles-is precise and difficult.

The woven base, if not endless, is spirally rolled up and the fibre blend is evenly needled.In some cases to get a better resilience, we use pre-needled base fabric while most of the

felts currently marketed are needled straight away on the fabric. This is why the cross-section of our felts shows a small layer of fibres between each base fabric.

It may happen, especially for dense and thick felts, that some needles break into the felt.

The control of needles presence is made with metal detectors in two different phases.The removal of the needles is made manually.

The finishingAfter needling the felts are finished i.e. they are processed to obtain the required features,

mainly in terms of:� thickness

� surface smoothnessSpecial calenders are used for these operation which may include:

� washing� stress relieving� heat setting� buffing

� cutting to width



Yarn Types

�Woollen Spun

�Cotton Spun

�Monofilament

�Multifilament



Felt Types

� Needled felt

� Needled felt

� Woollen Felt (felted and pressed)

� Woollen Felt (woven and felted)

� Woollen Felt (felted and pressed with woven base)




Heat Shrinking Jacket

B-DX8027

WEIGHT: 2.700 gr/m 2

THICKNESS: 8,0 mm

COMPOSITION: PolyesterPoliamide

Structure: Needled felt with one endless base fabric

Properties: Very smooth sanded surfaceDimensional and running stabilityThickness and permeability evennessExcellent heat resistanceWorking economy




Heat Shrinking Jacket

B-DK6525


THICKNESS: 6,5 mm

COMPOSITION: Polyester


Properties: Very smooth sanded surfaceDimensional and running stabilityThickness and permeability evennessExcellent heat resistanceWorking economy




FeltB-VAPWEIGHT: 400 gr/m 2

THICKNESS: 1,6 mm

COMPOSITION: High Temperature resistant fibres

Structure: Non woven open felt with light base scrim for cylindercovering

Properties: Very smooth surfaceThickness and permeability evennessExcellent heat resistanceExcellent strength



CONTINUOS DECATIZING

FeltTEXILINAWEIGHT: 33 gr/m 2

THICKNESS: 0,1 mm

Structure: Non woven veil cylinder covering

Properties: Surface and permeability evenness




FeltB-DK4022B-DK6024B-DK6522WEIGHT: 2.200 - 2.400 gr/m 2

THICKNESS: 4,0 - 6,0 mm



Properties: Very smooth surfaceDimensional and running stabilityThickness and permeability evennessExcellent heat resistanceWorking economy



USEThe final treatment with both steam and heat of wollen fabrics and mixed (wool) fabrics

to give to the the “hand”.This process takes place in a continuous decatizer having one drilled cylinder covered

with a felt jacket and with an under fabric felt.The jacket, fabric and felt (system) have the same speed.

The fabric to be decatized is picked up between the jacket and the felt.The system is first crossed by 1,0-1,5 bar steam flow and then heated at 100-120 °C.

After that it is immediately cooled down by a forced air flow.All the phases take place while the system is running at constant speed.

The jacket must perfectly adhere to the cylinder and have such a thickness and permeability allowing perfect steam distribution and suction on the fabric.

VARIANTSVariants agreed with the Customers are possible both for the jacket and the felt.

These variants can be made so as to obtain special effects or performances, for new machines with special features or old machines working with non-standard parameters.



SHRINKAGE INSTRUCTIONS OF DECATIZING JACKETS

Decatizing jackets and felts are manufactured with advanced technologies and first quality materials. A correct installation and some care during usage ensure excellent

life and working economy.Open the packing with care avoiding to touch the felt surface with sharp or cutting

tools.In particular, in case of felts packed in cardboard pipes, make sure that all hooks for

the fixing of the lid have been removed. In order to do this after having removed the lid and hooks, wear a thick glove and carefully run one hand inside the cardboard pipe.

Draw out the felt and remove PVC sheet which wraps it up.Close to the final fold on one edge, felt serial number, directional arrow and alignment

marks are made. Put the rolled jacket next to the machine or to the dismantled cylinder, so that, once unrolled, the arrow is in the cylinder rotation direction.

Insert the jacket in the correct running direction (see arrow) and apply strings and lateral anchoring springs without giving particular tension.

Shrinkage times and methods can be different according to the type of equipment available.

We recommend to begin by heating the jacket with hot air or a steam coil.Open up cylinder steam only when the jackets is heated in order to avoid that the

steam, once released, could condense on the cylinder thus wetting the jacket.It is important to avoid that the jacket should wet exceedingly.

Once cylinder is hot, open up steam and let the machine run slowly.Once a good adhesion is achieved it is possible to start-up the machine. Shrinkage will

come to completion during usage. Lateral strings and springs should be stretched at the correct tension. If not,

adjustment is needed.



FABRICS SHRINKAGE

FeltB-PW6022 WEIGHT: 2.200 - 2.500 gr/m 2

B-PW7023 THICKNESS: 6,0 - 7,0 mm

B-PW7025 COMPOSITION: PolyesterWool

Structure: Endless Needled Felt with Woven Base Fabric

Properties: Dimensional and running stability

Very smooth surfaceThickness and permeability evennessExcellent heat resistanceWorking economy



FABRICS SHRINKAGE

FeltB-PK6022 WEIGHT: 2.200 - 2.500 gr/m 2

B-PK7023 THICKNESS: 6,0 - 7,0 mm

B-PK7025 COMPOSITION: Polyester

Structure: Endless Needled felt with Woven Base Fabric

Properties: Dimensional and running stabilityVery smooth surfaceThickness and permeability evennessExcellent heat resistanceWorking economy



FABRICS SHRINKAGE

Felt

B-PK XY6006WEIGHT: 3.000 gr/m 2


COMPOSITION: Polyester - Polyamide

Structure: Endless Needled felt with Woven Base Fabric

Properties: Dimensional and running stabilityThickness and permeability evennessExcellent heat resistanceWorking economy



FABRICS SHRINKAGE

B-PK7023THICKNESS: 6,0 - 7,0 mmWEIGHT: 2.300 gr/m 2

MATERIAL: 100% poliester


Properties: Dimensional and running stabilityVery smooth surfaceThickness and permeability evennessExcellent heat resistanceWorking economy



INSTRUCTIONS FOR THE INSTALLATION OF FELTS FOR PALM ER CALENDER

The felt for Palmer calender is manufactured with very advanced technologies andfirst quality materials. A correct installation and some care during usage will ensure

excellent life and working economy.Open the packing with care avoiding to touch the felt surface with sharp or cutting

tools.In particular, in case of felts packed in cardboard pipes, make sure that all hooks forthe fixing of the lid have been removed. In order to do this after having removed thelid and hooks, wear a thick glove and carefully run one hand inside the cardboard

pipe.Draw out the felt and remove PVC sheet which wraps it up.

Close to the final fold on one edge, felt serial number, directional arrow and alignmentmarks are made. Put the rolled jacket next to the machine or to the dismantledcylinder, so that, once unrolled, the arrow is in the cylinder rotation direction.

Should there be enough room, fully unroll the felt beside the machine and examinethe whole surface, including the internal side.

Install the felt in the correct working direction (see the arrow).Be assured that all the cylinders are parallel. Align the felt carefully. Then slightly

stretch the felt starting its rotation only when the stretching allows the dragging of allthe cylinders.

Open the steam and heat the cylinder up to 60-70°C with the felt in rotation.Keep rotating the felt until it is stable and centered.

Finally increase the pressure load and the temperature up to the standard workingconditions.

When stopping and cooling down, keep the machine rotating till the heated cylinderreaches a temperature of 90°C.



Needled felts: dimensional production limits

Length: mt. 0,55 (minimum)Length: mt. 25,00 (maximum)Width: mt. 4,0 (maximum)Thickness: mm. 22,0 (maximum)

How to measure the felt length

With the felt on the machine:A)use a revolution meter counter on several runs (3-4) and then dividethe measurement by the number of runsB)use a thin rope and follow the felt path on the machie

With the felt aside the machine:C)unroll the felt completely and make it flat on the ground; measure thedistance between the edges (length wise); multiple by 2 and deduct thedelta due to the thickness (i.e. 3,14*2*thickness)

Note: felt length means flet internal length or circumference

felt external length / 2



FABRICS IRONING

Felt

B-SK XY6010WEIGHT: 4.000 gr/m 2

THICKNESS: 7,5-9,5 mm


Structure: Endless Needled felt Woven Base Fabric




FABRICS POLISHING/SHEARING

Felt

B-SAN XY5110WEIGHT: 4.000 gr/m 2


COMPOSITION: Nomex - Polyester





KNITTED FABRICS COMPACTION

HEAT SETTING

Felt

B-SAN/2WEIGHT: 6.500 - 8.500 gr/m 2

THICKNESS: 16,0 - 20,0 mmCOMPOSITION: Nomex

B-SAN/3WEIGHT: 9.000 gr/m 2

THICKNESS: 21,0 mmCOMPOSITION: Nomex


Properties: Very smooth surfaceExcellent heat resistance to high temperatureThickness evennessExcellent compaction effectLong lasting and working economy




HEAT SETTING

Felt

B-SAN/2WEIGHT: 8.500 gr/m 2

THICKNESS: 20,0 mmCOMPOSITION: NomexTEMPERATURE: 180°C


Properties: Very smooth surfaceExcellent heat resistance to high temperatureThickness evennessExcellent compaction effectLong lasting and working economy



COMPATTAZIONE MAGLIA

TERMOFISSAGGIO

Feltro

B-SAN/2Grammatura: 8.500 gr/m 2

Spessore: 20,0 mmComposizione velo: NomexTemperatura: 180°C

Costruzione: Feltro agotrattato con base tessuta

Caratteristiche:Superficie lisciaEccellente resistenza alle alte temperatureUniformità di spessoreOttimo effetto di compattazioneDurata ed economia di esercizioy

Realizzazioni personalizzate, collaborazione per lo sviluppo di nuovi prodotti, professionalità e

discrezione




Felt










Composition: Nomex - Synthetic

Properties: Thickness evennessExcellent compaction effect Adequate heat resistanceWorking economy




Felt

B-SAN XY5120



COMPOSITION: Nomex - Pes


Properties: Thickness evennessExcellent compaction effect Adequate heat resistanceWorking economy



U S E

In the latest years knitted wear fabrics increased their importance because of the newfinishing processes which enhanced their comfort properties. The main problem of

these fabrics type has always been the dimensional stability that is to say maintainingtheir size after washings. New finishing techniques strongly improved this feature

taking it to the range of the shuttle fabric.The best machines for fabrics settlement use high tickness felts type B-SAN.

Generally the felts are two so to have a better settlement on both knitted wear sides.The effect used is the reduction in length, which is reached on a high thickness felts

surface, when the felt inverts the radius of curvature in an “S” run.

V A R I A N T S

The standard products are the result of the co-operation with the most importantbuilders of machines for the textile finishing.

All the variants allowing a better or special effect on the finished - products arepossible.

Thickness is a fundamental feature for this process depending on machine design.A not sufficient thickness produces a limited mechanical compaction which becomes a

residual shrinkage.An excessive thickness may lead to early “orange peel” or “elephant skin”.

The choice can be taken according to the standard products and to the users’experience.



A

B

CD

E

A: compacting feltB: introduction cylinderC: tubular fabricD: compacting sheetE: heated cylinder



Stress-Strain DiagramB-SAN style

0

50

100

150

200

250

300

350

400

0 5 10 15 20 25 30 35

A%

daN

/cm



INSTRUCTIONS FOR THE INSTALLATION OF FELTS FOR SANF OR CALENDER

The felts for sanfor calender are manufactured with very advanced technologies and firstquality materials. A correct installation and some care during usage will ensure excellent

life and working economy.Open the packing with care avoiding to touch the felt surface with sharp or cutting tools.

Draw out the felt and remove PVC sheet which wraps it up.Close to the final fold on one edge, felt serial number, directional arrow and alignment

marks are made. Put the rolled jacket next to the machine or to the dismantled cylinder, sothat, once unrolled, the arrow is in the cylinder rotation direction.

Install the felt in the correct working direction (see the arrow).Be assured that all the cylinders are parallel. Align the felt carefully. Then slightly stretch

the felt starting its rotation only when the stretching allows the dragging of all the cylinders.Open the steam and heat the cylinder up to 60-70°C with the felt in rotation.

Keep rotating the felt until it is stable and centered.Finally increase the pressure load and the temperature up to the standard working

conditions.When stopping and cooling down, keep the machine rotating till the heated cylinder

reaches a temperature of 90°C.

IMPORTANT: do not wet the felt for any reason.



MARKING PROBLEMS

Marks on the fabrics may occasionally appears in knitted wear compactions.In this case several may be the causes, among which:

> excessive overfeeding of the fabric which lead to creases or overlapping onthe fabric itself: overfeeding and fabric inlet need to be checked and revised

> rough surface of the felts due to needling marks: the style of felt is notsuitable for the application (sanded / buffed felts may be necessary)

> rough surface of the felt due to elephant skin (surface cracks due tohydrolisys and wearing of the batt surface): the felt needs replacement; Nomexbatt is preferable to Nomex-Poliester or Poliamide-Poliester-Acrilic ones.

> rough surface of the felt due to orange peel (surface deterioration due towearing and hydrolisys of the batt surface): the felt needs replacement;Nomex batt is preferable to Nomex-Poliester or Poliamide-Poliester-Acrilicones.

> rough surface due to creases formation on the felt surface when the felt isbent: softer / less compacted felt may be necessary



FREQUENTLY ASKED QUESTIONS

What should be the material of a compacting felt?The compacting felts are used to pre-shrink the knitted fabrics (tubular or open width).The thickness varies from machine to machine and OEM to OEM and it can go from 12mm to 30 mm.Generally it is between 18 mm and 21 mm.The working temperature is from 90°C to 120°C.The material might be 100% poliester but poliester is very sensitive to humidity at hightemperature.In fact these operating conditions generate hydrolisys which is the brittleness andbreakage of the surface batt fibers.The breakage of the fibers causes cracks (initially small and then big) on the surface;this phenomenum is called "elephant skin" (or "orange peel").The cracks may lead to marks on the processed fabrics.Therefore, in order to improve the hydrolisys resistance of the felt, the working batt ismade of Nomex (aramidic fiber by Dupont) layer.The Nomex layer may be from 0% to 100%.AII has developed basically two styles:> top quality: B-SAN/2: working batt 100% Nomex, fine buffed surface> cheaper quality: B-SAN XY5120: working batt 50% Nomex

Generally you deliver the compacting felts to which country?We deliver our felts all over the world.

Are there any famous machine maker uses your compac ting felts?Of course: Sperotto Rimar, Lafer, Ferraro, Albrecth.But we have supplied felts on most of the main OEM machines as Ruckh, Weiss,Santex and others.

How about the delivery time normally be?It depends on the time of the order and dimensions of the felts: we may have the felt atstock or we may need to manufacture it completely. Therefore general delivery timemay be 4-8 weeks.



TRANSFER PRINTING

Structure: Needled felt

Properties: Dimensional and running stabilityThickness evennessExcellent transfer capacityHigh heat resistanceWorking economy

Felt

B-TA XY5116TWEIGHT: 2.800 gr/m 2


COMPOSITION:Nomex/Pes



TRANSFER PRINTING

Structure: Needled felt

Properties: Dimensional and running stabilityThickness evennessExcellent transfer capacityHigh heat resistanceWorking economy

Felt

B-TA6023

B-TA7025

B-TA8027WEIGHT: 2.300-2.700 gr/m 2


COMPOSITION:NomexNomex-Polyester



U S E

Transfer print consists in transferring a pattern from a paper support to a textilesupport by heating the colour and by close contact between paper and textile

supports.This process takes place on calenders with oil-heated cylinder and having a feltsgranting a perfect contact between paper and fabric able to resist for a long time

to the working temperatures.These temperatures are often higher than 200° C.

The felt wraps approximately 2/3 of the cylinder circumference and the systemruns at the same speed carrying both the fabric to be printed and the paper to

the heating area.The heat produces the sublimation of the paper colour which is transferred to the

fabric colouring it and leaving the pattern in a single passage.

V AR I A N T S

Standard felts are the result of years of study and development together withmachines builders and users.

However all variants allowing better or special effects on the finished fabric arepossible.

The weight, thickness and density of the felt can be changed within a wide rangein order to obtain the special effects the users require.



INSTALLING AND PRE-RUNNING INSTRUCTIONS OF FELTS FO RTR A N S F E R P R I N T I N G

A felt for calander is manufactured with advanced technologies and first qualitymaterials. A correct installation and some care during usage ensure excellent life and

working economy.Open package with care avoiding to touch felt surface with sharp or cutting tools. In

particular, for those felts packed in pipes, make sure that the hooks holding the lid areall removed. To do this, after having removed lid and hooks, wear a thick glove and let

your hand pass carefully inside the pipe.Remove the felt and unwrap the PVC sheet.

Felt number and directional arrow are easy to be detected close to the final fold.Position the roll so that, once unrolled, the arrow is in machine direction. Should the

space be sufficient, completely unroll the felt next to the machine and check the wholesurface, including back side.

Install the felt in the correct running direction (see arrow). We recommend that, at thisstage, machine is completely cooled. Should this not be possible, it is necessary to

protect the felt from direct contact with the cylinder, at least when the felt is notrunning.

Once the machine is closed make sure all cylinders are parallel and then moderatelystretch by rotating the felt only when the tension allows dragging of all cylinders.

Warm up keeping the felt rotating.Felt guide roll should intervene periodically to keep the felt well centered. In case ofshifts in preferential directions it is necessary to verify parallelism of all release rolls

and temperature evenness on cylinder, before modifying machine conditions.



Our felts for transfer printing of are heatset at 250°C.As the installation on machine is concerned, start running the felts idled on the print

calender with the cylinder at 90°C.Afterwards let the felt run slowly till the temperature of cylinder reaches to 220-230°C, that

usually is the temperature for transfer print.

Machine manufactures recommended for the starting of felt the following table:

TEMPERATURE PRESSURE TIME40° 0,7 30 minutes90° 1,5 30 minutes

150° 2,0 30 minutes205° 2,0 30 minutes220° 2,0 30 minutes

Other OEMs follow the following procedure:

TEMPERATURE TIME225° 120 minutes250° 240 minutes

When stopping and cooling down, keep the machine rotation till the heated cylinderreaches a temperature 90°C



SUGGESTIONS FOR CLEANING FELTS DIRTY WITH OIL SPOTS

Adsorb oil as much as possible with fabrics or adsorbent paper.

Soak the felt with solvent (trichina) on the dirty area so that it is wet throughouttop to bottom.

Adsorb solvent as much as possible with fabrics or adsorbent paper.

Dry the felt making it run with the heated cylinder warm and slight pressure.



felt

Left speedRight speed

Shinking due to wrapping

DIMENSIONAL STABILITY UNDER WORKING CONDITIONSThe transfer printing felts are extremely stable due to special heatsetting and finishingprocess on the finished product.According to our experience and feed back from final users:> length wise: the belt does not shorten but may become slighty longer

(up to +2,5%)> widthwise: the belt generally decrease slightly the width

(say within: 5,0%)

Note:Sometimes the felt may feature a higger rate of width shrinkageIn most of these cases the shrinkage is due to differential speed between the right andleft edges of the felt which causes the wrapping/twisting of the felt on itself (see skecth)



10 - 15 cm

AD

A certain dragging of the felt by the fabric in the working direction is a possible and common event. This phenomenum is given by the higher pressure and friction in

the fabric format area.It results in a transversal displacement of the felt in a simmetrical double “S”

shape within the fabric format.The displacement is generally lower than to 10 - 15 cm (blue line in below sketch).

Different and a-simmetrical transversal displacement are due to differential speed between the right and left edges of the felt.

This phenomenum is generally called wrapping/twisting of the felt. (see previous page).

The total shrinkage related to the felt twisting and dragging may be calculated approximately as:

(2*A+D)2 / (2*W)

W

To recover the wrapping isgenerally sufficient to run the feltin the direction opposite to theworking one.If the machine does not allowthis possibility it may be possibleto invert the poles feeding on theAC motor.

After recovering the wrapping,the alignement of the cylindersmust be check and theparallelism must be re-set.



SILICONE COATED BELTS

Structure: Needled felt Silicone coated and water-proof working surfaceSilicone thickness according to final use

Properties: Very smooth sanded surfaceThickness evenness - no beginning/end faultHigh chemical and heat resistanceLong lasting and working economy

Felt WEIGHT: 4.500-5.000 gr/m 2

B-G/FX THICKNESS: 5,0-5,5 mm




SILICONE COATED BELTS

Structure: Needled felt Silicone coated and water-proof working surfaceSilicone thickness according to final useBatt in Nomex for high working temperature

Properties: Very smooth sanded surfaceThickness evenness - no beginning/end faultHigh chemical and heat resistanceLong lasting and working economy

Felt WEIGHT: 4.500-6.000 gr/m 2

B-G/TRS THICKNESS: 5,0-7,0 mm

COMPOSITION: Nomex



U S E

B-G/FXContinuous potting/boiling and KD/crabbing.

During the potting/boiling process the silicone coated belt keeps the contact betweenthe wet fabric and the hot cylinder.

In the contact zone steam in generated from the water retained in the wet felt andcontinuous boiling is performed.

Proportionally related to the working temperature, the steam pressure is.The belt has to avoid any steam escape.

Maximum working load: 15/Kg. cm.Maximum working temperature: 140°C

V A R I A N T S

The continuous development of these belts makes unlimited the number of thepossible variants.

We can customize the design and composition of the support felt as well as thecoating type or thickness.



U S E

B-G/TRSTransfer printing by colour sublimation, plastic films lamination and bonding, non-

woven lamination/cohesion, thermo-fusible films coupling.For cohesion and bonding, the belt assures the contact between a hot cylinder and the

material (generally fabrics and films).The cohesion is made by fusion of special kind of glues, and the silicone coating must

avoid the materials to stick on the belt, allow easy cleaning and resist to the highworking temperatures.

A very special use is the one made in the plastic laminated industry, where a siliconebelt is installed on a continuous press for the “endless” manufacturing of laminated

fabrics..Maximum working load: 15/Kg. cm.

Maximum working temperature: 240°C

V A R I A N T S





INSTALLING AND PRE-RUNNING INSTRUCTIONS OF FELTS FO RS I L I C O N E C O A T E D B E L T S

Silicone coated belts are high technology products running successfully in many plants.Due to their peculiar design, studied for the specific application, the belts do not require

any long or special pre-running or cooling operations.Nevertheless some simple procedures and precautions must be taken into care when

installing the belt.The silicone coating is sensitive to shocks and cuts and localized pressure.

When opening the packing and taking the belt out utmost care must be paid not todamage the belt with nails, hooks, pliers and any clamping devices or other tools.

Install the belt on the machine as per machine manufacturer instructions being careful toshocks or cuts with machine cylinders and fixed parts.

Once the belt is installed, check the correct positioning and alignment of the cylinders.Start running the machine at low speed and low temperature for some minutes.

Check for any belt displacement.Correct, if required, the belt centring device position.

Increase slowly the load on the belt up to the standard working level; keep the machinerunning at low speed.

Increase slowly the temperature of the heated cylinder up to the standard working level;keep the machine running at low speed.


Increase the machine speed up to the working level and keep it running for some hourschecking for any belt displacement.

The complete pre-running time varies from plant to plant mainly due to skilfulness ofoperators and machine conditions, but it generally lasts less then 24 hours.



C O O L I N G ( M a c h i n e s t o p p i n g )

The standard working temperature is such that the cooling of the belt when stopping themachine does not require any peculiar cooling procedure.

Once finished to process the fabrics, let a disposable fabrics sewed on the previous onego through the machine.

The disposable fabric should be not a dyed one.

Let the machine run for some minutes decreasing the temperature of the heated cylinderand decreasing steadily the speed.

We suggest to stop the machine when such temperature reaches 80° to 90°C.

When stopping the machine the belt should be kept in tension until it reaches roomtemperature.



I N S T R U C T I O N T O C U T T O W I D T H T H E S I L I C O N E C O A T E DB E L T S

1) The belt must be stretched and flat (60 to 80% of working load)

2) Draw a thick straight line with a marker (b) all over the circumference to identify thecutting measure and path. To do this let the machine run and keep the marker at afixed distance from the belt edge. We suggest to prepare a wood T square (a) and leanit against the belt edges.

3) With the machine idle and stopped cut longitudinally the belt for 10/20 cmapproximatively (c).

4) Then cut transversally the belt (d) to avoid the cut stripe is endless.

cd

ba



5) Keep the cutter in the longitudinal cut and start up the machine at minimum speed.

6) Holding firmly the cutter with both hands proceed with the cutting following the drawnline. The cut stripe must fall down and not be torn apart as it could modify thestraightness of the cut.

7) When the blade of the cutter becomes not sharp enough, stop the operation and stropit. The blade must be short to avoid its breakage.

8) Whenever the operator gets tired stop and rest.

9) When the cut is complete, then trim any produting thread using a scissor and seal theedge with a hot blade.

The operation must be performed by two people:� one in charge of the cut� one familiar with the machine operation and located close to the ALARM button to stop

the machine in case of any emergencyThe person in charge of the cut must NEVER be left alone.



C L E AN I N G O F T H E S I L I C O N E C O AT E D B E L T

Wash the belt with clear water or/and soap with a sponge.Do not wash or get wet the back side of the belt.

Before starting the machine operation dry the belt by running it idle at 80% of workingpressure and 140 °C approx for 20 minutes.

If cold grease spots are visible, then try to adsorb them with powder talcum.Leave the talcum on the spots for some hours to react and then wash as above.

Do not sand paper the belt.

R E S I S T AN C E T O C H E M I C A L SB-G/FX

Working in continuous setting or boiling processes with silicone coated belts for formingthe hand of the textile should not require chemical products.

The desired effects can be obtained in a simply physical process.Nevertheless if it is not possible to renounce to softeners the following remarks should taken

into consideration.The composition of chemical products for textiles is various and therefore it is difficult to

quantify precisely how they will react with the silicone coating.Nevertheless the belt is resistant to mostly all chemicals, except of fatty acids and paraffin

which may be part of some softeners.Contact with oils, cold detergents like benzine, diluents or chemical solvents, must be

avoided.



Instructions to repair the silicone coated belts

The followings are instructions for the repair of the silicone coated belts in case of damageto the silicone coating in a limited area, i.e. scratches fill in.

Materials required� sandpaper (220/280)� broad knife (decorator’s type)� repair material (pre-mixed silicone)

ATTENTION: the pre-mixed silicone lasts approximately six (6) days at roomtemperature; as soon as it is received it should be kept into a refrigerator

� hot air gun (180 °C-220 °C)

Surface preparationRemove all the silicone parts around the scratch which are raised, cut or not firmly fixed to

the felt.With the help of a cutter flare the scratch to a slope of 45°

Do not widen excessively the scratch; beyond three (3) centimetres of diameter thedifficulties of repair increase considerably.

Sandpaper the area with a medium roughness paper (220/280) to make the surfaceenough rough and facilitate the silicone adhesion.

Clean well with compressed air and degrease with alcohol.Dry the area.



Fill in and polymerizationThe surface where the scratch is must be as horizontal as possible.

Apply the repair material with a broad knife:� the dimension of the broad knife should be proportioned to the area to be repaired,� the fill in should be made in one time only and not by repeated additions

(this to avoid air entrapments).With the hot air gun (at 180 °C-200 °C) blow on the filled in area to heat and dry the

material.Keep the gun at 10-20 centimetres far from the area to avoid to move the material.

During the heating the material could start becoming wrinkled; in such a case move theair gun farther by some centimetres.

Depending on the area and thickness of the repair the drying could take from 1 minute to 5minutes.

When the material is dry and solidified, proceed with a light sand papering till the area ismade opaque.

For a “fine” fill in it would be preferable to repeat the operation more than once with thinlayers of pre-mixed silicone repair material.

It may result in fact that the fill in is not well spread or plain.Each and every time the area should be prepared by sand papering it before filling.



SILICONE PRESSURE BELTS

Structure: Needled felt with one endless high tension resistant base fabric silicone coated and water-proof workingsurfaceSilicone thickness according to final use

Properties: Smooth and sanded surfaceThickness evenness - no beginning/end faultHigh chemical and heat resistanceLong lasting and working economy

FeltB-F/ACPWEIGHT: 6.000-7.000 gr/m 2

THICKNESS: 8,0-9,0 mmCOMPOSITION: Nomex

Polyester



U S E

B-F/ACPContinuous setting and high pressure boiling.

During the boiling process the silicone coated belt keeps the contact between the wetfabric and the hot cylinder.

In the contact zone steam in generated from the water retained in the wet felt andcontinuous boiling is performed.

Proportionally related to the working temperature, the steam pressure is.The belt has to avoid any steam escape as well as maintain the specific pressure.

Presently the treatment takes place also at 140° C with a working stretch of 200 kg/cmcreating specific pressures up to 4 kg./cm².

V AR I A N T S





PRE-RUNNING AND COOLING PROCEDURES OF HIGH PRESSURE SILICONECOATED BELT STYLE B-F/ACP

B-F/ACP style is a high technology silicone coated belt running successfully in manyplants.

Due to its peculiar design, studied for the specific application, the B-F/ACP does notrequire any long or special pre-running or cooling operations.

Nevertheless some simple procedures and precautions must be taken into care wheninstalling the belt.

PRE-RUNNING

The silicone coating is sensitive to shocks and cuts. Therefore when opening thepacking and taking the belt out utmost care must be paid not to damage the belt with

nails, hooks, pliers and any clamping devices or other tools.Install the belt on the machine as per machine manufacturer instructions being careful to

shocks or cuts with machine cylinders and fixed parts.Once the belt is installed, check the correct positioning and alignment of the cylinders.

Start running the machine at low speed, low temperature and low tension for someminutes.


Increase slowly the load on the belt up to the standard working level; keep the machinerunning at low speed.

Increase slowly the temperature of the heated cylinder up to the standard working level;keep the machine running at low speed.


Increase the machine speed up to the working level and keep it running for some hourchecking for any belt displacement.

The complete pre-running time varies from plant to plant mainly due to skilfulness ofoperators and machine conditions, but it generally lasts less then 24 hours.



COOLING (MACHINE STOPPING)

The standard working temperature is such that the cooling of the belt when stopping themachine does not require any peculiar cooling procedure.

Once finished to process the fabrics, let a disposable fabrics sewed on the previous onego through the machine.

The disposable fabric should be not a dyed one.Let the machine run for some minutes decreasing the temperature of the heated cylinder

(steam off) and decreasing steadily the speed.We suggest to stop the machine when such temperature reaches 80 to 90 °C.

When stopping the machine the belt should be kept in reduced tension until it reachesroom temperature.

We suggest a reduced tension of about 10-15 Kg./cm. (2-3 ton).

GENERAL REMARKS & NOTES

Decrease the tension on the belt should the stoppage be longer than 10 minutes.

The belt does not require cooling by water.

If necessary the belt may be cooled down with water on the silicone coated face.

We reccommend to avoid to wet the internal side of the belt (felt side oppsite to thesilicone coated one) not to jeopardize th esupporting structure.

If possible wet the the internal side of the belt only with cold water and machine incold condition, and dry it at warm termperature (80° - 120° C9.

Do not use high tension on the wet belt.



no hydraulic pressure

working pressureactual stroke

total (max) stroke

Types of tensioning systems:hydraulic with lever



Types of tensioning systems:electromechanical with servomotor and load cells

actual stroke

total (max) stroke

position 0working position

load cell



CONTIPRESS

D belt = 2* D stroke * cos (A/2)

L nominal = 6,20 mtL min = 5,90 mt

L max = 6,60 mt

Contipress



Cyl. Diam.

135 cm

MULTISET 2 - MULTICRAB

SUPERFINISH - SUPERCRAB



Silicone Coated Belts: dimensional production limits

Length: mt. 2,50 (minimum)Length: mt. 25,00 (maximum)

from mt. 2,50 to mt. 3,60 maximum thickness is mm. 6 totalWidth: mt. 3,40 (maximum)

Silicone Coated Belts: stretching under working condition s

The pressure silicone coated belts are extremely stable due to specialheatsetting and finishing process on the tubular base fabrics.According to our experience and feed back from final users.> length wise: the belt does not shorten but may become longer (up to+2,5%)> widthwise: the belt generally increases slightly the width and do notshrink ( say within max + 3,0%)



Albany International Italia manufactures and supplies state-of-the-artendless needled felts and silicone coated belts for textiles finishingprocesses, as:

�continuous decatizing�knitted wear compaction�fabrics shrinkage�transfer printing�continuous boiling, crabbing and setting�bonding and coupling�ironing, heatsetting and polishing

Albany International’s production meets the demands of both textile finishersand machine manufacturers by offering a wide range of products specificallydesigned for each type of process.

Albany International Italia S.r.l.Via Stazione, 8030035 Ballò di Mirano (VENICE) Italytel. +39 041 5135 211fax +39 041 5135 222e-mail: [email protected]: www.albint.com

Visit us at:ITMA 200322 to 29 October 2003The NEC, Birmingham UKHall 19 Stand DF19-1BSHANGHAITEX 200310 to 13 December 2003Shanghai New International Expo Centre, ChinaHall 1 Stand 1D13

where technologies and experience converge albany for textile... · 2014. 4. 1. · calator ruck...

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