KL 970

Modular manufacturing system (sewing) for filter bags

Features

The KL 970 is a high-efficient and full-automatic manufacturing unit for manufacture single filter pockets, e.g. filter pocket cassetts for air filtration.The systems (lightweight construction) have a modular structure and can be configured and implemented individually according to customer requirements (material and application). They are fully PLC controlled and operated via a modern HMI panel.

Unwind stacker/Infeed station

Unwind stacker is equipped with roll lifter for up 4 rolls of material
Material end control by means of a photocell in connection with a hand sewing machine
Infeed station with edge control for an exact and tension-free material feed
Edge control – possible for two or four or six layers

Multi-needle sewing station

Stitch type 101: Single-thread chainstitch (predestinated for the use on production units)
Equipped with up to 12 needles working in parallel
Single needle margin: max. 70 mm, max. sewing width 770 mm
Stitch length: max. 35 mm
Infeed station with material feed for two material layers
Thread feeding system to reach the requested stitch loosening between the two material layers (pneumatically adjustable in 3 levels)
Stitch loosening: 20 – 60 mm
Length of free stitch: up to 100 mm (free programmable)
Sewing speed: approx. 400 s.p.m.
Further details see: Finishing methods

Hot-melt station

Fixing the single thread chainstitch seams and sealing the penetrated needle holes
Glue station with 12 heatable application nozzles, individually switchable in 8 glue heads as required
Proportional glue supply adjustment (to material and speed) in automatic mode – adjustable on the control panel
Width of glue path 8 mm
Free programmable hot melt interruption at the point of intersection (at the beginning and at the end of the pocket)
Blower unit for fast cooling of the hot glue application
To avoid thermal damages to the filter fabric during stop-mode, the glue heads lift is programmed

Side-seam sewing station (with or without tapering)

Movable Pegasus 4-thread double needle overlock sewing machines (left/right) for manufacture of filter pockets with tapered or straight side seam (electro-motorically controlled, corresponding to the speed of the unit)
Sewing speed: approx. 6,700 s.p.m.
Thread movement monitoring of the 4 threads
Synchronization of the material feed and the sewing speed of the sewing machines
The side seam sewing machines can be moved sideways in automatic mode (tapered style)
The sewing contour (tapered style) is freely programmable and reproducible via parameters
Continuous edge trimming (right/left) by the knifes, integrated in the overlock sewing machines (= pocket width)

Cross-seam cutting unit

Cutting system HSCS II (servo-motorically driven double cutting blade for all materials)
Fabric transport system with coupled filter material downholder device (during the cutting process)
Winding station (only in connection with HSCS II) adapted to the cutting unit
Cutter outlet unit (for the single- and double bottom station)

Double-bottom sewing station

To close the cut to length filter bags at the bottom of the bag with TWO* transfer devices (from the cutting system to the respective bottom seam sewing station)

TWO* right-handed Pegasus 4-thread overlock sewing machines with top feed
TWO* thread guide control units for 4 threads
TWO* transport belt systems for pocket feed through the overlock sewing machines
TWO* electropneumatic warp scissors, integrated in overlock sewing machines

* Each ONE on the single bottom sewing station

Further components

Compensator for continuous processing while changing the material
Stacking device for manufactured filter pockets
Suction device for removal of cutting waste from the overlock machines at the side-seam station and at the bottom-seam station (Option)
Ink jet printer for customer specific print during the manufacturing process, printing width 12 or 24 mm (Option)
Depending on the processing (double bottom seam, single bottom seam, processing “roll to roll”) the following equipment variants are possible:

Finishing methods in detail:

Roll-to-roll
Continuous production from the roll to the roll

Single bottom seam
Single bottom seam, cut to the desired size of the pocket by the overlock machine of the bottom seam station

Remarks:

Multi-needle machine processes with sawtooth principle (only right pockets)
Pocket opening max. 100 mm
Only a straight sewing contour is possible on side seaming station

Double bottom seam
Double bottom seam, cut to the desired filter pocket size by the overlock machines of the bottom seam station (depending on the orientation of the pocket) to the right or left side of the machine

Remarks:

Multi-needle machine processes with wave-form principle (right and left pocket lying opposite)
Pocket opening max. 100 mm
Side seam with sewing contour “Tapered or straight pocket style”