Picanol News May 2011
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Picanol News May 2011

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Newsletter of Picanol focusing on weaving machines

Newsletter of Picanol focusing on weaving machines

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  • 1. Picanol NEWS PICANOL NEWS MAY 2011www.pic anol.be It’s all about winning, p. 2 Keeping the air consumption low with AirMaster, p. 6 The Picanol Quick Style Change system, p. 8 Picanol – 75 years in the lead with innovative technology, p. 10 Airtuckers with continuous reeds on OMNIplus 800 TC for tire cord, p. 16
  • 2. MAY 2011 Picanol NEWSIt’s all about winningIt’s been quite a year again, hasn’t it? After 2009 and 2008, during whichthe recession hit all of us very hard, 2010 seems to have been a turningpoint. At least for those among us with a winning mentality. 2Winners are the ones who get the most out of every single opportunity, 3who grasp every single chance. The ones who dare to reach out andseize the moment. Those who go for growth and act fast, with a long-termfuture in mind.So, are you a winner? Have you got the plans, the objectives, the talentand the stamina to make 2011 a winning year?Good. Because in that case, we’ll be there for you. Picanol has alwayshad one main objective: to make you “fit to win”. We aim to give you allthe tools you need to be successful in your market: the machines andservices, the know-how and dedication of our people. Being fast, reliable,flexible and cost-efficient ourselves, we want you to win. Because whenyou win, we win too.Let’s say we’ve gathered more than enough fuel to start 2011 in poleposition. Want to keep ahead of the competition? Buckle up!Luc Tack, Managing Director Picanol
  • 3. ‘The energy-friendliness of the Picanol machines lowers our ecological footprint.’ ‘At Cedro, preserving the environment is more than a slogan, it is the expression of good sense and respect for nature. That’s why we try to reduce waste as much as possible, since weaving waste is also waste of energy. That’s one of the reasons why we have chosen for Picanol airjets for our weaving department. Besides quality and performance these machines guarantee the best energy/ output ratio in the market.’ ‘We are running with mill efficiencies of 93% and above, thanks to energy-saving technologies.’ Mr. Aguinaldo – Cedro Textil (Brazil) ‘Insertion rate and tuning time, two speed aspects where Picanol is unbeatable.’ ‘When weaving high-value products, such as elite shirtings, suitings and other fine dress material, the fabric range is enormous. Here the Quick Style Change (QSC) system on Picanol machines has proven to be a real asset. This in combination with high insertion speed guarantees us an efficiency of over 90%.’ ‘We have invested only in the latest technologies, giving us an enormous competitive advantage.’ Mr. Dalmia – Century Textiles and Industries (India)‘There are no seconds in high-end syntheticindustrial fabrics!’‘We always go for the most stringentrequirements, not only from our yarns, butalso from the production equipment onwhich it is processed. That is why we chosefor the OMNIplus 800 to take care of theweaving. With efficiencies of 98% and abovePicanol gets the most out of our material.’Mr. Albert Schneider and his grandson –Schneider Mills (USA)
  • 4. MAY 2011 Picanol NEWS ‘Picanol takes talent further.’ ‘The imagination of our designers has no limits. That’s why we needed technology that can cope with this talent. Thanks to their flexibility and modularity, Picanol weaving machines can handle the most versatile fabrics without compromising on pattern complexity or efficiency.’ ‘Creativity has brought us where we are now: a leader in production of women’s clothing and tie fabrics.’ Mr. Taborelli – Tessitura Serica A.M. Taborelli (Italy) 4 5 ‘8000 new fabric versions for every collection!’ ‘At Monti we want to keep the distance between market demand and production capacities as small as possible. That’s why we already opted for the flexibility of the Picanol weaving machines many years ago. They permit a quick reaction to the changing market requirements, which is essential when exporting to more than 90 countries like we do, from Asia to the Americas, and from Europe to Australia!’ ‘Formed with the mission to be the world leader in the shirting fabric market.’ Mr. Monti – Tessitura Monti (Italy)Want to learn more about these winners and their companies?Go to www.picanol.be/fittowin
  • 5. Keeping the air consumption lowAirMaster AirMaster integrated on OMNIplus 800Packed with features for reduced air All data on air consumption can be retrieved byconsumption the monitoring system. This enables the userAlong with yarn and labor, energy is a major to monitor and compare air consumption oncost factor for airjet weavers. The big challenge different machines running the same style. Thefor weavers is to keep power consumption result is that the user has full control over airunder control, especially air consumption. consumption.For many years Picanol has focused intently Working on its ownon keeping the air consumption of its airjet AirMaster covers all the different aspects of airweaving machines as low as possible. Picanol consumption. Not only does it allow users toairjet weaving machines feature a double air measure and manage the air consumption oftank for the relay nozzles, high-performance their machines, thanks to Picanol’s integratedmain nozzles, multi-hole relay nozzles offering concept it is also possible to carry out a fullythe best performance/consumption ratio, two automatic testing procedure that detects leaksrelay nozzles per valve, fast and responsive in the compressed air circuit. The user decidespneumatic valves, adaptive insertion control, when to carry out this test and the machineseparate control for both fixed and movable does all the rest. A detailed report informs themain nozzle etc. They can also offer features user if a problem is detected during the test.such as ARVDplus, which automaticallyadapts the opening and closing time of the Needless to say the AirMaster system fullyrelay nozzle valves to the behavior and air- meets the requirements of all leading airjetfriendliness of the filling yarn. weavers. Today 20% of the airjet machines produced in our Ieper plant are equipped withKeeping track AirMaster.Keeping the air consumption at a low level alsomeans that users must be able to monitor air AirMaster can of course be seen in action onconsumption and check the condition of the our airjet weaving machines on display at theinsertion system on a periodic basis. And that ITMA show in Barcelona later this year.is exactly what Picanol’s new AirMaster systemoffers. The main feature of the AirMaster is anelectronic air consumption meter. This devicecan be fully integrated in each airjet weavingmachine, or it can be used as a separate toolconnected to the machine. In both cases there isan electronic link between the machine and theelectronic air consumption meter.
  • 6. MAY 2011 Picanol NEWS AirMaster is also available as a Weave Up product. 6 7Visit Picanol at ITMA!22-29 September 2011Barcelona, SpainHall 3 C140 and C142
  • 7. Picanol Quick Style Change (QSC)How an efficient pitstop makes you win the raceSince the introduction of the first airjet weaving With more and more weaving mills workingmachines in the early sixties, airjet technology with smaller batches, it is not possible to takehas progressed by leaps and bounds. Whereas advantage of the bigger volume afforded by thethe first airjet machines with a reedwidth of larger warp beam diameters. Moreover, delivery125 cm ran at 350 to 380 ppm, speeds of times need to be shorter than ever before,1000 ppm and more are now considered normal. requiring an increasing flexibility in the weavingOn rapier machines too, speeds are now in shed. In these cases, a high machine speed isthe range which just a few years ago were the not the (only) solution, but also the time forexclusive domain of airjets. For rapier machines, style change must be reduced to an absolutespeeds of 600 to 700 ppm are considered to be minimum. The key to success is to keep theproven industrial speeds. machine running during the preparation work for the style change.To take advantage of these higher speeds,larger warp beam diameters are used to afford QSC on OMNIplus 800 and OptiMaxlonger production runs. But even when using As we all know, the residual cost- & time-saving1000 mm or 1100 mm warp beams, a heavy potential in a modern weaving mill lies indenim style beam is woven within less than reducing downtime for warp and weft stops, for3 days. Larger warp beam diameters have style change and knotting, and for maintenance.their own disadvantages such as the need for Obviously, these stops become more and moreadditional floor space, longer downtimes because important as weaving speeds increase. Even in aof difficult handling for stop repair, loss of well organized weaving mill the standstill for aefficiency caused by additional stops due to more style change can be between 4 and 5 hours.difficult warp beam preparation, and the need A simple beam change (knotting) takes betweenfor expensive transport systems. 1 and 2 hours depending on the total number of ends. With the unique Picanol QSC, downtimes for style changes can be cut to 30 minutes.
  • 8. MAY 2011 Picanol NEWSThe development of new loom generations with The QSC system offers several advantages,split frame offers the ultimate solution. This is resulting in a higher efficiency and productionachieved by swapping the whole back part of the rate, while keeping first quality fabric:split frame, including the warp beam, the back • First quality fabric, due to:rest and the supports, the warpstop motion, the - Fewer crossed warp ends, and so fewer stops,harnesses and the reed. - Clean heddles, frames and reed, - Fewer seconds when starting up the loom. 8The system allows the flexibility to choose • Fewer operators in the weaving shed, due to:between warp change (knotting) and style - Less stops, 9change. The knotting can be carried out in a - Easier cleaning and maintenance of themore suitable area outside the weaving room. machine,Time-consuming mechanical settings in case - Mechanical settings done in the preparationof a style change (presetting the shed height, department, so only electronical settings topositioning the warp stop motion, complete be loaded in the weaving shed.setting of the backrest and setting up the • Improved flexibility for weaving a variety selvedges) are now done outside the weave room of styles and rapid response to samplingbefore style change. Substantial savings in total demands.time can be achieved by moving these operations • Faster deliveries: for big orders, as the effort to out of the weave shed to the weaving preparation divide the order over several looms is not thatdepartment, also enabling the operators to big anymore; for small orders, as you can easilycarry out these operations in a more pleasant switch a loom from one article to anotheratmosphere and under more favorable conditions. without having lots of downtimes. • Less stocks.Harness frames are presented as a package withthe drive elements. Starting up the loom is The QSC system described here, as developedspeeded up by using a foil welding tool to fix by Picanol and used for nearly 20 years in athe warp ends between two plastic sheets. This great many weaving mills around the world,prevents crossing ends during transport and represents a revolutionary step towards ansimplifies the start-up of a new warp or style. “operator-free weave room”. It offers the fashion- oriented “Just-in-time” weaver the opportunityThe split frame system also ensures maximum to supply goods faster and at competitive prices.accessibility for maintenance and greasing of the Only weaving mills that are able to producemachine frame inside the weave room as well as exclusive fabrics with long-lasting warps canof the module outside the weave room. A good afford to forego this QSC system.maintenance is the best guarantee for preventingunexpected breakdowns. A well-performed With QSC, the race will be won at the pitcleaning of the loom can only result in improved stop.productivity and fabric quality.Improving flexibility – IncreasingproductivityWinning an order is not only driven by thecost (increased productivity), but also by a fastdelivery time (improved flexibility).
  • 9. 1936-2011 Picanol – 75 years in the lead 75 with innovative technology On 22 September 2011, the first day The Picanol story really goes back to 1928. of ITMA, Picanol will celebrate its 75th In that year a company was founded with birthday. Over the space of seven and the rather unwieldy name of “Vansteenkiste a half decades the Picanol Group has Company to Promote Industrialization of Flax developed from a traditional builder of Fiber Production, Foundry and Workshops,” weaving machines to a worldwide supplier forming the basis of the later Picanol. The of global solutions for the textile and Steverlynck family was represented on the other industries. 75 years in the lead, board of directors when the company was first thanks to innovative technology, during set up, with Baldewijn Steverlynck (1893- which Picanol has played a pioneering role 1976) as chairman. This marked the appearance worldwide in development and production of the Steverlynck family in the industrial of high-tech weaving machines. development of the Ieper region, in which it played a leading role throughout the 20th century. When the great depression of the 1930s made the situation precarious for the Vansteenkiste company, Baldewijn Steverlynck teamed up with Juan Picañol, who had sought refuge in Flanders from the Spanish civil war. Juan had invented a revolutionary weaving loom at his father’s engineering works in Sabadell (Spain), but he still needed a partner to put his plans into effect. So why take 1936 as the baseline for 75 years of the Picanol Group? Because 1936 is when the name Picanol (then spelled Picañol) first appeared. The Vansteenkiste Company formed the basis of the later Picanol. The first Picanol factory was established in the Polenlaan in Ieper.
  • 10. MAY 2011 Picanol NEWS5Karel Steverlynck Jaimé Picañol 10The actual beginning - whats in a name? The war years: bartering looms for fishWith no end to the worldwide depression in and oranges 11sight, the Flemish machine builders and the In just a few years the company achieved anCatalonian inventor entered into negotiations. annual output of 120 Omnium machines andThese led to the formation of “Weefautomaten by the outbreak of World War II the levelPicañol NV” on 22 September 1936, marking had risen to one machine per day. But the warthe birth of the company as we know it conditions put a spoke in the wheels. Rawtoday. The Steverlynck family expressed their materials became scarce and output plummeted.gratitude by naming the company in Ieper Exports could only be maintained by barteringafter the Spanish inventor. However, Juan for food, with weaving machines beingPicañol’s modernized looms did not live up to exchanged for fish products from Denmark andexpectations, and the Steverlynck family called sardines or oranges from Spain and Portugal.on Jaimé Picañol (Juan’s younger brother) to After the war these export machines were thelead the development work. By the end of 1936 company’s first foreign references and helpedand after a lot of improvements, the company considerably to establish Picanol’s name aroundwas finally ready to launch the Omnium. This the world. In late 1946 the managementwas the first Picanol machine to enter mass decided to set up the foundry once more.production, laying the basis for later triumphs. With the new shock forming machines it was possible to mold the sand under pressure and break it out quickly after casting. In 1948 the foundry was equipped with a new laboratory for mechanical, metallurgical and chemical research. During this period Picanol became one of the first companies to use synthetic sand for its foundry molds. The Picanol foundry in the late fourties. 1936-2011
  • 11. 1936-2011 The 1950s The 1960s In 1951 Picanol presented its new President The demand for weaving machines gradually weaving machine to the public at the ITMA began to exceed supply. The average of 140 75 exhibition in Lille (France). This machine was machines per week was no longer sufficient such a success that the Picanol management to meet all the orders that were coming in, decided to expand production and to appoint and so it was decided to move to another representatives in other countries. A network location. In the spring of 1961 the company of agents was gradually built up, extending to built an impressive assembly hall in the new South America and the Far East. Meanwhile, industrial area. In 1962 the company invested production of the President created employment in setting up a new foundry. Picanol opted for hundreds of people in Picanol’s home for the most modern casting technique then region. The number of personnel expanded available, namely the high-pressure method. from 200 in 1945 to 700 in 1952. In 1958 By November 1966 a fifth of the cast iron Picanol unveiled a new version of the President output was being produced in the new foundry. at Expo 58, the world fair held in Brussels Picanol of America was set up in 1966 with that year. However, the textile industry was responsibility for the activities in the USA experiencing a worldwide downturn at the time and Canada, considerably strengthening the and the market remained flat, so Picanol went company’s position there. Later this subsidiary in search of new sales territories. Among others moved to Greenville, the center of the American it made an agreement with the Saco-Lowell textile industry. company, which represented Picanol in the USA and Canada. In 1960 the Omnium went The 1970s out of production, leaving only the President At the ITMA exhibition in Paris in 1971, in a series of smaller types. From the end of the Picanol surprised the textile industry with Second World War until 1955 Picanol had sold the MDC, the world’s first electronically more than 8,000 Omniums. By the beginning controlled flying shuttle machine. Research and of the 1960s Picanol had a wide range of development started to play an increasingly weaving looms for weaving spun yarns and the important role. In 1973 a new type of weaving Picanol looms were increasingly able to handle machine entered production: the Diplomat, an synthetic materials as well. inexpensive machine for weaving standard, light fabrics. But the end of the flying shuttle era was in sight. New assembly hall in 1951. Working at the new foundry, 1962.
  • 12. MAY 2011 Picanol NEWS5 The very last Picanol flying shuttle machine, ready for shipment, 1988.New assembly hall for production ofthe new GTM machine in 1983. 12 13The 1980s The 1990sIn 1980 Picanol introduced the revolutionary At the beginning of 1990 Picanol producedPAT airjet weaving machine. In 1983 Picanol a record number of machines and scored itslaunched a successor to the PGW machine, the highest ever sales. But an abrupt end to thisGTM. In 1985 the company built a new, success came in the second half of the year, due4,000 m² production hall for all the to the downturn in the economy, the recessionCNC machining centers, along with storage in the USA and the Gulf crisis, with manyfacilities for spare parts. In 1987 the company orders being cancelled and others postponed. Inset up the Picanol Service Center in Shanghai. the next few years more than 150 people left theThat same year it built its last flying shuttle company. Picanol did not allow these setbacksmachine and shipped it to Indonesia. In 1989 to blow it off course but instead invested in newthe foundry division was split off from the other assembly lines, new equipment and assemblyactivities and made into a separate company, robots. R&D too continued to play an essentialProferro NV. Also in 1989 Picanol acquired role. In 1992 the company introduced a newa stake in what was then Protronic (now generation of airjet weaving machines, thePsiControl Mechatronics). OMNI and the DELTA. In the following year the group expanded further with the setting up of the joint venture Suzhou Picanol Textile Machinery Works (SPT). Assembly of weaving machines began in China in 1995 with the GA733 (the Chinese version of the GTM-A). In 1996 Picanol (Ieper) introduced the Gamma, an entirely new rapier weaving machine. The German company Günne Webmaschinenfabrik was acquired in 1998. In 1999 Picanol acquired the other 40% of the shares in SPT and set up Picanol Suzhou Textile Machinery Ltd (PST) as a fully-owned subsidiary. 1936-2011
  • 13. 1936-2011 elotte Direct Digital Manufacturing 2000-2011 There followed a period of national and international expansion, with a number of takeovers as part of the strategic expansion of Picanol’s OEM activities. Verbrugge NV in Belgium and Steel Heddle Inc. in the USA were acquired in 2001. This was a first step to enter the market of hybrid frames. In 2003 among others Burcklé in France joined the group, while GTP Bandung was set up in Indonesia, GTP São Paulo in Brazil and GTP in Mexico. The Picanol Group was that time adopted as the collective name for all the group’s activities. In 2005 the OMNIplus 800 airjet machine was launched on the market. Meanwhile, more new machines were introduced: the OMNIjet, the OMNIplus 800 TC and the TERRYplus 800, 75 followed by the OptiMax and the GT-Max in 2007. In 2007 the group further expanded its international presence in China, India and Romania. The shareholder structure changed in 2009 as a result of the capital increase, with Luc Tack becoming the reference shareholder and managing director. In 2010 the Picanol Group was able to get back into profit. Picanol extended its product range with its new airjet weaving machine, the OMNIplus-X, and the group also moved all Ieper activities to Karel Steverlyncklaan, where its main production and R&D activities are located. June 2010 saw also the 300,000th weaving machine come off the production line since loom-building activities first commenced in Ieper.
  • 14. MAY 2011 Picanol NEWS 14 155Blog siteIn January 2011 we marked 75 years of the PicanolGroup with the launch of a blog site focusing on therich history of our group. In this blog we review thehistory from the very early start in 1936. Read more athttp://www.75yearsofpicanolgroup.blogspot.com. 1936-2011
  • 15. New on Picanol OMNIplus 800 TC weaving machines for tire cordAirtuckers with continuous reedsThe need for closed selvedges require closed selvedges because of their use.Shuttle weaving machines offer nice, closed Other fabrics such as tire cord need closedselvedges thanks to the weaving principle itself, selvedges to allow further processing.in which the weft yarn loops around the outsidewarp when the shuttle returns to the other side. One of the methods most frequently used toSince the introduction of shuttleless systems, obtain closed edges in these fabrics is tucking-however, the wefts are inserted from the same in: the fringe is turned back into the fabricside and cut to length, leaving a fringe at both before the next pick is inserted. This is done bysides of the fabric. But some fabrics such as means of a needle or even a burst of compressedsheeting, African damask and worsted wool air.
  • 16. MAY 2011 Picanol NEWS Closed selvedge 16 17 Selvedge with fringe Tucked selvedgeTire cord has special requirementsTire cord is used to reinforce the tire carcassesfor cars, motorcycles and even bicycles. Itconsists of viscose, nylon or polyester cabledyarns, called cords, that are crossed with cottonor elastic core-spun wefts. With only 1 to 0.4picks per cm the pick density is very low. In factthe amount of weft material in the fabric is lessthan 3%! This part of the fabric is called cord. Tire cord with tucked selvedge
  • 17. In order for it to adhere well to the rubber reduced, thanks to fewer moving parts and thecompound in the tire, the tire cord needs to be elimination of oil lubrication.impregnated and baked at high temperaturein a process called dipping. Since this process Customers who still have mechanical tuckersis continuous, customers want to wind the tire can easily convert their machines to airtuckerscord on huge cloth rollers as much as 2 meters with continuous reeds. This means theirin diameter. The pick density at the beginning existing stock of profiled reeds can be used.and end of the cloth roll must be much higher,so that the end of the previous roll can be One version of airtuckers with continuous reedsstitched to the start of the next one. This will be on display at the ITMA show inreinforced strip is called the tabby. Barcelona later this year.On a tire cord weaving machine, the tuckersneed to form a tucked selvedge in the opencord as well as in the very dense tabby section.New: airtuckers with continuous reedsBefore the introduction of the OMNIplus 800 TC,our tire cord weaving machines were equippedwith mechanical tucking-in devices usingneedles. A major advantage of this system isthat the profiled reed can be continuous overthe width. Using continuous reeds means thatthe stock of rather expensive profiled reeds canbe kept to a minimum. When only the widthof the fabric changes, the reed does not have tobe replaced, saving hours of work.Thanks to intensive re-engineering of theexisting airtuckers, Picanol has managed tomodify the airtucker units so they move withthe reed holder. This means that one of thedisadvantages of airtuckers – having to cutthe reed to the width of the fabric – has beeneliminated! At the same time, the quality ofthe closed selvedges in the cord and in thetabby section matches the excellent mechanicaltuck solution. In comparison with the previoussystem a considerable increase in speed canbe achieved. Needless to say maintenanceand servicing requirements for airtuckers are
  • 18. MAY 2011 Picanol NEWSFinancial results 2010Picanol Group realizes a58% increase in turnoverIn line with the previously outlined It has been decided not to pay out a dividendforecast, the Picanol Group realized a for the 2010 financial year. This will enableconsolidated turnover of 395.77 million the Picanol Group to make the necessaryeuros in 2010, an increase in turnover of investments to make the group even stronger58% compared to 250.23 million euros in for the future.2009. The Picanol Group expects the world market for 18The strong increase in turnover was realized in weaving machines to remain at the same levelboth the Weaving Machines division and the in 2011, but remains cautious in light of the 19Industries division. The Weaving Machines volatile world economy.division experienced a strong year in 2010following the quicker than expected recoveryof the weaving machine market, which wasmainly driven by a strong demand in Asia. TheIndustries division also showed a strong externalgrowth in 2010.If you want to receive Picanol News, pleasefill in this form and return it to us.Mr./Mrs.:Company:Job title:E-mail address:Postal address:Please fill in and return by mail to Picanol News, Karel Steverlyncklaan 15,8900 Ieper, Belgium or by fax to +32 57 222 001, or send your request andcontact details by e-mail to info@picanol.be.Please put me on the mailing list for the paper version of Picanol News.Please put me on the e-mailing list for the electronic version of Picanol News.
  • 19. 2011IS ALLABOUTWINNINGPicanol has always had, since its existence,one main objective: to help make you“fit to win”. We want to give you all thenecessary tools to be successful in yourmarket and win: machines, services, theknow-how and dedication of our team andour people.We’ve all had tough years to strugglethrough. At Picanol we know the only cureto fight this is to work even harder. Ourmotivation and determination have broughtus to where we stand today.By now our knowledge and expertise is widerand sharper than ever. And it’s to you to takethe advantage. Picanol News is the newsletterLet’s say we’ve gathered more than enough offuel to start 2011 in pole position. Want to Picanol nvkeep ahead of the competition? Buckle up! Karel Steverlyncklaan 15 BE-8900 Ieper Belgium Tel. + 32 57 222 111 Fax + 32 57 222 001 www.picanol.be www.picanolgroup.com info@picanol.be Chief editor: Erwin Devloo Subscriptions: Picanol News is free; if you want to be added to our mailing list, please fill in the subscription form and return it to us, or subscribe on-line at www.picanol.be.