A.T.E. OFFERS COMPLETE SOLUTIONS IN CARPET MANUFACTURING TECHNOLOGY

Carpet manufacturing offers a tremendous business opportunity due to the rapid growth in carpet demand. Carpet consumption is rising fast for both indoor and outdoor applications. A.T.E. brings to the Indian textile industry a wide range of state-of-the-art machinery for the manufacturing of carpets to help you grab this opportunity.

A.T.E.'s range starts with BCF yarn production and processing and goes all the way to confection and packing machines for the finished product from reputed global leaders. We can also help you with control system upgrades, effluent treatment solutions and material handling solutions.

Bulk continuous filament (BCF) extrusion lines – Trützschler Man-Made Fibers, Switzerland

Bulk continuous filament production is a one step process where one or multiple filament yarns are tangled by an airstream. BCF yarns are typically used in carpets as these yarns are very bulky and give carpet resilience, softness, loft, pin-point, longer life, dyeability etc.

The OPTIMA BCF system from Trützschler ensures manufacturing of perfect yarn that does not cause any trouble for the downstream process or in the end-products. This is an essential requirement for all carpet qualities and end applications.

The OPTIMA family offers MO40-Compact, MO40-Extended, TO40 (4 ends per position) and MO60 (6 ends per position up to 1500 dtex) for endless possibilities in producing BCF yarn:

• Mono-colour yarns for woven and tufted carpets
• Tri-colour BCF yarns
• Fine yarns down to 500 dtex and coarse yarns up to 7000 dtex
• Denier per filament (DPF) ranging from 1.5 to 40 DPF in mono-colour
• BCF from polymers such as PA6, PA66, PET, PP, PTT tailored to the requirements of one product category
• Spun-dyed yarns for the automotive applications

Carpet yarn heat-setting and winding machines – Power Heat Set, Germany

Heat setting is a thermosetting process that gives yarn dimensional stability, softness, resistance to wrinkles and temperature, and volumetric growth required for carpet yarn.

Power Heat Set builds two types of machines: GVA and HiPerSet.

GVA: It is used to heat set up to 96 ends of carpet yarn. Due to its 6 channels configuration, heat setting of small lots, different colours of same yarn or straight set and frieze is possible at the same time. With the modular system of the GVA, the following variants are available:

Model	Capacity
GVA 4.0+	Up to 7 tons per day
GVA 5.0+	Up to 19 tons per day
GVA 8.0+	Up to 15 tons per day

HiPerSet: It is a single belt solution for heat setting of up to 84 ends of carpet yarn with superheated steam. With the modular system of the HiPerSet, the following variants are available:

Model	Maximum no. of ends	Capacity
HiPerSet 4.0+	72 nos.	Up to 8 tons per day
HiPerSet 8.0+	84 nos.	Up to 12 tons per day

Automatic winder X-Wind Pro 1.0 - 3Dxx L/R

Following the heat setting process, the X-Wind winder winds the yarn optimally back onto the packages and communicates independently with the heat setting unit in a perfect symbiosis.

• Customer reference: AYM Syntex - Mumbai

Digital carpet printing solutions – J. Zimmer, Austria

Digital carpet printing is a process that uses digital printing technology to create decorative carpets. The method involves printing individual images digitally, which allows for a wide range of colours, patterns, and textures.

Zimmer, a pioneer in digital printing, offers its Chromojet and Colaris digital printing machines, most suitable for all types of carpets such as wall to wall, needle felt products, carpet tiles, rugs, mats, etc.

CHROMOJET is based on high-speed electromagnetic valves, controlled by software, based on information given by the design. Its valve technology is like a dot on demand printing system and is available with 25 and 76 dpi print resolution.

COLARIS digital inkjet printers are high resolution printers with a minimum of 400/400 dpi, which can be increased by each 200 dpi in carpet width and multiplied in carpet movement direction. As highly purified inks with very dense colours are filled, it is mostly sufficient to use 4 or max. 6 colours to achieve the full colour gamut required by the carpet industry.

• Customer reference: Raj Overseas – Haryana, AYM Syntex – Mumbai and Rhodenium Pvt. Ltd - Pune

Carpet back coating and shearing lines – Sellers, England

Carpet back coating is an important production step carried out to improve and enhance the stability of rugs and carpets. It also improves soundproofing and heat insulation.

Sellers provides complete coating and drying lines for backing of all types of carpets:

• Conventional and powder lamination
• Woven finishing for Axminster and Wilton carpets
• Artificial grass
• Carpet foam backing and bathmat products
• Tile coating lines for bitumen, PVC and PU
• Range of entry and exit equipment including scrays, accumulators, slitting units, nip rolls, and re-roll units

Sellers offers versatile machines that combine a unique design with advanced control technology to enable shearing of all types of carpets. A completely modular construction, with state-of-the-art control systems coupled with high-speed performance, ensures superior quality products.

• Customer reference: Welspun Flooring Limited – Mumbai

Carpet confection lines and bobbin winders – Matthys, Belgium

Matthys offers inspection, rolling and packing machines at the end of a carpet line. The product range includes length cutting and long side over-edging, cross cutting and short side over-edging, gluing machines, labelers, etc. Matthys also offers contract winders and profit winders.

Effluent treatment plants - A.T.E. HUBER Envirotech Private Limited, India

Comprehensive, innovative, and cost-effective wastewater treatment and recycling solutions, including zero liquid discharge. The scope covers various breakthrough technologies:

AAA® – reduces the chemical consumption and sludge generation by around 70% with consistent treated effluent quality.

RDRO – a unique combination of an ultra-fine gravity filter followed by reverse osmosis recycling about 80-85% of the treated water back to process to achieve zero liquid discharge.

EnviroCOLA® – a customised online assistance system designed to provide all the information needed to ensure a healthy performance of the wastewater treatment plant – anytime, anywhere.

Automated storage systems (ASRS) - Craftsman Automation, India

Established in 1986 and headquartered in Coimbatore, India, with factories in seven locations across India, Craftsman Automation is a diversified engineering company with vertically integrated manufacturing capabilities. They are particularly well-known in the automotive sector as an OEM supplier of automotive components such as engine blocks, cylinder heads, and the like. They have diversified into many segments and have products for varied industries.

Stacker Crane ASRS: for roll storage into single or double deep racks

Pallet Crane ASRS: recommended for caged pallets of roll storage into single or double deep racks.

Crane Shuttle ASRS: for higher density storage of finished goods (yarn) and garments.

Multi-deep Shuttle ASRS: a revolutionary multi-deep automated storage system for pallets.

VSTORE vertical storage system: high-performance, durable storage solution that ensures optimal space usage and high ease of us.