Carpet Yarn Heatsetting

Happy Valentine day!

On the 14th of February was Valentine Day. In our company it is customary that all women get a bunch of flowers.

We were happy about this nice gesture and want to thank our management for their generous mindfulness!

Acrylic Bulking with Power-Heat-Set

Acrylic fiber is thermoplastic (heat sensitive) similar to polyester and nylon, but is even more heat sensitive. Acrylic, because of its heat sensitivity, can be closely  made to resemble wool, due to its high bulking power. The fibers are strong, absorb very little water, and are resistant to most chemicals likely to be encountered in normal use.

High bulking acrylic yarn is produced by mixing high shrinkage fibers with low shrinkage/non-shrinkable acrylic fibers and then spinning it into a yarn.

When the yarn is subjected to steaming or hot air treatment, high shrinkage fibers shrink and force the non-shrinkable fibers to buckle, thus increasing the voluminosity of the yarn.            

For bulking, acrylic yarns are generally subjected to steaming for 20 min. Studies made with acrylic fibers found that yarns made of coarser fibers resulted in more voluminous yarns when treated in hot air as compared with steaming treatment. The best crimp contraction for coarser yarns (i.e. carpet yarns) will be achieved by hot air treatment with approx. 100°C for approx. 10 seconds.

With our Power-Heat-Set GVA equipment you can determine individually the temperature and the duration of the hot air treatment. Additionally, with a Power-Heat-Set type 5000, e.g. a GVA 5000 belt version, you can mix the bulking process by using the first chamber for the hot air treatment and the second chamber of the GVA 5000 for steam treatment.

Acrylic Balking with Power-Heat-Set equipment based on Internet research results with following links:
http://cms.americanthreadcleaners.com.content/view/4/37  http://personalpages.manchester.ac.uk/staff/mike.wilding/Textile%20Materials/Handouts/MATS-10061-FJW-B11-Acrylics-Elastomerics.pdf                            

Overheated steam vs. saturated steam

We are exicted about our development of our new compact Heatsetting (CHS) and that we are able to offer our customers now both systems:

– The open systems with overheated or superheated steam, the so called GVA-machine!
AND/OR
– The closed system (under pressure) with saturated steam, the compact Heatsetting (CHS)!

Both systems are equal to each other and depending on what quality the carpet market wants to have our customers can now decide about what to buy from Power-Heat-Set.
The main differences (especially for PA) are:

GVA (overheated steam):
In the most recent five years Power-Heat-Set have placed more than eighty GVA machines in the world wide carpet industry. For all BCF, as well as, Staple Fibres like PA6, PA6.6, PP, PET, acryl, or wool blends. Besides others the latest development for the GVA 5000 are focused on three important areas:

• Energy conservation improvements are centered on optimizing the window configuration and special passges or recycle exhaust to utilize the heat in the exhaust before it leaves the machine. Energy savings are increasingly valuable in justifiying expenditure for new machines.
• The combination of the Twin Roll Box (TRB) and coiler bring a new level of flexibility to the GVA 5000. Quick changeover from one system to the other and the ability to process frieze and straight-set yarns on the same machine at the same time are definite advantages. The unique design of the Twin Roll Box allows the production of a wide spectrum of textures  through simple , repeatable touch screens adjustments.
• New yarn path improvements allow efficent processing of as many as eight ends per channel with excellent separation at the winder and smooth process flow.

Compact heatsetting, the completely NEW heat setting system with saturated steam:

• Materials: PA6, PA6.6, PP, acrylic, PET, wool
• Number of ends: 24
• Throughput up to 250 kg/h (550#h)
• Yarn input speed: up to 700m/min
• Saturated steam process up to 140° C
• Integrated yarn cooling
• Vertical material throughput with minimal points of contact (yarn contact points)
• Controlled yarn take-up and take-off
• Possiblility of varying the bulk
• Controlled yarn tension during winding up
• Constant winding up speed
• Quickstop after yarn break
• No heating, no water consumption
• No need for yarn storage (accumulator)
• Steam consumption between 30 and 40 kg/h (66 and 88 #/h)
• Power consumption up to 7 kWh
• Air consumption up to 15 co/h (9 cu. ft/min.)
• Required space (creel, compact heatsetting, winding machine), a total of: 14 x 5 m (46 x 16 ft)

For the new compact Heatsetting (CHS) we even received recently the innovation award at the FloorTek in Dalton!

It is your decision now what we shall serve!

Find both brochures under http://www.power-heat-set.com/

Discovered Dalton

I am Karin Mueller from Power Heat Set Germany. Some weeks ago I got the opportunity to come over to Dalton to see the capital City of the Carpet Industry. As Power Heat Set of America is based in Dalton since June 2007 I was pleased to come over to make some experience and to meet my colleges Dan Dawson and Beth Powell. I already met Dan in Germany at the ITMA but I was very happy to see him again.I was also very excited to meet Beth because we I’ve been working together with her for a while. I felt very welcome here and I learnt a lot.

Carpeting - natural or synthetics?

Recently I read an informative article about carpets. I would like to make this interesting information available for everybody.