Case study
Roller blinds
THE PROJECT
One of Europe’s foremost sun-protection system manufacturerscommissioned a complete production line for roller blinds. Ultimately, they were looking to automate their manufacturing process in order to create a high-quality product of variable dimensions in under two minutes.
The finished product had to be strong and seams had to be thoroughly welded and appealing. For this client, the aesthetic component was just as important as its durability. Fabric edges had to be clean cut, and the cut seared. The lower pocket-with-keder would have been visible in the finished product, therefore had to be high-quality. The tolerance of the diagonals on the finished product were required to be less than 2 mm. This machine should also had to accommodate rolls of various weights and dimensions.
THE PROCESS
We designed a machine that automatically pulls the fabric off the roll, cuts the fabric to size with twin motorized rotary blades, and applies a coextruded PVC profile to the top while simultaneously creating a pocket-with-rope to the bottom. Finally, an automatic ultrasonic machine crosscuts and rewinds the created products on an aluminum tube.
The new machine produces a perfectly cut and welded roller blind, rewound and ready for insertion in the box, in less than 90 seconds: 30 seconds less than their original request!
The software interface can communicate with machine’s manufacturing software and our customer’s order database system, resulting in a complete automation of their order management system and load handling.
A series of cleverly designed tools ensure the welded seams are perfectly flat and straight. The powerful motorized electric rotary blade cuts through the profile and pocket with speed and great precision while the ultrasonic blade creates beautifully seared cuts on the sides of the blind.
