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Leading provider of air texturing and interlacing jets, Heberlein has also used its experience to create a special air-saving method for a seamless and effective weaving operation. Compared to previous jets, the Heberlein WarpJet-KV requires up to 38% less compressed air.
Yarns with smooth surfaces are necessary for effective processing in warp knitting and high-speed weaving processes. Sizing and air interlacing are two unique processes that are needed to provide the necessary yarn quality. Sizing is less preferred when considering sustainability because it requires water to remove after weaving, resulting in significant pollutant burdens.
Karl Mayer, a top producer of warp knitting and weaving preparation equipment, turned to Heberlein to create a new interlacing method. Heberlein was a reliable name in filament yarn processes, and its expertise with air jets made it a perfect partner. In 2015, they began working together to develop a brand-new air interlacing technique that offers significant cost benefits for both the warp preparation process and the next fabric production steps.
Creating dependable intermingling sites has multiple advantages because it prevents the weaving machine from stopping due to friction from broken filaments or shedding problems with filament apertures. Therefore, weaving proceeds at faster speeds, which also makes it possible to apply less size.
When the process requires the highest level of efficiency and yarn strength, Heberlein's high-precision components can be employed. To accommodate specific needs throughout the weaving process, the WarpJet-KV can increase the intermingling points to 60 to 90 per metre, or roughly treble the typical number. 15 to 30 nips per metre are typically allowed at common spinning speeds of 4,500 to 5,000 m/min, which may be enough for a seamless weaving process. Still, a lot of mills would rather be cautious than sorry, especially when working with yarns that are ≤ 75 denier and DPF ≤ 1.0. For this reason, they choose to install the Heberlein intermingling device.
The air pressure required to ensure a higher number of intermixing points and filament cohesion—especially with fine yarns—is the second crucial factor. An air blast physically intertwines the individual threads of a multifilament yarn during air interlacing.
Lower energy expenses are the outcome of using less compressed air during the air interlacing process. The Heberlein WarpJet-KV serves as evidence for this. Tests conducted at the same machine with 1,536 threads and the same air pressure level reveal that the WarpJet-KV can save between 307 and 491 m3/h when compared to a normal jet. The savings total 38% when comparing the air pressure required for the same number of intermingling points (FP/m). 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.
The requirements for warp knitting are intricate and demanding. Under the tenet of sustainable production, uncompromised yarn quality with the maximum production efficiency at the lowest cost is essential. This makes it the perfect moment for a refit using the Heberlein WarpJet-KV, a tried-and-true solution. Based on the identical air consumption and intermingling point stability requirements, the figures demonstrate interlacing performance up to 10 to 30% higher than rival jets. For an equivalent number of intermingling sites, air consumption can be reduced by 13 to 40%.
Heberlein's WarpJet-KV can be installed on Karl Mayer machines by retrofitting by altering the primary air connection. Up to 64 yarns can be interwoven in one unit thanks to the jets' modular architecture. Customers benefit from the simple JetPack exchange process and, as is usually the case with Heberlein jets, simple maintenance, cleaning, and replacement, depending on the application.
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