Home Furnishing is a lucrative segment of sewn product industry which is expected to achieve 5% growth in financial year 2009-10. While sewing machine manufacturers like Kansai, Brother, Pegasus, Siruba supply specialized sewing machines for home furnishings, the specialized brands that supply equipments for this segment are Rimac and Monti (both Italy), Texpa (Germany), Jensen (Switzerland) and Automatex (Canada). Team StitchWorld put together a review of machineries and equipments for home furnishings.
Curtains, table linen, bed sheets, pillows and cushions are some of the most common home furnishing commodity products made from silk to polyester to warp knitted fabrics. Besides the 350-odd leading companies in home furnishing, almost all apparel manufacturing organizations now have a home furnishing division mainly concentrating on table linens and bed linens since the technology requirement is almost the same that is being used for apparels. However, fully- or semi-automatic devices exist to speed up production and assure quality.
Following the three-step production process the first step, after the fabric inspection, is the cutting of the fabric for sheets, pillow and duvet cases including the stacking; step two is the sewing, followed by turning of the cases; and the third step is folding and packaging. Some companies offer the fully automatic lines while others concentrate on one or two steps of the whole process.
Curtains
Curtains making involves pleating, ruffling, lattice effect, cording and gathering and tape attaching at back. Automation in curtain making involves automatic roll handlers, automatic spreading and cross cutting of flat sheets, simultaneous length cutting and continuous hemming, multi-needle automatic pleating for single or double pleats.
RIMAC curtain pleating machine PG343A is a multi-needle sewing machine with needle transport for the automatic pleating of curtains, table-skirt, etc. The machine is completely controlled by a PLC (Programmable Logic Controller), and the pleat length is electronically regulated, giving the possibility to change the measurement very quickly and easily and also to adjust the distance between two consecutive pleats. The different types of pleats that can be made are lower simple pleat, upper simple pleat and double pleat. In order to change the type of pleat, the operator has to only press the required button on the control panel. Once the available fabric length has been set, and the desired length of the curtains has been realized, the machine makes automatic calculation of the length and the number of pleats that will be made. Tape can be automatically stitched on to the back side of the pleated curtain with the help of the roller placed under the machine table. This machine can easily sew at a maximum speed of 700 RPM. RIMAC TS305 automatic cutting/spreading table is an automatic unit used for cutting and stacking of flat sheets, fitted sheets, curtains, table linen, etc. The cross cutting model allows to cut up to 4 layers at the same time and to a maximum width of 3.2 metre. All the parameters of the machine can be set using a touch screen which enables the material to spread and cut with great precision. This gives the option to programme the cutting length, speed and the number of cuts to be made. The longitudinal model is equipped with 3 cutters with rotating blade which can cut-to-thread the selvedge and even cut the fabric length wise. The position of the cutter can be manually adjusted too. The unwinder/aligner model allows performing both the functions at the same time till up to 4 rolls of fabric. Even as the unwinder ensures a smooth cut of the fabric at a minimum tension, the motorized aligner grants a complete aligning of the fabric being fed into the machine.
Impulsa Decocut-2 cuts the fabric vertical – horizontal and vertical also. The fabric is transported automatically through two endless transport tapes from the left. The machine includes a working platform where the measurement occurs while the deco runs. The machine runs on an electronic blade control through digital input on display.
MONTI R12-4A is an automatic unit for longitudinal hemming and seaming on drapery by ajour stitch. The maximum production speed that can be achieved is of 2 metres/minute on a maximum fabric width of 900 mm. MONTI R12-4C is used for longitudinal coupling of two fabrics by Fagoting and Picoetta edging. With a special setup, the machine also produces continuous crocheted stitch. Both the machines have a PLC-driven automatic operation.
KANSAI DFB-1402P-MR-E is a twin needle double chainstitch box pleat machine for box pleating curtains, table skirts, pelmets and bed coverings. Its programmes, including number of stitches per pleat and number of pleats, are electronically controlled and the machine can make forward and reverse pleats with its pneumatic action. The machine also has an innovative pin system for pleating difficult fabrics. The DFB-1412P-MR-E is used to pleat curtains or marquee linings or net curtains onto header tape. It is fitted with a puller feed unit. The requirement of the pleats can be easily fed into the machine. The Multi-pleat STH-KP (four-to-one knift pleat) is a single needle, needle feed, walking foot machine, available in double lockstitch and in bottom loading lockstitch. It is used for pleating upholstery, curtains and household furnishings. The machine comes with a range of folders, guides and reel holders.
Impulsa double head sewing automation is used for sewing on curtains, bedclothes, etc. It is a double needle chainstitch machine with the two needles adjustable to widths from 300 to 450 mm. The balancer present can be changed depending on the size and weight of the fabric rolls. An automatic edge control with the function of cutting on the side is also present.
BROTHER B872-5-65 mm is a wide gauge curtain tape machine which can be converted to 65 mm gauge for inserting curtain tape on cotton or even velvet type of fabrics. V92-PR top feed piper ruffler is a five thread overlocker used for making curtains. The machine can sew the piping cord into the binding, attach to the body fabric and ruffle in one operation. B720-NFSB-TB is a single needle, needle feed lockstitch machine fitted with a synchronized binding attachment to produce curtain tie-backs. The automatic blind spot tack machine is used for sewing blind spot tacks on corners of curtains or blind spot tacks on ties. The mechanical knives, clutch and stopping mechanism have been removed to allow predetermined stitch count programming.
SIRUBA VC008-02064/VMR is a fully auto-lubricated machine for ruffling regular wavy tucks. It has six different decorative cams which can be used for ruffling of curtains, bed covers, table cloths, etc.
Table Linen, Bed Sheets and Pillows
Table linen, bedsheets and pillow cover making involves cross cutting the fabric, do label dispensing, cross hemming, folding, lateral closing, turning and folding of the stitched pieces. Fitted bed sheet making involves automatic elastic insertion at pre-determined regular intervals. Fitted sheet making also require corner formation and corner sewing, which is a cumbersome process. Specialized machine gives high output and flexibility and consistency. Long seams, continuous hem with automatic corner making, label feeding are the special operations required in bed linen/flat sheet making.
Cushion cover and pillow cover making generally involves simple profile stitch, while cushion cover is finished by zipper attachment, often pillow cover is finished open. Zipper attaching is done in different sizes and shapes and can be done using continuous zipper attaching machine. Frills are common for pillow covers and can be done by frill making attachment using simple lockstitch machine.
The TEXPA fully integrated machine for manufacturing of pillow cases ensures continuous production on single machine. This machine can crosscut the fabric, do label dispensing, cross hemming, folding, lateral closing, turning and folding of the stitched piece. The QSNFFQN model is a transfer sewing line that can ably use the complete fabric width giving high output and high flexibility. Data can be input using a display menu. The WA-FA model can turn the pillow cases, do inspection, length and cross folding as well as stacking. It gives high output, offers a high capacity, and can be integrated in a transfer sewing line. The QSNN model for the fully automatic manufacturing of fitted sheets does cross cutting, label dispensing, elastic feeding, cross hemming, corner formation and corner sewing. It gives high output and flexibility and is simple to operate. The FA model is a folding installation which can do inspection when feeding the fabric, length and cross folding, as well as stacking. It gives high output and a fast change of the folding programme through simple programming by menu. The VA is a packing installation which can do fabric feeding with and without cardboard, fabrication and tightening of the bag, and closing of the bag. It does high quality packing with a fast change of the article, can close by flap and label and also by welding. It can also do cardboard feeding.
Rimac 2500L Bed Sheet Hemming Line comprises of longitudinal hemming machine which is equipped with 2 sewing heads that perform the hemming operation on both sides of the fabric. Loading of the fabric on the machine can be either in the roll form or layered form. The fabric width on the entrance feeding is regulated with the help of cutters-to-thread. High quality hem is achieved by automatic alignment of the 2 sewing heads, thanks to 2 photocells on each side of the unit. Depending upon your buyers, you have the option to choose either lockstitch hem or a chainstitch hem. The sewing speed varies from 4500 spm (stitches per minute) to 6000 spm and can be controlled as well. Productivity of the machine is approx. 13 metres per minute in case of lockstitch head, while 18 metres per minute in case of chainstitch head – considering stitch density of 3 stitches/cm. The hemming width is adjustable from 8 cm to 10 cm and power required is 4 KW, 380V, 3 phase. Model 3000 from Rimac is a semi automatic machine for the insertion of elastic in fitted sheets. This programmable machine is easy to use. It inserts elastic and hems in desired positions without stopping, thereby tripling the performance of the operator. Once the length of the elastic insertion is set in sewing stitches, and adjusted to the stretch, the operator has to only start hemming the sheet. The machine automatically inserts the elastic and cuts the same, leaving it completely inside. An automatic feeder allows maintaining a constant tension with the desired stretch which can be easily adjusted through a potentiometer. The K3 model of this machine does automatic hemming with elastic insertion.
Multitex from JENSEN is a highly flexible folding system for fitted sheets, flat sheets, duvot covers and other flat products. This machine has been designed as an all-in-one folder, offering multiple possibilities. It works on a maximum length and width of 3200 mm/125”. All machine operations are controlled from a microprocessor and the control system can be easily programmed to accommodate innumerable options. Fabrics no longer than 1600 mm/65”, are pre-folded, ensuring that they can enter the lateral fold section without problems. At the external cross fold station, folding plates automatically adjust to different thickness of fabric. The inserter can also be used to insert book folded card boards. The inserted are hidden inside the product. An automatic press unit is installed on the last cross fold station in order to optimize the folding quality.
AUTOMATEX FDP-7725 automatic flatsheet unit has an electronic edge guiding and trimming section and a roll joining station, in addition to quick change header/folder attachments to minimize downtime. The machine also has belt folders for quality hem. The machine gives an output of 3,300 units per 8 hours at 100% efficiency.
FTO-7880-T automatic width for length pillow case unit has an electronic edge guiding and trimming section with a roll joining station, a quick change folder with attachment capabilities to minimize downtime and a servo motor for folding and transfer of fabric to minimize waste. It also has an automatic latch tack and label feeder, automatic turning station and pinch type stacker with bundle return. The machine has an output of 7200 units at 7 SPS per 8 hour at 100% efficiency. The CL-4300-S-120 automatic multi-score slitter comes with a motorized roll support and an electronic edge guiding system with an automatic tension control mechanism. Its adjustable score type knives give a smooth cut of the fabric. Working at a maximum speed of up to 60 metre per minute, the machine can handle a maximum roll diameter of 30”. The machine is also equipped with anun loading system.
Baratto 158/3/D has two scallops of 4 mm width running next to each other. The machine can run on a maximum speed of 2000 SPM and with a knotted stitch on the edge of design cutting becomes easy. The machine also has an option for scallop padding by inserting a cord underneath the scallop. The CPT-4700-110 panel cutter has an electronic edge guiding system and is controlled by a pneumatic dancer roller for tension control. It can have up to litter knives, a servo measuring system, programmable length counter and a scissors lift table with platform. This machine gives 8 single or double panels per minute at 100% efficiency.
PEGASUS E256-231/504-123-N1.5Y is a curved needle overedger for turndown hemming on pillow cases. There is enough space around the needle drop hole, so the operator can easily check to see if the direction in which the fabric is fed is correct. As a result the operator sews the fabric uniformly, and the tedious job of replacing the needle and threading the machine are easy. This machine eliminates the problem of skip stitching that tends to occur during sewing when more stretchable threads are employed.
MONTI 2074-STR is an automatic unit for the making of house cleaning articles. It can cut at pre-set size or as per requirement. The machine can perform tasks such as labelling, cross overedging, final folding and stacking on conveyor with a production capacity of up to 450 cycles/hour.
Cushions
Cushion and pillow making involves filling machine and closing machine. Cushions also often require quilt tucking or tufting machine.
RIMAC Q1300 is an automatic machine which quilts the inside of seat cushions with a particular drawing. The machine stitches using a lockstitch sewing head with automatic thread trimmer. The loading of cushion under the foot-lift is easy because of the automatic lifting of sewing head at the end of the sewing operation. At the beginning of the sewing operation, a blocking arm presses the cushion so that it does not move when the sewing begins. This machine can stitch any type of pattern which can be directly programmed into the computer of the machine. The maximum working speed of the machine is 2000 SPM which allows it to produce up to 9 cushions per minute.
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