Dinarsu Installs High-Productivity Carpet Coating Line
Dated- 05 Jul , 2012 - Turkey
Brückner has supplied a high-tech carpet-coating line to Turkish carpet giant Dinarsu.
Established in 1955 in Istanbul as a manufacturer of yarn and blanket, Dinarsu Imalat ve Ticaret TAŞ began to produce tufting carpets in 1975 and developed into one of the most important industrial complexes in Turkey, with annual production of about 10 million sqm of floorcoverings, including tufted carpets, nonwoven carpets and artificial turf.
It exclusively uses leading European or American technologies, from tufting machines, to Chromojet digital printing, and coating and finishing lines.
The recently commissioned Brückner coating line for tufted carpets is said to be one of the biggest of its kind, with a total length of around 170m. The production capacity extends to a maximum of 20 million sqm/year, depending on the type of fabric and the process. The line permits the following processes:
The drying process takes place in a total of 23 Duo-Therm drying zones, a type Brückner claims has proven to be excellent for coating in the carpet sector. The gas-heated dryer is operated with split temperatures for the thermal treatment of the pile and the coating side. This is said to ensure a high drying capacity while being very gentle for the pile. The separated air circulation of upper and lower air allows temperature differences of up to 60°C.
With the Venturi mixing system for gas heating, Brückner says a perfect temperature distribution is achieved. The use of inverter-controlled circulating air fan motors allows a fast reaction on different types of fabric, preventing pile deformations. The central Siemens S7 control system ensures ‘perfect’ reproducibility of production data.
The different coatings are applied as foamed latex mixtures. For this purpose the newly developed Brückner carpet application unit is used. This has side dams, with motorised control via edge sensors and motorised traversing paste distribution. The chromium plated squeegee is water-cooled to prevent adhesion of the latex.
The motorised nip adjustment via spindles is made on both sides and is monitored by angle encoders. Normally, says Brückner, a parallel adjustment is made but corrections on both sides are possible. The squeegee can be decharged pneumatically via a fourfold joint. Due to the rotation around the joint, the squeegee roller gives way not only vertically but also horizontally, for example when passing a seam. This prevents strikes or ruptures of the material.
There are two application units in the machine, one for the pre-spread and one for the glue/foam application. The integrated straightener correct fabric distortions. In addition, a function ‘straightening according to pattern’ is available. Two camera systems detect either the carpet back or the pile side and distortions are then corrected automatically.