Business

A.T.E. - Single Window Solution Provider For Carpet Manufacturing

Driven by rapid urbanisation, rising disposable incomes, lifestyle changes, and increased spending on home furnishing and interiors, the market for carpets and rugs is growing phenomenally the world over. According to reports, the global carpet market is valued at US$ 91.20 billion in 2020 and is expected to reach US$ 117.14 billion by 2026, growing at a CAGR of 3.6% during 2021-2026. India's carpet industry, which employs 2 million people and exports US$ 1.8 billion every year, has however stagnated in the last five years. One reason for this is that the Indian carpet market is currently highly fragmented. It is imperative for India to invest in the right carpet manufacturing technologies and build scale if India is to be a part of this global growth story. It is with this intent that A.T.E. has tied up with a number of global leaders in the field to offer all the equipment needed for carpet manufacturing right from BCF yarn production to carpet confection. Here is a line-up of A.T.E.’s carpet manufacturing portfolio that comes with A.T.E.’s assurance for quality, reliability and service:

BCF yarn production lines from Truetzschler Nonwovens & Man-Made Fibers, Germany
Carpet yarn heat setting lines from Power-Heat-Set, Germany
Tufting machines from Card-Monroe Corp., USA
Digital printing from Zimmer, Austria
Supporting equipment for digital printing lines from Yamuna Machine Works, India
Carpet back coating/drying and carpet shearing/finishing from Sellers Textile Engineers Limited, England
Carpet confection lines, auto packing lines and winders from Matthys Group, Belgium, and
Robotic tufting from EFAB, Germany

BCF yarn production line from Truetzschler Nonwovens & Man-Made Fibers, Germany Truetzschler Man-Made Fibers manufactures machinery and systems for the production of BCF and industrial yarns. Truetzschler’s symTTex carpet yarn solutions produce high quality yarn with flexible and economic operation. The newly developed 4-end BCF MO40 combines highest productivity and top yarn quality. Some of the MO40’s prominent features include an optimised yarn path with proven components and processes. Trützschler and EREMA (Engineering Recycling Maschinen und Anlagen Ges.m.b.H) jointly offer a compact inline solution for the processing and spinning of recycled polyester. EREMA is responsible for the VACUREMA reactor, the single screw extruder and the polymer filter. The first-class polymer melt with high IV value serves Trützschler’s spinning and the downstream components directly, resulting in highly uniform BCF yarns. All components including the spinning beam, spinning pack, quenching, texturing, godets, and winders are designed for optimum yarn quality. Carpet yarn heat setting line from Power Heat Set, Germany Power-Heat-Set equipment operates with superheated steam, which offers many advantages, including a higher stain and soil resistance of the yarn. The different versions of PHS machines called GVA and HiPerSet, enable manufacturers to offer a wide variety of products, thus allowing them to choose a machine that meets their needs. Tufting machines from CMC USA These state-of-the-art tufting machines from CMC, USA, are designed to produce carpets with multiple colours, multiple pile heights, and a variety of textures. Nearly all carpets are therefore being produced on tufting machines. The precise execution and reliability that a CMC tufting machine provides is unmatched. CMC machines are custom manufactured to match the unique requirements of each individual customer. ChromoJET printing and Colaris Inkjet printing/digital printing systems from Zimmer, Austria [caption id="attachment_20215" align="aligncenter" width="625"]

CMC's Colorpoint Tufting Machine[/caption] Zimmer’s portfolio includes screen printing, digital printing, digital functionalization, coating, drying and steaming systems as well as a broad range of sample, lab and washing machines. Zimmer offers a range of solutions for application areas such as home textiles, wall covering, fashion, upholstery, towels, blankets, technical textiles, nonwoven, paper and even glass fibre. ChromoJET is the optimum solution for printing on high pile carpets (as well as short pile carpets) with dyes and chemicals and for resolutions ranging up to 100 DPI. Colaris is suitable for printing on low pile with high density carpets with ink and chemicals and for resolutions up to 400 DPI. Supporting equipment for digital printing lines from Yamuna Machine Works, India Yamuna designs, develops and manufactures state-of-the-art supporting equipment like entry units, J scrays/accumulators, centering units, lint cleaning units, presteamers or prewashers, stenters/dryers, infrared heaters, and exit units for digital printing machines for carpets and rugs – all manufactured to global standards of excellence. Carpet back coating, drying, shearing and finishing from Sellers Textile Engineers Limited, England Sellers provides complete back coating lines for tufted secondary backing, 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. Sellers also manufactures a range of equipment such as scrays, accumulators, conditioning drums, slitting units, nip rolls, re-roll units, and chest steamers for face and back steaming. Sellers additional offerings include scrays with “no carpet” detectors, dedicated back and face cleaning units with extraction, bow and weft correction equipment. Direct spread and lick roll applicators are available with full automated control, latex applicators with traversing feed and circulation system, heavy duty vertical chain, pinned stenter, up to 5000 mm wide. Carpet confection lines and auto packing lines from Matthys Group, Belgium Matthys provides automated solutions for sewing, cutting, and confection processes for carpets and fabrics in general. Applications include carpets, bathmats, rugs, bed sheets and blankets. With the best systems for automation, all Matthys solutions provide great flexibility and consistent quality output. The product range for carpets includes long side cutting, long side over edging, inspection machine, cross cutting, short side over edging, gluing machine, rolling and packaging machine, finished goods manipulator, wall to wall roller and custom-made projects. EFAB GmbH, Germany EFABoffers is a seamlessly integrated innovative and high quality robotic tufting solution with advanced carpet design software. EFAB is also into manufacturing and exporting of portable stationary carpet shearing equipment which is very good for the samples and small volume production. eTuft is an advanced robotic tufting machine to produce fashionable tufted carpets, area rugs and samples. EFAB tufting solutions in combination with eDesigner and eHMI are the perfect combination for creative and cost-effective carpet and rug production.

A.T.E. with over 80 years’ experience in the Indian textile industry is associated with the who’s who of the Indian textile industry for decades. A.T.E. is committed to support the Indian carpet industry to leverage the opportunities in the carpet and rugs market. A.T.E. has recently worked on a project for Welspun, supplying a majority of the machinery for their new integrated carpet flooring project in Telangana, Welspun Flooring Limited.