Ecocard, Nuova Cosmatex / Monteleone Group

Ecocard

The project developed after realizing the changes occurred in the textile market in recent years, old rules are no more valid, overturning the current logic of production.

Scenario market changes
Innumerable ranges of items and colors have been created.
The single lots have been greatly reduced; consequently the efficiency of the production plants has decreased and the costs have grown up. The fashion trends are for garments lighter and lighter; that means finer and finer count yarn, but keeping a soft and pleasant “hand-touch”.

Our answers
New carding system, with unique features, turned towards the environmental sustainability: ECOCARD

It is narrow, 1500mm, and short, about 20mt. (it takes up less space, consequently it is possible to save energy for the workshop air conditioning system);
It does not require the foundation pit (no masonry works are required);
It is made up of a smaller number of machines and moving elements, so it requires a lower energy consumption;
Thanks to a new and more efficient driving system, it can carry out a high speed production;
Through the cooperation with the most important accessories manufacturers, the direction movement and the parallelization of the slubbing fibers has been reconsidered, to allow an intense drafting in the following spinning machines. Nevertheless this won’t cause the missing of the typical woolen yarn soft “hand-touch”;
According to the current market requirements, split up in a great deal of items and colors, it is designed for a high efficiency and versatility with controls, speed and settings that can be adjusted by the operator panel;
Thanks to a new fiber transport system and to its multi-layer effect, it is possible to reach blending results with different materials and/or different colors never reached before;

It is almost completely self-cleaning and this, considering also the reduced dimensions of the machinery, allows very rapid changes of lots, and decreases the very expensive costs for downtime and machine stand still;
It can process the most different types of fibers.

It is a modular system and concept, in which single parts of the project can be implemented in the existing plants, i.e.:

fiber loading system, with a new electronic hopper feeder that carries out pre-loadings to optimize the weighing times, without missing the precision;
traditional feeding system of the carding groups totally revised, using air blades that allow to decrease short and medium count unevenness;
new transport and web overlapping system that allow the creation of a continuous fiber mattress mixed and crossed in an unthinkable way, feeding the next carding group with a very high precision;
new direction movement and fiber parallelization on the last carding group, mixing different technologies, to increase the yarn count drafting times in the spinning machines and increase the machine production;
review of the alternating motion of the condenser, acting both on the displacement of the single controls of the rubbing aprons pairs and re-designing the movable and grooved driving system of the rubbing aprons shafts. In this way it is possible to obtain high production speed, avoiding vibrations and consequent expensive maintenance operations for the wearing.

Ecocard, Nuova Cosmatex / Monteleone Group