Vibemac is known for their jeans and casual trouser automation machineries and innovative solutions to upgrade product consistency. Automation means mechanization in process to deskill the operation, thus increasing product consistency and increase in productivity. As the operation becomes more and more specialized, the solution becomes more specific thus reducing flexibility. Automation introduces specialization and in turn reduces flexibility in a process. Traditionally automated workstations used to address a specific operation, with a specific stitch type for specific fabric type whereas a new trend is emerging among machinery manufacturers to offer flexibility in the automated workstations, which can handle a wide range of specifications. Team StitchWorld explored some of the automated yet flexible machines.
Automatic Pocket Hemming Unit (007V-006VLS)
[bleft]The 1010V4/V3 range machines are more flexible, economical, saving on delivery time and expenses. They can be indistinctly used by both manufacturers or even large factories [/bleft]
This machine has the flexibility to stitch on all kinds of fabrics, from stretch to polyester, from nylon to the heaviest jeans materials, with the maximum consistency of quality. And all this can be done by making a quick and easy mechanical adjustment to the machine because all of the main regulations are electronic and therefore made through the control panel. There will no longer be any wave effect or arching of the pocket hem, which eliminates quality problems and creates a considerable gain in sewing speed along with very high production rates.
All these units are also equipped with an innovative transport system which is driven by a stepping motor. The operator places the material to be hemmed on a base where a photoelectric cell reads the presence of the pocket and activates the belt transport system. When the pocket comes out from the hemming cycle perfectly sewn, the photoelectric cell positioned at the end of the transport belt commands the unit to stop the cycle. The length of the thread at the beginning and at the end of the pocket can also be easily adjusted by means of a control panel. At the end of stitching cycle the transporter belt and an unloader automatically stacks the pockets either to an inclined belt where a maximum of about 200 pockets can be stored or on a rotating disk of large productions, where up to 600 pockets are perfectly stored.
This unit offers flexibility in using either two-needle chainstitch (model 007V), or two-needle lockstitch (model 006VLS) or three-needle chainstitch (model 007K). It also offers three flexibility options in label attaching while hemming. In Manual Label Application, the operator manually inserts the precut label into a guide during the sewing operation which is then inserted into the correct position using a suction pipe device. In Automatic Label Application, the label is cut to the proper size using a heat cutting device, and automatically inserted into the pocket hem sewing cycle. In Automatic Loader Robot Model R6H, the operator loads the pockets on the robot and lets the machine do the rest! This allows 2400 pockets per hour with no operator, and only requires a helper to collect the hemmed pockets from the rotating disk every 15 minutes (capacity 600 hemmed pockets). R6H robot is sold separately as an integration of the standard manual loading unit. The machine has adjustable ergonomic stand with wheels, offering flexibility of height adjustment based on operator.
1010V4 Automatic Embroidery and Labelling Unit Double Colour
The whole 1010V4 range machines has benefited from adoption of improved performance and versatility of the PLK-G VMAC stitching head.
The programmable pattern tacking unit have a wider stitching field (256 mm x 159 mm for the PLK-G Vmac head), which allows applications such as flap stitching, embroidering rear pockets or applying labels and hook and loop, sewing coin pockets, and performing other types of ornamental stitching. These modular, programmable units are extremely flexible and have a very simple design and construction distinguishing them from other products in the market. Available also with double colour (DC technology), which enables the end user to stitch 2 colours at the same time!
By using the double grip (patented system) it is possible to use the most varied jigs which not only provide high performance but extreme flexibility of usage. The technical solution adopted to make the jigs (economical and easily available materials) and the programmable control panel fitted (for any application) enables the end user easily produce the jigs on site avoiding delivery time and delivery expenses. For example, a V4L unit, with a hook and loop or label application device is supplied with an adaptable universal jig. The user just has to cut the central plastic template as desired. This means that there is a reduction in management costs and more flexibility.
With this unique unit it is possible to switch from one function to another in a matter of few minutes. We cannot stress enough the fact that the end user can substitute one device with another without requiring the intervention of a technician, because of the ease in replacement procedures of the equipment parts.
This extreme flexibility makes the 1010V4DL a very special unit, one suitable to be used indistinctly by small manufacturers and large factories. It is possible to use a unit as versatile as 1010V4DL entire working day easily achieving high production rates and thus drastically reducing purchase and running costs for the end user.
001V Pocket Pressing Unit for Curved Pocket
These machines operate using a very simple but incredibly efficient system, with two independent pressing heads that can be managed by a single unskilled operator, which runs both sides at the same time and considerably increases the rate of production (maximum capacity of 450 pockets/hour). The units also have two independent electronic thermostats to regulate the pressing temperature and a Programmable Logic Controller (PLC) to set up the cycle time.
The design of the pocket jigs is extremely simple, making it possible for them to be delivered in a very short time and at low cost or even made locally. They are supplied to suit light weight (L), medium weight (M) or heavy weight (H) material, accordingly to the specifications of the customer.
Perfect creasing quality is achieved using patented Wave Curve System, which applies to both round and square pockets, and the fact that the creasing jigs are quick and simple to change because of the lock-unlock device which eliminates the use of screws. This is very important because with this feature customers can easily handle the production of a small quantity trouser order of several sizes (like children’s wear) and the production of trousers with asymmetrical pockets. And when needed, regulating the setting and adjustment of the machine for different thickness of fabric is also simple; all that is needed is to turn a plastic grip!
3022WB406 Waistband Application
The automatic 3022WB406 unit series is for the application of a waistband with flexibility of having 2/4/6 needle chainstitch (model CS), two needle lockstitch (model LS), or combination of single needle lockstitch and chainstitch together (model FLX). The waistband application can be sewn onto jeans or casual trousers and jackets in general with the “continuous waistband” working method. The unit automatically cuts and skips stitches at the two ends to the required measurement.
The remarkable simplicity of design, improvement in speed, and electronic management of material transport removes the need to mark the fabric and also allows easy and correct label positioning. Along with many more ingenious and easy solutions and its ergonomic design, make the 3022WB406 a perfect unit that meets every kind of fashion requirement desired by jeans and trousers producers. Design flexibility can be achieved by mixing the two types of stitches according to the pattern desired by the designer/buyer. Flexibility in waistband finishing is achieved by choosing waistband initial cut length and user programmable number of skip stitches.
[bleft]The automatic 3022WB406 unit cuts and skips stitches as per requirement and meets every kind of fashion needs. Adjustable ergonomic stand with wheels allows ultimate user flexibility[/bleft]
The 3022WB406 machine series is equipped with combined needle feed and special puller for double transport (upper and lower). This particular device permits users to obtain the best quality in the anatomic sewing of the waistband like mixed fabric waistbands are perfectly matched and avoiding sewing waves which is not possible to obtain with drop feed. This unit has been developed and mainly recommended to work using the continuous waistband roll system. Adjustable ergonomic stand with wheels allows ultimate user flexibility.
3022BHE-C/L Bottom Hemming Unit
The new 3022BHE unit is accurate, productive, and fully embodies the flexibility that has become the hallmark of all Vibemac products, thus presenting a solution to the market’s trouser hemline problems. 3022BHE is a cylindrical arm machine with single needle, lockstitch or chainstitch both in one unit, plus a large rotary hook and needle feed with special patented double roller (puller) for hemming the bottom of the trouser leg. The machine can sew every kind of fabric, chain and lockstitch in the same unit, all stitch lengths programmable.
This unique unit makes it possible to change from light to heavy fabrics without any alteration to mechanical components or electronic adjustments. A lower roller feeder with an extremely powerful patented upper puller can easily handle the more delicate operations like crossovers or lap felling, especially with heavy fabrics. Special innovative hemming device enables sewing the hem both on the front and on the reverse sides. Equipped with a standard guide, the width of the hem ranges from 8 mm to 30 mm, up to a maximum of 42 mm. Pneumatic system for the toggle-joint opening of the guide which can be set in manual or automatic mode by the operator, with the foot lifting at the same time. It is easy to switch between lockstitch and chainstitch and also quick change of stitch length in less then one minute.