Jakob Müller’s in-house machine with least expenses on spares
Juan Carlos Germann, Label Systems Product Manager, Jakob Müller AG, Frick, CH
At ITMA Asia, Jakob Müller AG introduced its new MÜJET MBJL6 air-jet label weaving machine. With a speed of 950 min-1 and a working width of 1,200 mm, the MBJL6 facilitates efficient production of labels, images and technical narrow fabrics with cut selvedges. The machine presented was for taffeta qualities with 54.6 warp threads per cm.
The robust and compact design of the MÜJET MBJL6 1/1380 is ideally suited for top production performance and offers proven Müller quality (Image 1). Its simple, clear design allows easy access to all the important machine components and control elements. Moreover, the MÜJET MBJL6 represents the systematic further development of the MBJL machine series and also employs tried-and-tested elements from the MÜGRIP MBJ6 rapier loom.
In comparison with its predecessor model, the working width of the MÜJET MBJL6 has been increased to 1,200 mm. Furthermore, a significantly higher production capacity has been achieved, thanks to a reed width of 1,380 mm and a speed of 950 min-1.
Shedding takes place using an electronically controlled SPE3 1536 jacquard machine with patented bottom shed read-in (Image 2). The jacquard machine is mounted directly on top of the basic machine, reducing the space required to a minimum. Additional advantages include a machine height of 3.65 m and its low weight. The new air-jet weaving machine can manufacture more labels per hour in a production area of only 2.05 m by 4.25 m and a reduced building volume.
High cost efficiency
Straightforward machine programming, great label production flexibility, short resetting times and minimum maintenance requirements guarantee high cost efficiency. The careful handling of the warp and weft material during production allows for top speeds and optimum efficiency. The MBJL6 is outfitted with MÜCAN controls, and various production conditions can be easily entered using a MÜDATA C-series touch screen (Image 3). Furthermore, the machine speed can be quickly and easily adjusted for every pick with the VARISPEED system.
The warp is provided on a warp beam with a maximum diameter of 800 mm. A controlled warp let-off system with a servomotor ensures quick and simple setting of warp thread tension.
Weft insertion
Weft insertion on the MÜJET MBJL6 takes place using standard main, acceleration and relay nozzles. The main nozzle is designed for the insertion of eight weft threads (Image 4). To remove threads from the weft bobbins, Jakob Müller AG recommends the ROJ Super Elf G2 weft thread storage system with layer separation and integrated thread monitoring. The arrangement of the weft colours can be adjusted using the “replacement and change” function. Apart from the individual regulation of air pressure, the retention air can be switched on and off separately, which provides a significant reduction in air consumption.
Optimising the relay nozzle positioning has also resulted in a further improvement to the overall weft insertion system. The compressed air system now consists of two air circulation loops, which can be used to individually adjust the left- and right-hand sections of the relay nozzles. This ensures stable and gentle weft insertion even at a machine speed of 950 min-1. Air consumption is around 60m3/h to 75 m3/h (four to eight colours) and the installed air volume totals 80 m3/h. The machine requires feed pressure of 800 kPa (8 bar).
The number of weft threads per centimetre can be quickly and easily adjusted via a torque motor using the VARIPICK system. This electronically-controlled fabric take-off allows the number of weft threads within a repeat to be varied between 18 picks and 120 picks per cm.
There is growing demand in label weaving for special effects and in particular in the production of labels for high-quality products. The MÜJET MBJL6 can process a wide selection of weft materials such as textured PES, untwisted, reinforced Lurex from 30 dtex to 250 dtex and other fancy yarns.
The cutting system
An important criterion for label quality is the cut edge. Labels with sharp edges are caused by temperature fluctuations in the cutting elements and often irritate the skin of the wearer. As such, they are frequently removed from the clothing. The MÜJET MBJL6 is fitted with the TC2 cutting system (Image 5). This ensures uniform cut quality with up to 120 cutting elements. Moreover, if desired, a second cutting beam can be employed when narrow labels with widths of 6 mm to 8mm are to be manufactured. A further option is provided by the cableless TVT2 cutting system, which enables creation of even softer cut edges.
For high-quality labels (Image 6), Jakob Müller AG offers its MÜSONIC2 ultra-sound label cutting machine. In a separate step, this machine cuts the pre-cut blank rolls on the label weaving machine to the desired width using ultrasound. The patented edge compactor and infinitely adjustable pressing force ensure markedly finer edge quality, which can already be monitored during the cutting process.
Label programming
Like other Jakob Müller label weaving machines, the MÜJET MBJL6 is programmed with MÜCAD pattern creation software, which is available in German, English, French, Spanish, Italian, Turkish and Chinese. The actual pattern creation process takes place once a motif has been selected. This involves pattern processing, the simulation of the woven product and translation into the control software of the jacquard machine.
Drafting and binding patterns are available for every textile product to ensure efficient operations. Having the option to define the bindings and backbindings for each weft sector as well as the input of any weave rules makes it possible to achieve markedly higher quality.
The MÜCAD base station can be supplemented with a variety of packages. MÜCAD DIGICOLOR is additional software for jacquard weaves produced using a digital weaving process. It allows for motifs to be realistically replicated in true colour by using five to seven weft colours to achieve natural colour effects.
The MÜNUMBER-MASTER software package serves the production of individually woven, distinctive and forgery-proof labels with either consecutive or random numbering. The specific data is already compiled during the design process to create a virtual label. Using an additional option, a visible bar code can be integrated into the label for mechanical scanning. Moreover, when used in combination with DIGICOLOR software, it is possible to integrate high-resolution, multi-coloured images.
MÜBARCODE software is employed for the manufacture of labels with visible bar codes. This programme provides a large number of standard market codes, such as PDF 417, Data Matrix, and QR Code, which can be generated and then subsequently implemented in the label.
Summary
The MÜJET MBJL6 was developed entirely in-house by Müller and is manufactured in Switzerland. Its high productivity and flexibility sets it apart from other machines on the market. A modern touch screen makes operating the machine extremely simple. Compared to its predecessors, the MBJL6 requires significantly less air. This reduction in consumption – made possible by a new nozzle configuration and the option of switching retention air on and off – enhances the value of the MÜJET MBJL6 from both an economic and an ecological standpoint. Moreover, during the design process, special focus was placed on reducing the number of wear parts, and this results directly in lower expenditure on spare parts.
As with all other Müller Group products, Jakob Müller AG offers a global customer service network staffed by experienced technicians for the MÜJET MBJL6. These specialists are stationed at centres around the world, many of which also have comprehensive stocks of spare parts, thus enabling quick delivery in an emergency.