SPREADING EQUIPMENTS

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 SPREADING EQUIPMENTS

7.1 INTRODUCTION
Spreading is the process where the fabric lay is prepared by laying the
plies one above the other. Spreading can be carried out by hand in olden
days. This process of spreading is the time-consuming process, when the
length of lay is more or machine.

7.3 SPREADING USING A TRAVELLING MACHINE

Spreading machines carry the piece of fabric from end to end of the
spread, dispensing one ply at a time onto the spread. Their basic elements
consist of a frame or carriage, wheels traveling in guide rails at the edge of
the table, a fabric support, and guide collars to aid the correct unrolling of the
fabric. In the simpler versions, the operator clamps the free end of fabric in
line with the end of the spread, pushes the spreader to the other end, cuts off
the ply in line with that end, clamps the beginning of the next ply, pushes the
spreader to the other end and so on.
More advanced spreading machines may include a motor to drive the
carriage, a platform on which the operator rides, a ply-cutting device with
automatic catcher to hold the ends of the ply in place, a ply counter, an
alignment shifter actuated by photo-electric edge guides, a turntable, and a

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direct drive on the fabric support, synchronized with the speed of travel, to
reduce or eliminate tension in the fabric being spread.
The advent of microprocessor control has enabled the development of
more automatic functions on spreading machines. Thus a spreader can be
pre-set to a selected number of plies, emitting an audible signal when it has
reached the selected number or has come to the end of a piece of fabric.
Automatic turn tabling gives automatic spreading even for corduroys which
are normally spread face to face.
With robotic spreading, when the piece is finished, the spreader returns
to an auto-lifter at the end of the table, transfers the empty centre bar to the
lifter which then advances the next piece to the spreader. It repeats the
process until it achieves the required number of plies. This method requires
automatic sensing of previously marked flaws and damages.
7.4 Spreading Parts
Basic spreading equipment consists of:
​ (i) Spreading surfaces,
​ (ii) Spreading machines
​ (iii) Fabric control devices
​ (iv) Fabric cutting devices
Many firms operate productively with manually operated equipment,
while other firms find the automated, high-tech equipment to be cost-effective
for their operations. Under-standing the parts and complexities of spreading
equipment provides insight for troubleshooting problems and better
preparation for the process.
7.4.1 Spreading Surfaces
The appropriate type of spreading surface is determined by the fabric
type, spreading equipment, cutting method, cutting equipment, and the firm's
quality standards. Spreading requires a flat, smooth surface. If the spreading
surface doubles as a cutting surface, it also must be level. Spreading and
cutting may be done on the same surface, but automated cutting often
requires spreading and cutting to be done in adjacent but separate locations.
Spreading and cutting surfaces are available in standard widths that
correspond to fabric width. Narrow fabric can be spread on a wider table. A
spreading surface needs to be about 10 inches wider than the fabric.
Spreading tables may have tracks or rails placed along one or both sides of a
tabletop or just a few inches off the floor. This track helps guide and control
the spreader as it moves up and down the length of the table. With some

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types of equipment, the table tracks are geared to synchronize the movement
of the spreading machine with fabric unrolling, in order to regulate tension.
Spreading tables may also be very specialized for certain types of
fabric and cutting equipment. Pin tables have rows of pins located below the
surface that can be extended through slats to hold fabric in a precise location
for accurate matching of pattern repeats. Vacuum tables are used to
compress lay-up and prevent shifting or movement during cutting.
A spread is covered with a plastic film that forms a seal over the lay-up
when a vacuum is applied. A lay-up of quilted fabric can be compressed as
much as 75 percent when the vacuum is used. This allows more plies in the
lay-up and restricts the movement of slippery fabrics for more accurate
cutting.
Cutting equipment may be moved to a lay-up as another lay-up is
prepared further down the table, or fabric can be spread on one surface and
then transferred to the cutting surface. Air flotation tables, when activated;
allow easy movement of a lay-up onto an adjacent cutting area.
A layer of air between the table surface and the bottom layer of paper
reduces friction and allows a lay-up to be moved easily without putting stress
on the fabric or the operators.
Spreading tables with conveyorized surfaces carry the fabric to the
cutting machine so that no time is wasted. Ideally one lay-up can be cut while
is being spread. Conveyors may be used with computerized cutting systems,
large die presses, and laser cutters.

7.4.2 Spreading Machines

The fundamental purpose of spreading machines is to superimpose
layers of fabric in a smooth, tension-free manner for accurate and efficient
cutting. Manually operated spreading machines can be as simple a roll bar
mounted on four wheels that is pushed up and down a spreading table by an
operator. Manual spreaders travel only as fast as an operator moves them,
while some of the faster automated machines can spread 100-150 yards per
minute.
Spreading speed can only be utilized on long spreads with few defects.
Spreading speed may affect productivity, quality, and cost of the operation, but
it should not be the primary focus for purchase of new equipment. Manual
spreading machines may be used by small firms as the primary spreading

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device and by large firms for short spreads. As spreading machines become
more sophisticated, they are motor driven and have fabric control devices
included increasing productivity, decreasing variability, and making spreading
more cost-efficient.

Fig. 7.1 Spreader head

Fig. 7.2 spreading machine

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 Fig. 7.3 Spreader table

Fig. 7.4 Automatic fabric feed section

7.5 SOME OF THE MACHINE PARTICULARS

The M 400 S comes with an automatic cutting device, with adjustable
speed, digital electronic layers-counter and digital meters-counter – flexible to
your measurement nit requirements. The TUKAspreader can be equipped
with a load-un-load unit that brings the fabric roll from the ground up, or a
built-in loader that loads the fabric roll from the table.

Featured with a cradle turntable, the ST 4000 allows spreading of any

type of fabric without the need for a roll bar. This model is able to operate in
three different modes:
1) The turntable positioned at 180° for face-to-face spreading
2) Turntable in stationary position for face-up spreading with end cut
3) Face - to-face with the zig-zag spreading device.
Highly efficient machine that adapts itself to most varied applications. It
is Compatible for a broad range of fabrics. Automatic threading, specially
designed for goods rolled inside out. Built-in loader provides loading from
table level, or separate loader can be attached for ground loading.

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 This versatile spreading machine is capable of traveling from table to
table for continuous spreading. Built-in loader and unloader are available.
Designed for spreading flat or rolled tubular fabrics, the Knitmatic allows
Spreading of all types of tubular fabric with or without center crease. Loading
and unloading is simple and automatic.

7.6 FABRIC CONTROL DEVICES

Fabric control devices are mechanisms that control fabric as it is

carried up and down the table and unrolled by the spreading machine.
These devices include:
​ (i) Tensioning mechanisms,
​ (ii) Positioning devices, and
​ (iii) End treatment systems.

7.6.1 Tensioning involves synchronizing the rate of spreading with the rate
fabric is unrolled. A positive feed system utilizes a covered roller that is driven
and timed to the movement of the machine. It prevents the momentum of a
large roll from continuing to unwind when the machine slows down or stops.
Roller covers of different materials may be used to give better gripping power
for different types and weights of fabric.
7.6.2 Positioning devices and sensors monitor position and control fabric
placement during spreading. These devices improve the quality of a spread.
Electronic edge sensors monitor selvages as fabric is spread. A deviation
from the proposed alignment triggers a motor that shifts the roll to the correct
position. Alignment can be held to one-eighth inch tolerance with these
devices.

7.6.3 Width indicators may sound an alarm to alert the operator whenever
fabric becomes narrower than the established width. Width variations are
analyzed to determine where in the marker they fall, whether the fabric will still
fit the marker, or whether the variation should be treated as a defect and
removed.

7.6.4 End treatment devices are used with spreaders but are separate and
placed at the end of the spread. The specific end treatment equipment
needed depends on whether the spreading mode is face-to-face or
face-one-way. A face-to-face spread utilizes an end catcher and folding
blade that work together.

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 These are mechanical parts, mounted at opposite ends of the marker
to catch and hold the fabric as the blade shapes and creases the fold. An
overfeed device may be built into the spreading unit, which automatically
feeds extra material when a fold is to be made. End treatments have a major
impact on fabric waste. There must be enough fabric at the end of a lay to
retain it in place, but any fabric beyond the end of the marker is wasted.

For F/O/W spreads, a knife box is needed along with an end catcher. A
knife box contains a cutting unit (usually a small rotary knife) that operates in
a track and cuts across the fabric width when engaged. With face-one-way
spreads, each ply must be cut from the roll at the end of the marker. The
catcher simply holds the fabric end in place for cutting. As multiple plies are
spread, the fold blade and/or knife box must be elevated to the height of the
top ply in order to fold or cut the fabric.

7.7 SUMMARY
The spreading process is made easier by employing the spreading
equipments. Semi automatic, automatic and robotic controlled spreading
machines are available to prepare the lay. In this chapter the spreading
equipments are classified and their component parts and its functions were
discussed in detail. Some of the advanced spreading machines have
features like turn table, ply counter, defect scanner, etc. Spreading
equipmetns are having two strokes forward and dead stroke. The spreader
head is equipped with knife to cut the ply whenever required. The working
turn table system is explained. It is used to have all face up plies in all the
strokes of the spreading machine without dead strokes. This system reduces
time consumption and makes the process more effective and efficient.

7.9 KEYWORDS

Basic elements consist of a frame or carriage, wheels traveling in

guide rails at the edge of the table, a fabric support, and guide collars to aid
the correct unrolling of the fabric.

More advanced spreading machines may include a motor to drive

the carriage, a platform on which the operator rides, a ply-cutting device with
automatic catcher to hold the ends of the ply in place, a ply counter, an
alignment shifter actuated by photo-electric edge guides, a turntable, and a

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direct drive on the fabric support, synchronized with the speed of travel, to
reduce or eliminate tension in the fabric being spread.
A spread is covered with a plastic film that forms a seal over the
lay-up when a vacuum is applied. A lay-up of quilted fabric can be
compressed as much as 75 percent when the vacuum is used.

Positioning devices and sensors monitor position and control fabric

placement during spreading. These devices improve the quality of a spread.
Electronic edge sensors monitor selvages as fabric is spread.

This versatile spreading machine is capable of traveling from table to

table for continuous spreading. Built-in loader and unloader are available.

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7.10 TERMINAL QUESTIONS
Part A

1. What is automatic spreading machine?

2. what are the advantages of automatic spreading machine/
3. What is dead stroke?
4. What is the angle of rotation in turn table?
5. What are the parts in carriage/
6. What is platform?
7. What is defect scanner?
8. What is end catcher?
9. What are the needs of floating table?
10. Why is the lay compressed?

Part B

1. Write about turn table?

2. Compare automatic and semi automatic cutting machine.
3. Discuss the advantages and disadvantages of spreading machines.
4. List the various parts of spreading machines.
5. Write about tensioners and end catchers.

Part C

1. Explain in detail about various parts and their function in spreading

machines.

2. Explain in detail about the modern developments in spreading

machine.

7.11 FURTHER READING

1. Harold Carr& Barbara Latham,“ The Technology of Clothing

Manufacture”, Om Book Service, 1994.

2. Jacob Solinger, “Apparel Manufacturing Handbook”, Reinhold

Publications, 1998.

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