CARDING AND STUFFING

Carding

Fiber preparation includes multiple feed hoppers that begin to opening the fiber and weigh the individual fibers to get an accurate blend percentage. Once the different fibers are weighed and layered in the Blend Conveyor, the fibers are conveyed into the Fine Opener. The Fine Opener will further open the fiber and properly blend the different fibers together.

Once blended, a pneumatic conveying or feed system is used to transport the fiber from the blend line to the Card machine. The feed system could include features such as inline hump magnet, active metal extractor, differential pressure switch, site tube, material fan and duct work.  A negative pressure system is used to reduce the amount of static and airborne fiber or dust.

The Card Machine will process the fibers at a high rate and produce a uniform quality web. The web will be lapped to the correct width of the pillow.  The Card Machine includes an auto doffed and self-threading feature.  This will allow the operator to initiate the Card Feed Rolls then monitor the machine while the system automatically begins running product. The Carded web will enter the Pillow Lapper.

Cross lapping

The web will be lapped to the correct width of the pillow.  The Pillow Lapper is able to produce a travel or airline pillow up to the largest body pillow on the market. The Card Machine includes an auto doffed and self-threading feature.  This will allow the operator to initiate the Card Feed Rolls then monitor the machine while the system automatically begins running product. The Carded web will enter the Pillow Lapper.  The Lapper will layer the fiber to the correct product width, thickness and weight. The Lapper includes a Hanging Floor Apron.  The height of the apron can be adjusted depending on the product thickness. All the product specs and machine settings are displayed on the touch screen.

The Carded and Cross Lapped web enters the Pillow winding unit.

Pillow winding

This machine automatically rolls the lapped fiber to the correct weight, cuts and discharges the fiber batt into the Roll-carded fiber (Garnetted) stuffing unit.

Insert application

As an option is available an automatic device for adding an insert (made by foam, rubber, visco, …) inside of the carded and lapped web before winding it into the final rolled carded fiber core.

The insert is included in order to grant a head support feature to the finished pillow.

Roll-carded fiber (Garnetted) stuffing

A complete set of ALAN STUFFER machines are available for inserting the roll-carded fiber inside of the related pillow cover. Those machines are designed in order to manage very different core sizes, thickness and stiffness.

Pillow shell automatic warehousing

Pillow shells can be stocked in a fully automatic vertical warehouse in order to optimize the space occupancy, the material pick up and the warehouse level management. Feel free to ask us about a proposal in order to optimize the inner material flow logistic.

Pillow shell unfolding and loading

Some foam and latex core production lines are heavy speed and so they require a higher degree of automation for producing the related finished pillows.

BORSOI is providing an integrated automatic solution for unfolding the pillow shell, compress the inner core and stuff it into the shell and close it with the desired seaming.

From there the pillow can be moved to the packaging line if present.