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since 1945
ORTHOPAC® REMC-15Process Control System
ORT
HOPA
C® R
EMC-
15
Quality madein Germany
Edition Stenterkit
NONWOVEN PAPERCOATING & CONVERTING
EXTRUSIONTEXTILE
2 Orthopac® REMC-15
NONWOVEN PAPERCOATING & CONVERTING
EXTRUSIONTEXTILE
PROCESS CONTROL SYSTEM
ORTHOPAC® REMC-15Edition Stenterkit – Quality does not have to be expensive!
Problem
A cost-efficient and quality-oriented textile machine is primarily an operative matter. However, it is often critical for the market involve-ment. Using suitable measuring and control systems with drying and fixing processes is therefore absolutely essential. The main problems with processes in stenters include:- Wrong dwell times of the product in the stenter- Excessive energy consumption with the exhaust air moisture- Poor residual moisture values of the product - Product skew during drying process.
Much unused energy is wasted through these problems. In addition, the process continuity and quality of the goods suffer.
Solution
Maximum economy of production and high, continuous product qua-lity can be achieved only through optimal control and regulation of the processes in the stenter. The stenter can only work efficiently and economically by addressing the four basic problems just enumerated. With life-cycles of up to 30 years, energy savings through economy plays a decisive role. Translated to the service life of a stenter, the energy costs amount to roughly 10 million Euro. If up to 30 % of this sum can be saved, the investment for the necessary control equip-ment is only a secondary matter.
Edition Stenterkit – simple, effective, affordable
We have learned through intensive analysis of the market, spanning several years, that up to 80 % of the textile outfitters have the same basic problems. Based on this awareness we have created a product that offers a solution exactly for this issue. “Meet the needs” was the motto with the “Edition Stenterkit”. Process control for drying and fixing processes.
Because of the well-chosen and exactly defined functions, in addi-tion to series production, Edition Stenterkit can be produced in a cost-optimized manner. We pass this cost benefit on to you – 100 %. Thus your investment quickly turns into profit.
2
Edition Stenterkit
We have learned through intensive analysis of the market, spanning several years, that up to 80 % of the textile outfitters have the same basic problems. Based on this awareness we have created a product that offers a solution exactly for this issue. “Meet the needs” was the motto with the “Edition Stenterkit”. Process control for drying and fixing processes.
Because of the well-chosen and exactly defined functions, in addi-tion to series production, Edition Stenterkit can be produced in a cost-optimized manner. We pass this cost benefit on to you – 100 %. Thus your investment quickly turns into profit.
basic problems. Based on this awareness we have created a product that offers a solution exactly for this issue. “Meet the needs” was the motto with the “Edition Stenterkit”. Process control for drying and fixing processes.
Because of the well-chosen and exactly defined functions, in addi-tion to series production, Edition Stenterkit can be produced in a cost-optimized manner. We pass this cost benefit on to you – 100 %. Thus your investment quickly turns into profit.
3Orthopac® REMC-15
ORT
HOPA
C REM
C
Package
Process control AR AV ARV
Exhaust air moisture X X X
Dwell time X X
Residual moisture X X
Components
Edition Stenterkit includes everything required to solve the process problems outlined here.
- Automatic process control: Applying state-of-the-art microprocessor technology, process control ensures
product quality and energy balance. The basic unit is integrated in the straightening system. Depending on the equipment package different components are supplied.
- Orthopac REMC Automatic straightening system: An optical scanning system with electronic control for skew correction in
connection with a precise straightening unit. Removes skews and bows fully automatically. The unit is controlled via a TFT touchscreen monitor
- Ecomat AML (A) Exhaust air moisture measurement: A dual zirconium oxide cell measures the humidity of the exhaust air, regulates the
exhaust air volume and helps to minimize energy consumption.- Textometer RMS (R) Residual moisture measurement: A rod electrode at the dryer delivery determines the residual moisture through electrical
resistance measurement and controls the level of drying of the product via the dryer speed.- Permaset VMT (V) Dwell-time / Fixing time measurement: Infrared pyrometers determine the temperature curve and the software determines the current dwell /
fixing time. The dryer speed is automatically optimised.
Designs
The systems for woven or knitted fabric differ in the design of the straightening unit.
Design Product width Scanning Accessories
Woven fabric 3200 6 Scanner heads Base frame
Woven fabric 1800 / 2000 4 Scanner heads Base frame
Knittted fabric 2400 / 2600 4 Scanner heads Product tension controlSpreading unit Base frame with 1 roller and tachometer
Equipment packages
Three equipment packages with different process control functions are available
4 Orthopac® REMC-15
PROCESS CONTROL SYSTEM
Product-highlights
✓ A single system controls all essential drying / process parameters✓ Intuitive user interface✓ Easy to install
Product-highlights
✓ Highest alignment accuracy✓ Progressive straightening speed✓ Very compact construction✓ Low goods content
Customer benefi ts
✓ Guaranteed product quality✓ Optimizing the energy balance at drying and fixing processes
Customer benefi ts
✓ Maintaining tight distortion tolerances✓ Avoiding complaints✓ Improved customer relation-ship✓ High repeatability✓ Short amortisation times✓ High reliability / Service life
Process Control System
Straightening system
The basic unit of the process control is accommodated by the straightening system.
The sensors are simply connected to the system base via a single CAN-bus cable.
A classic straightening unit in proven mahlo® quality provides absolutely straight-threaded products through state-of-the-art technology.
Edition Stenterkit
The best of two worlds!
ORTHOPAC® REMC-15
5
200 40 60 80 100
exhaust humidity (Vol. %)
rel. volume of fresh air-cost index
rel. evaporative capacity
Orthopac® REMC-15
Ecomat AML (A) exhaust air moisture
Textometer RMS (R) Residual moisture
Permaset VMT (V) Dwell-time / Fixing time:
The amount of water to be eva-porated during any period of time depends on the product weight, incoming and residual moisture, product width and transport speed.
Best possible control of the exhaust air flaps and fan speed produce optimal exhaust air moisture values. Much energy is saved through the adjusted heat output.
In the area of residual moisture, the conductivity of the textile substrates‘ water content depends most strongly on the electricallymeasurable properties. The residual moisture can be determined directly by measuring the electrical conductivity.
Heating energy is saved and the product quality as well as the drier capacity are increased by pre-venting overdrying of the goods.
When wet product enters the dryer, it first heats up to the cooling limit temperature. At a certain temperature threshold – called the fixing temperature – the temperature necessary for processing, fixing or condensing is reached.
Infrared pyrometers determine the temperature curve and the software determines the current dwell / fixing time. The dryer speed is automatically optimised.
% H2O
OHM
40 8 12 16 % H2O
104
106
108
1010
1012OH
M
wool polyamideviscose fibre moisture atcotton x % humidity
20
40
60
80
100
120
140
160
180
200
°C
14
Fabric temperature
Length of the setting machine
Constant-rate period temperature
M1 M2 M3
16 24 m
Measuring points
Setting temperature
t1 = 12s; s1 = 10 m
t2 = 12s; s2 = 8 m
t3 = 12s; s3 = 6 m
Dwell time
Line-speed for 3 different products:
V1 (50m/min)V2 (40m/min)V3 (30m/min)
213 6 9 12 15 18
A
R
V
ORT
HOPA
C REM
C
6 Orthopac® REMC-15
NONWOVEN PAPERCOATING & CONVERTING
ExTRusIONTExTILE
Orthopac REMC Straigthening unit Woven fabric Knitted fabric
Straightening mechanics 3 skew rollers, 2 bow rollers
Drive Electrical: Selction via servo-motors through frequency converters
Straightening capacity (at w = 1800 mm)
Skew max. ± 750 mm; Bow max. ± 220 mm
Positioning time Bow / skew adjustable, minimum of 6 - 8 seconds at maximum displacement
Product width 1800 / 2000 / 3200 mm 2400 / 2600 mm
Max. product speed 250 m/min 150 m/min
Fabric capacity (basic machine with scanner assembly)
3 skew / 2 bow rollers: ~ 3250 mm
Scanning head bridge 4 (6) scan heads, manual adjustment via high-quality linear slides with latch positions
Weight (when w = 1800 mm) ~ 950 kg
Mains connection 3 x 400 VAC 50/60 Hz, no neutral, transformer station available for other voltages
Max. power consumption 2.2 kVA 3.0 kVA
Max. ambient temperature 50 °C (air condition is standard)
Display and operating station 12.1" TFT Touchscreen mounted in side section
TECHNICAL DATA | WOVEN FABRIC • KNITTED FABRIC
7Orthopac® REMC-15
Dimensions
ORT
HOPA
C REM
C
B-B
A-A
size
Nur zu eigenem Gebrauch!Diese Unterlage darf ohne unsere Zustimmung weder vervielfältigtnoch dritten Personen gezeigt oder ausgehändigt werden. Zuwi-derhandlungen sind strafbar und verpflichten zu Schadenersatz.MAHLO GMBH+CO KG 93342 Saal/Do.
For private use only!This document may neither be reproduced, nor shown, norsurrendered to third parties without our prior consent. Anycontravention will be liable to prosecution and damages.MAHLO GMBH+CO KG 93342 Saal/Do.
copyright after DIN 34
material number:
page
of1
1
type
knitted fabrics�����
����
surf
ace-
data
date name
93342 Saal / Donau (Germany)date namenorm
reg.aud.
mar.
nr. modification
DIN
ISO
1302
DIN
3141
arra
y3
08.02.2017 E-gaf
raw
Rz63
Rz16
Rz4
Rt=
63R
t=16
Rt=
4
assemblypart dimensional drawing
REMC-15 91-018701
1234
-A2
drawing number:
behalt gages without tolerance data allowed deviations DIN 7168 medium
B B
F
E
D
C
B
A
B
45678
F
E
D
C
A
124 35678
A
A
cable inlet
C&D station 12''
670
500
325
300 b + 480
b + 47025
30375
720
440
500
1150
1210
1462
b (2400 / 2600)
b + 420400 400
b + 1220
130
550
1053
280
doorway
726
doorway
� 20
b + 420
720
140
web tensioncontrol(dancer roller)
side panelunderframes
Ø100roller diameter:ø101,6 / ø114,3depends onproduct width
inlet spreaderroller
200
58
620
60°-1
20°
60° - 0
°5°+
= compressed air supply p min = 4 bar / V = 10 l/min tube = Da = 8mm
= drive
fabric run
b = product width 2400 / 2600
all dimensions in mm
cooling system
control panel
B-B
A-A
size
Nur zu eigenem Gebrauch!Diese Unterlage darf ohne unsere Zustimmung weder vervielfältigtnoch dritten Personen gezeigt oder ausgehändigt werden. Zuwi-derhandlungen sind strafbar und verpflichten zu Schadenersatz.MAHLO GMBH+CO KG 93342 Saal/Do.
For private use only!This document may neither be reproduced, nor shown, norsurrendered to third parties without our prior consent. Anycontravention will be liable to prosecution and damages.MAHLO GMBH+CO KG 93342 Saal/Do.
copyright after DIN 34
material number:
page
of1
1
type
woven fabrics�����
����
surf
ace-
data
date name
93342 Saal / Donau (Germany)date namenorm
reg.aud.
mar.
nr. modification
DIN
ISO
1302
DIN
3141
arra
y3
07.02.2017 E-gaf
raw
Rz63
Rz16
Rz4
Rt=
63R
t=16
Rt=
4
assemblypart dimensional drawing
REMC-15 91-018700
1234
-A2
drawing number:
behalt gages without tolerance data allowed deviations DIN 7168 medium
B B
F
E
D
C
B
A
B
45678
F
E
D
C
A
124 35678
A
A
cable inlet
C&D station 12''
500
1150
1210
1462
400 400
b + 1220
550
1053
280
doorw
ay
726
doorway
720
140
Ø100
roller diameter:ø101,6 / ø114,3depends onproduct width
b (1800 / 2000 / 3200)
standard roller position A
b + 420
fabric run
b = product width 1800 / 2000 / 3200
all dimensions in mm
side panelunderframes
25325 b + 470
30b + 420 375
b + 480300
500
670
440
620
720
� 20
optional rollerposition B
cooling system
control panel
ORTHOPAC REMCKnitted fabric 91-018701
ORTHOPAC REMCWoven fabric91-018700
NONWOVEN PAPERCOATING & CONVERTING
ExTRusIONTExTILE
8 Orthopac® REMC-15
Sensor Textometer RMS residual moisture
Measuring principle Residual moisture measurement
Measuring range Depending on type of fibre, mixture and electrode e.g. cotton: 3 - 20 %
Controller output Digital
Measurement display Standard electrode (1-channel): highest moisture value
Operating limits Sensor controller: 0...+ 50 °C
R
TECHNICAL DATA | ECOMAT AML • TEXTOMETER RMS
Sensor Ecomat AML exhaust humidity
Measuring range H2O
0 – 100 vol.-%
Measuring accuracy ≤ 2 vol. -% of the top-end of range
Output signal 0 – 20 mA, 4 – 20 mA
Temperature range Measuring amplifier: 0 – +65 °CSensor: 0 – +300 °C
Climate class JWE according to DIN 40040
Mechanical Data Sensor Measuring amplifier
Design Stainless steel housing Aluminium die-cast housing
Protection class Only measuring gas allowed IP 67
A
9Orthopac® REMC-15
A-A
A A
� 145
� 35
508
80
100
200
100
� 126
Ø9
45° 45°
260
max
Klemmschraube / locking screw
160
Strömungsrichtung / flow direction
ECOMAT AML91-015470-01
TEXTOMETER RMS91-015683
Dimensions
ECOM
AT A
ML
/ TE
XTOM
ETER
RM
S
NONWOVEN PAPERCOATING & CONVERTING
ExTRusIONTExTILE
10 Orthopac® REMC-15
TECHNICAL DATA | PERMASET VMT
LISTENINGOur sales team knows how to listen: with our customers' individual requirements, wishes and ideas firmly in mind, they point our R&D engineers in the right direction. So you get exactly what you really need.
Mechanical Data Sensor Measuring amplifier
Design Stainless steel housing, 6 m connecting cable in Teflon design
Aluminium die-cast housing
IP protection class IP 65 IP 67
Sensor Permaset VMT Dwell-time / Fixing time
Measuring range 0 – 250 °C
Measuring field Field of view 120°
Measuring accuracy ≤ 1 % of readout range at 23 °C
Response time t0,9
= 6 s
Output signal CAN, analogue 0 – 20 mA
Temperature range Measuring amplifier: 0 – +85 °CSensor with cable: 0 – +250 °C
Climate class KPA according to DIN 40040
V
11Orthopac® REMC-15
PERMASET VMT91-015449
A
A
100
200
350
690
175
163
30
17SW
M5 - 7 deep
Kabellänge 6mcable length 6m
5280
� 49,5
R min. 30
grounding
(12)
PERM
ASET
VM
T
Dimensions
FIRST AID
You can count on our service team, especially when ‘first-aid’ is required. A call is all it takes to get our technicians on-site. Around the clock – and around the globe. So that you can concentrate on your work without worry.
Support-Hotline:
+49-(0)180-50 62 456
Online-Support:
Best-possible technical support and transfer of know-how are written in capital letters at Mahlo®. Thanks to an international network of agencies and service centres, customers have at their disposal competent support worldwide. We are there for you 365 days a year, 24 hours a day. Just get in touch with us!
Monitoring and control systems, automation:
MAHLO® GUARANTEES QUALITY.WORLDWIDE, IN YOUR VICINITY.
WWW.MAHLO.COMORTHOPAC® REMC-15 84-010475-enSubject to revision! © Mahlo GmbH + Co. KG
Mahlo GmbH + Co. KG Germany
Donaustr. 12, 93342 Saal/Donau
Tel.: +49-9441-601-0
Fax: +49-9441-601-102
Mahlo Ouest S.P.R.L. Belgium
Quartum Center
Hütte 79 - Bte 10
4700 Eupen
Tel.: +32-87-59-69-00
Fax: +32-87-59-69-09
Mahlo Italia S.R.L. Italy
Via Fiume 62, 21020 Daverio
Tel.: +39-0332-94-95-58
Fax: +39-0332-94-85-86
Mahlo España S.L. Spain
C/ Santa Margarida, s/n - Nave n°13
Polígono Industrial Riera de Caldes - Boada Vell
E08184 Palau Solità i Plegamans (Barcelona)
Tel.: +34-938-640-549
Mahlo America Inc. USA
P.O. Box 2825, Spartanburg, S.C. 29304
Tel.: +1-864-576-62-88
Fax: +1-864-576-00-09
Mahlo do Brasil Ltda. Brazil
Rua dos Lírios 849 e 851
Cidade Jardim II - Americana – SP
Brasil CEP- 13466-580
Tel.: +55-19-3407-7954 / +55-19-3601-7363
Fax: +55-19-3405-4743
Quality madein Germany
since 1945
3 Over 40 service centres worldwide
3 Service partners in over 100 countries
3 Direct service and supply of spare
parts within 24 hours
3 Remote diagnostic system
3 Service-hotline: +49-180-5062456
