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Air-jet Weaving Machine

ITEMA Weaving:
Pioneers in weaving machine construction

With its high performance and ease of operation, the Sul- ceptionally broad range of standard spun yarn or filament fabrics.
tex L5500 air-jet weaving machine sets the new standard for pro- The features that set it apart are:
ductivity. With regard to excellence in fabric quality it offers no
compromises and the low air consumption is unchallenged. • versatility and flexibility
The Sultex L5500 is designed to produce a broad range of • yarn-friendly insertion of up to six weft colours or different types
fabrics – for industrial applications, for home, sports and lei- of yarn as well as multiple weft insertion
sure activities. With unbeatable value for money, a small footprint, • ergonomic design in every detail for enhanced ease of operation
plus low energy and maintenance costs, this latest generation • lowest air consumption through intelligently controlled weft
air-jet weaving machine fulfils all the expectations of competitive insertion process
and quality-conscious weavers with regard to economy and
efficiency. The Sultex L5500 excels in producing an ex-

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With regard to the engineering design, the Sultex L5500 running even when weaving heavy fabrics. The sley drive
is built for reliability in respect of performance and quality. by means of complementary cams results in optimal sley
The clearly and ergonomically arranged controls help dwell. The cam boxes on both sides are directly integrated
alleviate the workload of weaving personnel. The result: faster in the frames. This results in less components and increased
completion of warp and style changes due to shorter reliability with maximum precision while avoiding
set-up times. Thanks to the torsionally rigid machine frame and vibrations caused by the coupling of different parts. As a
the harmonic sley motion with active mass balancing and low consequence, the extended weft insertion time has a positive
vibration, operation is assured up to the maximum effect on the running characteristics, in particular with delicate
possible machine speed. This makes the Sultex L5500 the and/or low tensile strength weft materials. This pays off in terms
most dependable system for speed and efficiency, smooth of consistent high fabric quality and low power consumption.

The tried and tested Sultex L5500 air-


jet weaving machine is available in 13
working widths from 170 to 400 cm
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and attains a maximum weft insertion


rate of up to 2592 m/min. With multiple
weft insertions the effective production
is up to three times higher.

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Modern control:
Simple to operate, outstandingly reliable

The high fabric quality achieved with the Sultex L5500 air-jet weaving machine is essentially the result of the
low yarn tension in both warp and weft.

Pick repair automatically under control.


Automatic pick repair (APR) effectively reduces the operating
personnel’s workload and leads to shorter downtimes. The
result:

• maximum efficiency and increased productivity


• higher machine allocation per operator
• efficient utilisation of human resources

With its chronologically controlled and freely programmable


starting mark prevention, the Sultex L5500 guarantees fault-
less fabric quality.

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The clearly arranged controlls for the adjustment of the air pressure
simplify the operation of the machine and are easy accessible.
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The weaving width can be changed in a matter of moments without affecting


the settings of the temple, cutter and stretching nozzle.

The colour touch screen terminal guides the operator clearly and directly
to the desired setting. Easy-to-understand symbols on the user interface
help ensure that operators quickly master the Sultex L5500. Integrated user
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help, the logbook and the built-in debugging system further enhance the
machine’s user-friendliness.
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Adaptable to the new markets of tomorrow

The Sultex L5500 air-jet weaving machine weaves virtually all customary spun yarns, made of
cotton, synthetic, blends, as well as texturized and plain filament yarns in warp and weft.
That makes it the right machine to have, also for the long term; an investment that really pays off. The
low air consumption and energy friendliness assure a quick return of investment.

The relay nozzle design plays an important role in the efficiency importance to choose the right shaped nozzle for spun or
of the weft insertion process. The Sultex L5500 is equipped filament yarns in order to produce the best quality of fabric.
with multi holes relay nozzles (standard). Multi hole nozzles With the Sultex L5500, the modern weaver is investing in a fu-
have a higher concentration of the air flow and therefore cre- ture oriented weaving system that fulfils the requirements of to-
ate less turbulence. This results in a better flow direction and morrow’s markets in every respect.
reduced air consumption. Even for yarns of the future with different fibre blends or new
For very special applications, the standard nozzles can be spinning processes, the Sultex L5500 will be up to the chal-
replaced with single hole relay nozzles. Furthermore, it is of lenge; and all this with the lowest air consumption.

On the Sultex L5500 air-jet weaving machine, not only everyday apparel fabrics and plain textiles for household requirements, but also quality materials for
fashion designers are produced with maximum economy.

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Optimized compressed air consumption
Minimal energy costs

Thanks to the new Active Weft Control system (AWC), comprising of NTC (New Time Controller) and RTC
(Real Time Controller), the compressed air consumption is drastically reduced. The main- and tandem
nozzles ensure gentle acceleration of the weft yarn with minimal air consumption. Patented real-time
monitoring of the weft yarn makes predictive control of the relay nozzles possible.

NTC (New Time Controller) Reduced air consumption


The new air control system with separate valves and air control The main- and tandem nozzles blowing pressure is dynamically
units for each tandem- and main nozzle results in great controlled with the NTC (New Time Controller) function. The
efficiency of the nozzles. The special design to increase air-flow nozzles switching-off point is calculated in real time, depending
evenness allows the use of a standard nozzle insert with 2.5 mm on the momentary weft speed and weft position in the shed
diameter opening as a solution for a wide range of weft yarn. as calculated by the RTC.

RTC (Real Time Controller)


Short reaction and blowing times are responsible for the reduced
compressed air consumption, with values never achieved
before. The patented RTC (Real Time Controller) is an intelligent,
active control system that influences the current weft insertion
rate, optimizing the nozzle blowing times. The RTC controls the
duration of the blowing times, irrespective of the weft material
and yarn count being woven. The weaving machine adjusts
continuously during every pick insertion for minimal air consumtion.
The system is acting so fast that it is possible to adjust the blowing
times during the insertion and instantaneously, not only for the
next pick. Depending on the weft yarn and machine width, air
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consumption can be reduced by 10 to 40 percent.

The main and tandem nozzles ensure gentle acceleration of the weft yarn
and in combination with the RTC (Real Time Controller), even Lycra yarns
can be inserted flawlessly at high speeds.

Benefits
Besides the precious savings of energy and reduced air
consumption, additional benefits are

• Less stress on weft yarn because the main- and tandem


nozzles’ blowing duration is always optimized.
• Automatic adjustment of the valves
• Simplified weft insertion handling for the operator
• Reduced number of weft insertion parameters.

RTC is easy to handle, only three parameters need to be programmed on


the terminal. Thereafter, the RTC will function fully automatically, eliminating
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any intervention of weaving personnel.


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Reduction of CO2 - Emission over 5 years - Savings of energy in kWh per machine over 5 years

Energy kWh
0 200000 450000
Comparison of CO2 - Emission

6’235 kg
Comparison of energy saving

321’000 kWh with RTC

8’535 kg

449’000 kWh without RTC

Your picture 
0 2000 4000 6000 8000 9000
Emission kg

Flow rate 1,25 m3/min: CO2 - Emission (kg) Energy consumption with RTC in kWh
Flow rate 1,75 m3/min: CO2 - Emission (kg) Energy consumption without RTC in kWh

What I have 
Besides the reduced air consumtion and CO2 emission, the savings of precious energy over the same period of 5 years per machine is approx. 128’000 kWh,
considering a spun weft yarn of Ne 40.

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Solenoid valves Stretch nozzle


The solenoid valves for the relay nozzles are mounted directly The stretch nozzle is reliable, user friendly and most important
on the air supply tanks on the crossbar, which results in the because it controls the weft tension until beat-up. The stretch
shortest possible compressed air hoses. As a standard solu- nozzle is suitable for all types of weft yarn materials. When
tion, each valve controls four relay nozzles. The multi-hole relay using the cut reed option, an auxiliary selvedge is not required,
nozzles give the highest performance with very low turbulence, resulting in less yarn wastage.
a high and more even air flow concentration. The stretch nozzle is also available when weaving with a full
The highly efficient multi-hole relay nozzles contribute further to width reed.
the low air consumption and improved fabric quality.
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Short set-up times:
Maximum productivity

High flexibility, with low maintenance and operating costs are the outstanding features that distinguish
the Sultex L5500 air-jet weaving machine positively from other air-jet machines. Operator-friendly
design and up-to-date user interfaces further enhance overall productivity.

Machine setting data can be transferred from one Sultex The simple design concept of the weaving machine also
L5500 air-jet weaving machine to another, quickly and proves its worth with regard to servicing and maintenance.
easily. Once the settings for a particular style have been All transmissions are oil-immersed and virtually maintenance
optimized, they can be reproduced anytime and any number free. The Sultex L5500 has almost no wearing parts which
of times – an invaluable advantage in optimizing any weav- need to be replaced regularly. As a consequence, also con-
ing mill producing on an industrial scale. sidering long-term, it produces with low maintenance and
operating costs.

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Easy data download for all style and machine parameters, easy managment of Pneumo-mechanical tucking-in devices for perfect and stable selvedge
all operations. Fast setting of the insertion parameters and data transfer from quality.
one weaving machine to the other.

The electronic let-off is driven by a maintenance free


servo motor. The normal density ratio ranges from
11,5 to 230 picks/cm, the low density ratio from 2,5
to 40 picks/cm. This system requires no belts nor
gear changes and guarantees an even warp tension
throughout the length of the warp, from full to empty
beam.

The quick lock warp beam bearings assist fast style


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changes and easy handling. The warp beam gear


remains on the machine.
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Affordable in the markets of tomorrow

The Sultex L5500 air-jet weaving machine is equipped with a positive, mechanically driven back rest
roller. As an option, the air-jet machine can be equipped with a positive, motorized controlled whip
roller, which is programmable according to the weave pattern, pick by pick. The result is increased per-
formance due to less warp induced weft stops because of better warp separation in the front shed.

For selvedge formation on the air-jet weaving machine, Depending on the yarn material (man-made or natural fibres),
ELDs (Electric Leno Devices) are standard. The RLD (Rotary the finishing processes and the end use of th woven product,
Leno Device) with the fully independent electronic drive, may the requirements of the type of selvedge may change.
be fitted as an option.
Independent Selvedge Devices (ISDs), selvedge sealing de-
vices and pneumatic or pneumo-mechanical tuckers are
available as options.

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The RLD (Rotary Leno Device) is easily accessible and guarantees a high
quality selvedge.
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Pneumatic tucking-in devices for simple handling and utmost performance.


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Thanks to the vision of our engineers, all possible selvedge forming units are available. The motorized warp control system guarantees less warp
related weft stops.
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Modern design
Secure the future

The solid frame is responsible for the low vibration and high rigidity. The sturdy construction supports high
speeds and the production of heavy fabrics. The perfectly balanced sley drive ensures great stability and
perfect running conditions.

The outstanding adaptability and flexibility of the Sultex simpler styles and highest possible production, the tap-
L5500 air-jet weaving machine assures the production of a pet motion is available. Whether the demand is for leno sel-
wide range of fabrics with natural and man-made fibres. For vedges, for tucked-in selvedges, either with pneumatic or
demanding patterning it will be equipped with a dobby, for pneumo-mechanical tuckers or selvedge melting, the machine
can easily be adapted to
the appropriate selvedge
system. The direct main
drive by means of a servo
motor allows for empty
pick start-up and freely
programmable speed vari-
ation. There are no brake
and clutch, no wear and
tear parts.
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The tappet motion accepts a maximum of 10 heald frames and is equipped The resulting benefits are less maintenance and lower energy consumption.
with an automatic leveling device. Cams are available in weave repeats of Thanks to the empty pick start-up, there are no peaks in power supply.
4-, 5- and 6-pick repeats in all possible variations, even for symmetrical or
asymmetrical shed opening.
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Optimized dwell for different machine widths and dynamics for high speeds.
This results in less stress on the weft yarn thanks to extended insertion time Due to the perfectly balanced sley, the rigid frame and sturdiness, the machine
and reduced air consumption. The sley cams are running in oil bath. requires no fixing to the floor.
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Specifications

Weaving widths 170, 190, 210, 220, 230, 260, 280, 300, 320, 340, 360, 380, 400 cm with cut or uncut reed

Width reduction 80 cm, symmetrical with double warp beams or asymmetrical with single warp beam

Performance Maximum weft insertion 2592 m/min (or up to three-fold in case of multiple weft insertion)

Raw material Spun and filament yarns

Weft colours 2, 4 or 6 colours

Weft yarns Spun and filament yarns

Weft densities 11.5 to 230 picks/cm standard, 4 to 40 picks/cm optional

Weft insertion Fixed tandem nozzles, main and relay nozzles fixed on sley with single or multi-hole relay nozzles

Weft feeders LGL Evolution, Roj Super Elf C

Weft cutter Electrically driven scissors

Weft monitoring Electronic Eltex or Microtex

Pick finding device Synchronized with let-off

Shedding Positive cam motion, electronic positive dobby

Warp beam Up to diameter 1100 mm

Warp monitoring Warp detector with 6 or 8 electro bars

Warp and cloth run Synchronised

Cloth take-up Electronically controlled take-up, beam diameter up to 550 mm or batch winder

Main drive Direct drive with servo motor

Sley drive Conjugated cams on both sides with dwell

Selvedge formation Leno, mechanical and pneumatic tuckers, melting device

Selvedge cutter Electrically driven scissors

Lubrication Central lubrication

Machine control Microprocessor, touch screen terminal


system

Machine installation No fixing to floor required

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L5500 B 190 N 2 EP
Weft Insertion System Shedding
EP tappet motion max. 10 heald frames
Type Series SP dobby, max. 16 heald frames

Weft Colours
Raw Materials
2 weft colours
B Cotton
4 weft colours
S Synthetics (filament yarns)
6 weft colours

Nominal Weaving Width (WNB) cm Design


170 230 320 400 N low build
190 260 340
210 280 360
220 300 380

ITEMA Weaving is a Business Unit in the textile industry. Also Savio


of the ITEMA group with operations (automatic winders), Loepfe (yarn
in Italy, Switzerland and China. Our clearers), BarcoVision (MES and au-
experienced team develops and tomatic inspection systems), SEDO-
manufactures state of the art weav- Treepoint (Dyehouse automation)
ing machinery. All our products are and Eutron (industrial electronic
sold and serviced worldwide. Our products) are brand names of the
brand names Sultex, Somet and ITEMA Group.
Vamatex are well known to anybody

Promatech SpA
Via Cav. G. Radici 4
24020 Colzate (BG), Italy
Phone +39 035 7282111
Telefax +39 035 740505

ITEMA (Switzerland) Ltd.


Binzackerstrasse 41
8620 Wetzikon ZH, Switzerland
Phone +41 (0)43 488 21 21
Telefax +41 (0)43 488 21 01

ITEMA Weaving Machinery (China) Co., Ltd.


98, Dong Xing Road
Song Jiang Industrial Zone
Printed in China / 37.40.09 Bao

Shanghai 201613, P. R. China


Phone +86 (0)21 67742618
Telefax +86 (0)21 67742608

www.itemagroup.com Specifications subject to change without notice.

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