| Micro Processor Based Pneumatic Fabric Stretching System |
 |
|
| |
Today when world demands quality, consistency with economical prices no
one can afford rejections especially due to problems in screen making.
Some times we pay lots of attention on a quality of material but we forget to
pay attention on our process and the way we use those quality materials.
Finally no one gets proper justification. We purchase and inquire always for
best Polyester Fabrics available in the market but lets ask ourselves that are
we paying attention on our stretching system or the service provider who
supply’s you ready made stretched screen are they quite equipped to give
you quality with consistency.
If we calculate the screen making cost in our production it works out to be
marginal if its made right from the beginning. The only part which makes
screen making process or screens expensive is the way we prepare our
screens.
We all know that in screen printing, screen is the heart of printing and when we talk about screen it means
Fabric (Mesh), Aluminum (or Metal) Frames, Adhesives and Stretching System.
After knowing and experiencing the problems we have designed this unique trouble free system which offers
lot of flexibility and also help to achieve quality with consistency (repetition accuracy).
|
| |
| The following are the factors which affects the screen making cost : |
| |
- Supervision cost
- Man Power
- Remaking
- Job rejection
|
Its an optional feature and should be specified in your inquiry or orders. Currently available
only on our Semi Automatic CAM SHELL series (For print area: 20”x30” & 30”x40” only) |
| |
| Comparison an ordinary stretching system with an micro processor based system : |
| |
| KEY POINTS |
Regular System with
control panel |
Micro Processor based
system |
| Man power cost |
One full time person required |
Person only required to clamp
the fabric rest operation is
automatic |
| Tension lost after stretching |
2 to 10 Newton |
1 to 2 Newton thus depends on
Fabric Manufacturer and Grade |
| Fabric breakage |
Most likely |
Least likely |
| Repetition accuracy |
Depends on operators skill |
100% if the fabric quality is
consistent batch to batch |
| Registration Accuracy on Multi
Color Jobs |
Depends on operators skill |
100% if the fabric quality is
consistent batch to batch and
machine parameters are set
correctly |
|
| |
| How to eliminate the error in stretching? |
| |
| The only solution is to change to an automatic stretching system. |
| |
| Few examples why an automatic stretching system is important : |
| |
- Repetition accuracy.
- To achieve close tolerance registration.
- Maintain tension and consistency.
- Minimize labor and supervision cost.
- Reduce cost.
- Eliminate errors.
- Cut down rejection cost.
- Increase production speed with consistency.
- Minimize tension loss after stretching.
- Reduce risk of fabric breakage especially when stretching 27 micron fine threads.
- Achieve higher print runs without tension loss.
- Optimum use of fabric.
|
| Regular stretching system with manual control panel : |
| |
The control panel is coupled with FRL (Filter Regulator Cum Lubricator) to filter the moisture content from the
Air + lubricates the cylinders but mainly used for setting the max tension level. Direction control valve to
stretch & release the air pressure. Flow control valve to set cylinder speed. Rest all depends on operators
skill and system standardization and we all know that the labor never follows the given instructions most of
the time it might be due to pressure in production which ends to speed up the stretching process or what so
ever. In an automatic system the risk of error from operator side is completely eliminated and he is forced to
follow the system parameters strictly. |
| |
| Disadvantages using manual control panel : |
| |
-
Regulator can be set to max pressure as per the tension requirement or increase gradually in intervals
with continuos supervision which again requires full attention, skill and patience.
-
Flow control valve at high tensions takes time and some times lead to air trap in the cylinder.
-
Continuos man power and supervision required.
|
| Fully automatic Micro Processor based stretching system : |
The control panel is coupled with FRL but instead of direction control
valve and flow control valve it is replaced with a microprocessor system
to control the air speed max with adjustable tension levels. This system
is designed to stretch the finest fabric without much tension loss and
maintain consistency throughout the process. It stretches smoothly and
slowly on both directions (warp & weft) and does not disturb finer
threads and maintains mesh geometry thus reduce risk of fabric
breakage. It stretches in five stages and at every stage there is an
interval for few seconds before it goes further. Once it reaches the final
tension it stretches and releases two times to minimize the elongation
properties from the fabric. This help to get the optimum result from a
particular fabric and maintains tension levels in longer print runs thus
reduce risk of rejections due to registration accuracy.
A user friendly keypad on the micro processor allows operator to set desired tension levels rest all
controlling parameters are set in the processor to avoid human errors in stretching.
The complete stretching cycle takes approx. 7 to 10 min where in no one can change any parameters once
the start push button is pressed to begin the stretching process. One the stretching process is completed an
led indicates the operator to start gluing.
Once the push button is pressed the operator has 7 to 10 min to prepare next screen or to continue with
other work with saves companies time and minimize man power cost.
So why to wait for save money and time, increase profit and quality call us for a free demo at our works. |
| |
 |
|
| |
