TEXTILE MACHINE COMPANY LTD.

Harding Street, Leicester LE1 4DH, England.

Tel: 0044 (0) 116 262 9661 - Fax: 0044 (0) 116 251 3041 - E-Mail: sales@bates-textile.demon.co.uk

Key Benefits

The Bates Model "Y.C.B." Machine is a high speed yarn processing machine of advanced technology which has been developed to produce fully stabilised, heat stretched, coated and bonded yarns.  Throughout the range from 100 denier to 3,000 denier, at throughput speeds of up to 120 metres per minute.

The Bates Model "Y.C.B." Machine was primarily designed to produce stretchfree frictionless sewing threads for use in garment manufacturing at speeds of up to 8,000 stitches per minute without seam distortions of any kind.  Other specialised yarns, such as those for braids, tyrecords, dental floss, ropes, shoelace threads and yarns for a wide range of industrial textiles can be produced with quick efficiency.

The Bates Model "Y.C.B." Machine offers important features both from the technological and economic viewpoints to give high outputs and reduced factory and labour costs coupled with minimum energy requirements.   A "Y.C.B." Machine arranged to process 50 yarns of 3 ply 210 denier, for example, requires a power consumption of only 40 k.w. for a total collective yarn throughput speed of 6,000 metres per minute.

In operation, the incoming yarns from individual supply packages are collected into a parallel warp and travel side by side through the polymer coating tank, across a four section drying and heat setting zone, on to a stretching zone and then on to a yarn lubrication zone, prior to individual yarn separation and finally to a heavy duty multi-tier take-up where individual yarns are precision built on to double flanged bobbins or parallel cheeses.

Supply Creel.

The angled multi-tier yarn supply creel is designed to contain at least twice the number of yarns required to be processed and is supplied to customer's requirements.  It can be arranged to accommodate "supercones", double flanged bobbins, cheeses, parallel tubes or fibre produced packages all controlled by individual tensioning and balloon control units.

Yarn Dipping and Bonding.

From the supply creel the incoming yarns are assembled into a warp sheet as they pass through a stationary comb.  The collected yarns are then transferred down into the polymer bonding tank and travel beneath two polished stainless steel bars which control the entry, immersion and duration of dwell in the tank to ensure that each yarn is fully coated by the liquid polymer.

After immersion, the yarns travel up and through an oscillating full width comb, which separates the yarns to prevent grooving of the squeeze roller (s) which are pneumatically controlled.  A three roller tensioning unit is mounted above the squeeze rollers and guides the yarns horizontally into the heating zone.

The stainless steel polymer coating tank is water heated and mounted onto a mobile chariot which in turn is supported on a pneumatically operated platform which enables the tank to be easily lowered out of contact with the yarns during maintenance, or, when setting-up for processing.  The chariot and tank are disconnected and removed for easy replacement when required and can be reconnected elsewhere in the factory for recharging and heating if required.  The water jacket tank is provided with an electric heater and a thermostat to pre-set and control water temperatures from 30 to 100 degrees centigrade.

Drying and Heat Setting.

The heating zone is arranged in four operating sections.  The first section is usually operated at a low temperature sufficient to evaporate solvents or water from the bonding liquor and to prevent yarn blistering in consequence.  The second, third and fourth sections of the heating zone are used to dry and cure the yarns prior to lubrication.  Two fume extractor units are mounted below the heater zones to exhaust the vapours into the factory fume removal trunking system.

Each section of the heating zone is provided with its own infra red heater units, operated by electricity, and are located above the yarns at a distance of 50mm.  The heater units are mounted on slides controlled by a pneumatic cylinder.

In the event of a yarn stoppage, the heaters then automatically move horizontally away from the yarns, thus preventing heat distortion or melting.

Each heating section is provided with an independent temperature control unit and its own temperature sensor thermocouple which can be set to operate from 100 to 400 degrees centigrade.

Required temperatures are reached quickly and controlled by the self diagnostic controllers to within plus or minus two degrees centigrade.  The heaters operate with up to 98% efficiency with the use of state of the art insulation and reflection rear panels.

Stretching.

An important feature is the yarn stretching zone which contains two positively driven rollers, one of which is a rubber covered large diameter nip roller, which is pneumatically operated and can be adjusted to provide the required pressure.  An oscillating comb is provided to prevent grooving of the nip roller.  In the stretching zone the output speed of the yarn can be controlled in relation to the input speed so that stretch rates of up to 30% can be obtained depending on types of yarn being processed.

Yarn Lubricating.

The yarn lubricating unit coats the yarns usually with a silicone lubricating fluid or hot wax.  From the oven unit the yarns travel across a large diameter positively driven applicator roller which is provided with a choice of variable speeds in 2 directions, in order to determine the rate of application.   After lubrication, the yarns diverge into single ends and pass across to the take-up unit.

Take-Up Zone.

Each end of yarn is wound on to double-flanged bobbins (or parallel tubes) on the multi-tier take-up unit.  Each take-up package is wound at a constant linear speed by surface friction between positively driven rollers and the double flanged bobbin (or package).

The heavy duty traverse bars are variable in speed to control the uniformity of the package build.  Micro-adjustment of the yarn traverse is provided to accommodate slight variations in bobbin depth.  Ceramic thread guides are fitted to minimise wear.

Controls.

The main controls are housed in a separate free standing cabinet for ease of access and maintenance and contain all the necessary isolators, relays, solid state switches, motor controls, time delays, fan and auxiliary heater controls.  All operator controls are located on the front facia of the machine itself and allow for control of temperature to coating fluid, input roller, main setting zones, haul off roller, and lubricating zone.  Start/Stop of main motors, speed control and indicators, through-put speeds and percentage change of input or output.   Only one start button is fitted for safety reasons although several stop buttons are provided at the front, rear and sides.  The heater position control is automatic in the case of stoppage.  A manual override switch is provided for threading up purposes.

When dental floss is produced, additional controls are added to enable hot wax to be applied and to control the refrigeration sections as well as flavour applications.

Heater Positions.

Each section of the heating zone is provided with its own infra red heater units operated by electricity and are located above the yarns at a distance of 50mm.  The heater units are mounted in slides controlled by a pneumatic cylinder.

In the event of a yarn stoppage, the heaters then move horizontally away from the yarns thus preventing heat distortion or melting.

Each heating section is provided with an independent temperature control unit and its own temperature sensor thermocouple which can be set to operate from 100 to 400 degrees centigrade with an accuracy of plus or minus two degrees centigrade.

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