Techno-Economics of Shuttleless

Looms

Lohit Bakore
Final year
Textile Technology
SVITS, Indore
11/02/2021 1
 Introduction

The Shuttleless looms came in to existence as a result of the

growing production demands. The shuttleless Looms apart from
their high Speed weaving abilities are also ahead of their shuttle
counterparts in various other aspects.
This is the reason which makes them more suitable as present
day weaving machines.

11/02/2021 2
 Advantages of Shuttleless looms over
Predecessors

 Higher operating speed resulting in higher production.

 Less picking energy is required.
 More colours in weft direction.
 Higher design capabilities.
 Wider width fabrics can be woven.

11/02/2021 3
 The Technology of Shuttleless Looms

These looms are different in the picking , beat up, let-off and
take-up mechanism.
Also these looms are equipped with the QSC systems , ESLY
Motions, electronic controls and microprocessor devices which
make them an entirely different and more productive machine.

11/02/2021 4
 The Filling Insertion Technique
Instead of a heavy shuttle these looms use
comparatively lighter weft carriers.
The advantages are:

• Higher weft insertion rates and loom speeds

• Lesser vibrations and higher stability
• More production
• Lesser power requirements

11/02/2021 5
11/02/2021 6
 The Beat Up Mechanism

These machines use a matched cam Beat Up Mechanism. The

sley is driven by a set of complementary cams with cam followers
on both sides of the machine. The reed holder is made of light
alloy with great stiffness. The sley with its reed holder is perfectly
balanced by means of counter weights and provides a powerful
beat-up over the whole weaving width, without any vibration.

11/02/2021 7
 The Let off and Take Up Mechanism

• These machine use electronic let off and take up

mechanisms.
• The required pick density is electronically set and makes
it possible to weave patterned fabrics with alternating
pick densities
• The take-up and let-off are driven by the same type of
motor. The electronic link between let-off and take-up is
an additional tool for the weaver to manage fabric
quality.

11/02/2021 8
 Electronic Selvedge System

In the Electronic Selvedge System full leno false selvedge

motions are electrically driven by individual stepper motors.
They are mounted in front of the healds, so that all the
healds remain available for the fabric pattern.
The selvedge crossing and pattern are programmed on the
microprocessor.

11/02/2021 9
 The
Electronic
Selvedge
Mechanism

11/02/2021 10
 Automatic Full Pick Finding Mechanism

At a filling break the machine stops and only the healds are
moved automatically to free the broken pick for removal by
the weaver.
The automatic pickfinder and the slow motion movements
are not driven by a separate motor – the pickfinding is simply
done by the Sumo at slow speed.

11/02/2021 11
 Quick Style Change

The Quick Style Change (QSC) system enables a style change to

be carried out in about 80 minutes*. The style change is done
by replacing the entire rear part of the split frame, with the
warp beam, backrest and support, warp stop motion, harnesses
and reed. All the settings involved in preparing the fabric on
the warp side are done before the style change, outside the
weaving shed.

* Picanol loom
11/02/2021 12
 Average Loom Stoppage Time *

Without QSC
Stop factor With QSC system
system
Waiting time 5 5
Loom unloading 10 40
Trolley waiting time 10 40
Loom loading 8 25
Reed,hardness
6 60
locking
New style setting 15 15
Loom restart 5 25
Interference loss 4 12
Total 74 203

11/02/2021 * For Picanol Loom 13

 The Loom drive
The oil-cooled Sumo main motor drives most of these weaving
machine directly, without belt or clutch and brake. The
combination of the highly energy-efficient Sumo motor with the
direct drive of the main shaft and shedding motion results in
power savings of more than 10% in comparison with conventional
clutch and brake configurations. The speed of the motor is
controlled electronically, without a frequency converter, thus
reducing power consumption.

11/02/2021 14
 The Sumo
Motor

11/02/2021 15
 The following table presents a comparison of
production rates of different weaving machines.

Available width Weft insertion

Loom Type Speed in rpm
in cm Rate(m /min )

Conventional
180 180 300 - 400
Powerloom
Projectile      
Sulzer Ruti      
P7100 190-540 320 1100-1200
P7200 190-540 430 1500
STB Russia 180-330 300 750
Rigid Rapier      
SACM 150 550 1100
Dornier 150-400 460 1000
GUNNE 230 330 1200
11/02/2021 16
 Available width Weft insertion
Loom Type Speed in rpm
in cm Rate(m /min )
Flexible
     
Rapier
Somet 165-410 550 1300

Vamatex 160-380 510 1300

Sulzer Ruti 110-280 325 1200

Nuovo Pignone 220-420 440 1000

Water Jet      

Metor SPA 230 1000 1600

Nisson 150-210 1000 2000

Tsudakoma 150-210 1000 2000

11/02/2021 17
 Available width Weft insertion
Loom Type Speed in rpm
in cm Rate(m /min )
Air Jet      
Sulzer Ruti upto 300 750 1600
Picanol Omni 190-380 800 1800
Picanol Delta 190 1100 2000
Toyoda 150-330 850 2000
Tsudakoma 150-340 1000 2200
Lakshmi Ruti 190 500 1200
Dornier 430 600 2520
Linear Multiphase      
Elitex About 190 1100-1600 2000-3000

Drum type
     
Multiphase

Sulzer M8300 190 3230 6088(Plain)

  170 2430 4118(Twill)
11/02/2021 18
 Economics of Shuttleless Looms
AUTO NEW
PLAIN AIR JET PROJ. D W PROJ. S W
LOOM RAPIER
(SEMI
ITEM H.S
AUTO)

REED SPACE
190.00 190.00 190 190 190 190
CM

RPM 120.00 180.00 450 700 300 400

AVG PPI 72.00 72.00 72 72 72 72

EFFICIENCY 70.00 80.00 85 85 85 85

PROD/
DAY 34.17 62.18 165.16 256.92 146.81 220.22
MTRS/MC

PROD/YEAR
11959.50 21763.00 57806.00 89922.00 51383.50 77077
MTRS/M C

11/02/2021 19
 AUTO NEW
Loom PLAIN AIR JET PROJ. D W PROJ. S W
LOOM RAPIER

TOTAL WVG
COST
CONSIDERING
NET OF RS. 11.36 11.85 10.19 7.80 7.58 6.55
0.70 PROFIT
/-MTR

Details of the fabric being produced

40s Warp 40s Weft, 136 EPI, 72 PPI, 63" Width.

11/02/2021 20
 Conclusion

Conclusion: Net profit is one of the major considerations

to keep any organisation running.
Analysis of the results shows that shuttleless looms are
more economical than shuttle looms.

11/02/2021 21
 References
• Weaving Mechanisms – Dr. M. K. Talukdar, Prof.
Srirammalu.
• Shuttleless Weaving – Richard A Morrocks
• Power loom Development and Exports Council –
www.pdexcil.com

11/02/2021 22
 Thank You

11/02/2021 23