Category Archives: Industry Analysis

All About Sewing Machines – Research and Review

Sewing Machine

A machine that uses thread to stitch fabric and other materials together is called a sewing machine. The main purpose behind the invention of sewing machines was to decrease the amount of manual sewing work performed by workers of several companies. The credit to the invention of the first working sewing machine goes The English Inventor and Cabinet Maker, Thomas Saint in the year 1970. It is not known whether Saint really manufactured a working model of his creation. The patent depicts a bit that punched a gap in calfskin and went a needle through the gap. A later propagation of Saint’s creation in light of his patent drawings did not work.

In 1810, German, Balthasar Krems imagined a programmed machine for sewing tops. Krems did not patent his development and it never worked well.

Austrian tailor, Josef Madersperger made a few endeavours at developing a machine for sewing and was issued a patent in 1814. The majority of his endeavours were viewed as unsuccessful.

In 1804, a French patent was conceded to Thomas Stone and James Henderson for “a machine that copied hand sewing.” That same year a patent was allowed to Scott John Duncan for a “weaving machine with various needles.” Both innovations fizzled and were soon overlooked by the general population.

In 1818, the principal American sewing machine was imagined by John Adams Doge and John Knowles. Their machine neglected to sew any helpful measure of texture before breaking down. The categories of sewing machines can be broadly divided into two streams, namely, Industrial Sewing machines and Home Sewing Machines.

Though further details on the over said terms will be provided as we move ahead.

The textile industry has grown in ways unimaginable. As vast as it gets are the lengths of the industry. But, what we should not forget is that, the very growth of today’s global scale industry started from nowhere but just a piece of thread and a needle. Yes indeed, these two are the most essential part of the dynasty.

Though in earlier times, only people were seen sewing or stitching clothes. But with the passage of time came a revolution which introduced machinery in the world of clothes which made the world even brighter.

The stories of the first sewing machines however lack the aura of success. The cause of this failure was odd, the inventors tried to develop machines that could mimic the motion of hands but it never worked.

The breakthrough finally struck in the year 1830, when Barthelemy Thimonnier (1793 – 1857) a French embroiderer invented a machine, rather an embroidery machine that adopted a traditional yet modified hooked embroidery needle. It had a hook near the point of the needle to sew basic and easy chain stitches. Though the machine was not up to the mark for the stitches it made were too weak to produce strong seams. This went on for some time, for in every few years, someone else would come up with a better model of the machine, but none of them achieved perfection soon enough.

Top 5 Most Popular Merrow Sewing Machines

Merrow sewing machines are hand built to the highest quality standards in the sewing industry. The company manufactures over 360 models for industrial and home use. If you are looking for a high performance machine that is built to last, look no further than Merrow sewing machines. Some of them are designed delicate garments such as lingerie and satin clothing, while others can sew wool, fleece, jersey, tricot, denim, linen, and synthetic fabrics.

Here are top five most popular Merrow sewing machines for industrial and home use:

Merrow 18A

This sewing machine has been refined over its nearly century long existence. Merrow 18A sews at speeds of up to 1400 RPM and requires very little downtime. It can be used at home, as well as in large production facilities. You can use this machine to edge pillows, blankets, mittens, hats, and shawls. Merrow 18A is designed to operate longer than any other machine in its class. Its components are handcrafted and hand built.

Merrow M-3DW

Merrow M-3DW overlock sewing machine sews a tight edge or seam on lightweight to medium weight fabrics. Its operating speed can reach 5500 RPM. The stitch is uniform and can be used to provide accent. This sewing machine uses Merrow’s cam-driven technology to sew quietly and smoothly. Millions of people from all over the world use this machine for its remarkable durability and fast, quiet operation. Merrow M-3DW is also used in factories.

Merrow 72-D3B-2

Merrow 72-D3B-2 is an innovative machine featuring three feed dogs for superior fabric handling, an extended cutting system, and an improved dust shield. This machine can be used not only for sewing, but for many other operations such as pad and steam dyeing, scouring, mercerizing, steaming, slitting, singeing, and shrinking (sanforizing). This unit is hand assembled using premium steel parts within the traditional Merrow cast iron frame. The machine is suitable for both home and industrial use.

Merrow MG-3Q-3

This high speed machine can be used anywhere an accent on a garment is required, from baby blankets and children clothes to athletic socks, burp cloths, and fleece lined baby jeans. This machine produces the most beautiful stitch for garment edges. Users can vary the color and appearance of the shells and sew a wide range of materials, from woven to fleece.

Merrow MB-4DFO

This revolutionary sewing machine was released in 2012. You can use it on protective combat uniforms, merino wool hiking pants, running jerseys, cycling jerseys, and base layer activewear. This new model uses Merrow’s unique barrel cam architecture to sew more consistently and precisely than other machines.

Using a Nitrogen Purge in the Food and Beverage Industry

A simple nitrogen purge system can greatly benefit packagers in the Food and Beverage Industry by removing oxygen from a container. Replacing oxygen with nitrogen – either just before performing the fill, just after the fill or right before capping a container – can prolong the product’s shelf life while preserving the taste, color and texture of the food or beverage.

To understand how the nitrogen purge system works, consider the packaging process and the effects of oxygen on foods and beverages. On automatic packaging lines, bottles and/or other containers will be loaded on to a power conveyor system using a laning conveyor, a loading turntable, using manual labor or in some other manner. Of course, the bottles that are loaded on to the conveyor are empty, and in the Food and Beverage Industry will likely travel through a rinsing machine or other container cleaning machinery to remove dust and debris prior to continuing down the packaging line.

While the container cleaning equipment helps keep the packaging process sanitary and removes dust and debris build up, it does not have the same benefits as using a nitrogen purge system. While container cleaning equipment helps keep the product free from outside contaminants, nitrogen purge creates an atmosphere that assists in prolonging the useful life of a product.

Once rinsed or otherwise cleaned, containers will normally move to the filling machine. At this point, a nitrogen purge can be set up to inject nitrogen into a container before the container is filled with product. The main reason for using a nitrogen purge before a fill, however, is usually not the preservation referred to above. Instead, adding nitrogen to an empty container can strengthen the container, making it more rigid. This is especially useful for certain plastic bottles (like certain water bottles, for example) that are truly manufactured to be a rather flimsy bottle, sometimes to simply save on cost.

More often than not, a nitrogen purge system will be found between the filling machine and capping equipment on a packaging line. Once the container has been filled with a food or beverage product, some headspace will remain – the empty space between the product and the top of the bottle. This headspace, when not run through a nitrogen purge system, can have a detrimental effect on food and beverage products.

In a normal environment, the headspace will be filled with some oxygen. Long term contact with oxygen can lead to the deterioration of food products. When in a closed container, oxidation can destroy vitamins and nutrients as well as help to create an atmosphere for the breeding of certain bacteria and other contaminants that lead to spoiling. Using the nitrogen purge system removes the oxygen from the headspace, replacing it with nitrogen gas to counteract the negative aspects noted above. As bottles or containers leave the filling machine, or as they enter the capping machine, a purging head will blast the headspace with nitrogen gas. Immediately capping or otherwise sealing the containers minimizes the oxygen captured in the headspace. The result, less oxidation and an environment less likely to foster bacteria and other contaminants, which in turn leads to a longer shelf life and the retention of the normal taste, color and texture of the food or beverage product.

Nitrogen purge systems can be manufactured in many different shapes, sizes and forms. Single head machines can attach directly to a conveyor system to purge each bottle as it passes under the purge machine. Other nitrogen purge machines may be manufactured with multiple heads on a single frame, allowing the machine to roll up to an existing packaging line. In general, each nitrogen purge system will be manufactured based on the project for which it is built, with production demands and the existing equipment greatly influencing the design.

Vibration Testing Technology

To the savvy maintenance professional, industrial machinery almost “talks” to reveal its condition. The key to success is in understanding what the machine is saying. To detect problems, the professional “listens” in many ways: With eyes and ears, to see and hear conditions that may indicate problems and…

• With thermometers and thermal imagers, to detect overheating, poor electrical connections or failing bearings

• With digital multimeters and power analyzers, to diagnose electrical problems

• Using techniques like lubricant analysis, to gauge machine condition over time

And now new vibration testing tools provide the maintenance professional with a valuable new way not just to listen, but to find mechanical problems and fixes: these new troubleshooting tools are engineered to detect and evaluate machine vibration immediately and recommend any needed repairs.

A new kind of troubleshooting tool

Many industrial maintenance teams today work under severe restrictions on money and time. They may not have the resources to train for and implement the typical long-term vibration analysis program. Further, many professionals may think there are only two options for vibration testing; high-end vibration analyzers that are expensive and difficult to use, and low-end vibration pens, which aren’t particularly accurate.

Fortunately, a new breed of vibration-testing tool fills the middle of the category, combining the diagnostic capability of a trained vibration analyzer with the speed and convenience of lower-end testers, at a reasonable price. This type of tool is designed to be not merely a vibration detector, but a complete diagnostic and problem-solving solution, and targeted specifically for maintenance professionals who need to troubleshoot mechanical problems and quickly understand the root cause of equipment condition.

These tools are designed and programmed to diagnose the most common mechanical problems of unbalance, looseness, misalignment and bearing failures in a wide variety of mechanical equipment, including motors, fans, blowers, belts and chain drives, gearboxes, couplings, pumps, compressors, closed coupled machines and spindles.

Not just data, but actionable results

When these new testers detect a fault, they identify the problem, its location and severity on a multi-level scale to help the maintenance professional prioritize maintenance tasks. They may also recommend repairs.

Mechanical diagnosis can begin with the user placing the device’s accelerometer on the machine under test. The accelerometer may have a magnetic mount or can be installed using adhesive. As the machine under test operates, the accelerometer detects its vibration along three planes of movement (vertical, horizontal and axial) and transmits that information to the tester. Using a set of advanced algorithms, the tester then provides a plain-text diagnosis of the machine with a recommended solution.

No training? No problem

Mechanical equipment is typically evaluated by comparing its condition over time to an established baseline condition. Vibration analyzers used in condition-based monitoring programs rely upon these baseline conditions to evaluate machine condition and estimate remaining operating life. System operators must have considerable training and experience before they can determine the meaning and significance of the vibration spectra they detect.

But what about the maintenance pro who isn’t trained in vibration analysis? How do you tell the difference between acceptable vibration, and the kind of vibration that demands immediate attention to service or replace troubled equipment?

Fortunately, extensive experience with mechanical vibration, what it means and how to fix it is built into the advanced algorithms of today’s testers. Now the maintenance professional can quickly and reliably determine the cause of the machine vibration, learn the severity and location of the problem and receive recommendations for repair. It’s all done with the intelligence built into the tester, without the extensive training, monitoring and recording required for typical vibration monitoring programs.

These testers deliver plain language recommendations about what to do next. For equipment maintenance teams hard pressed and on the go, these precise directions are what they need to take action now, maintain mechanical equipment in top shape, and keep facilities productive. One example of this type of tool is the handheld Fluke 810 Vibration Tester (For more information on the Fluke 810, visit http://www.fluke.com/machinehealth).

Which Software Do You Need to Run a CNC Hot Wire Foam Cutting Machine?

A CNC hot wire foam cutter is a computer controlled machine used for mainly cutting Polystyrene foam and similar materials, such as polypropylene and polyethylene. The machine consists of a wire running between 2 towers, which is heated via hot wire power supply, thus melting and cutting the foam into the desired shape. The towers can move in an X-Axis (right-left) and a Y-Axis (up-down).

Cutting the foam is done in 3 basic steps:

1. Drawing the desired shape to be cut.

2. Converting the shape into G-Code

3. Running the machine with the software to execute the desired shape.

Any Cad tool, such as Auto Cad or Corel Draw can be used for drawing the shape, as long as the file can be saved in a DXF format. CAD means Computer-aided Design. It is a modeling tool used to design curves and figures in 2 dimensional space (2D) or curves, surfaces and objects in three-dimensional space (3D). There are various CAD files in the market. More recommended ones include Instant Engineer 14, which can be purchased online for few dollars, DesignCAD, AutoCAD and TurboCAD. Another Cad tool software is DevFoam, that combines both the drawing and the G-Code generation. It is a user friendly application for cutting foam with a 4 Axis CNC machine.

Next step is to convert the shape into G-Code. The G-Code is another name for the computerized tool by which we tell the machine what to cut and how to cut it. For the conversion one can use software such as DeskCNC, DevCad or FoamWorks.

DeskCNC was originally designed for a 3 Axis CNC Router machines. It was later on modified to enable a 4 Axis foam cutters to run as well.

FoamWorks is known for its simplicity and being a user friendly software. It is designed to drive a 4 Axis foam cutter via a parallel port of any windows based computer. It can cut any shape, but works best for cutting RC wings.

For the last stage of running the machine, software such as Mach3 and DeskCNC can be used. The Mach3 program is a G-Code reader. It allows you to turn your PC computer into a 4 Axis CNC controller for machining and cutting. It is an operating system for running the CNC hot wire foam cutter. It was originally developed for the home hobbyist, and later modified for use for any CNC machine operation for industrial use.

The Top 5 OEE Trends for 2020

2020 is just starting and this is looking like a great year for OEE. 2019 saw some great trends taking root for OEE and 2020 looks to continue that trajectory. The OEE trends for 2020 are starting off strong with OEE and OPE, Machine Health, the increased spread of IIoT, Smart Manufacturing, and Cyber-Physical Systems.

Let’s take a deeper look into just how these rising trends in manufacturing will reshape and enhance the OEE landscape.

OEE and OPE

As 2020 comes around OEE has been incorporated into the growing landscape of performance analysis. OEE has become a part of the emerging analytical framework of OPE, or Overall Production Effectiveness.

This analysis takes OEE and adds an additional layer to it. OPE uses OEE and also analyzes data from personal as well. This poises OEE as being a foundational technology for the coming year and the changing analytical tools.

OEE and Machine Health

Measuring machine health is the future of manufacturing and is expected to be on the rise in 2020. Machine health measurements try to analyze the wear and tear that naturally occurs to manufacturing equipment. This preemptive study attempts to estimate repairs ahead of time in order to streamline manufacturing downtime. OEE naturally folds into machine health. Minimizing downtime with OEE threads naturally into machine health.

IIoT

IIoT was supposed to be 2019’s big change up, but the roll out was slower than expected. IIoT relies on massive infrastructure changes to manufacturing. These changes involved updating both existing machinery and the software that runs them. As 2020 unwinds IIoT might actually be poised to make the changes that many analysts hoped it would in 2019. IIoT will provide OEE with more data from, and more access to, industrial machinery. This opens the door for OEE to have more impact on the industry.

Smart Manufacturing

Smart Manufacturing is the process of shifting from traditional manufacturing technology to smart technology. Think less centralized factories with lengthy distribution networks and more on-site production with on tap services. This type of manufacturing necessarily requires less downtime in order to run smoothly. OEE bridges this production gap by giving manufacturers the resources they need to increase efficiency and reduce downtime.

Cyber-Physical Systems

Cyber-Physical systems are manufacturing processes that connect digital technologies with physical systems. This encompases a lot of technologies. Everything ranging from IIoT to AI operated manufacturing systems. As manufacturing technologies increase their use of digital technologies, OEE can begin to take a larger role in the industry.

These OEE trends for 2020 are poised to increase OEE’s presence in the manufacturing world. The big takeaway here is that manufacturing and the industrial scene have become increasingly digital spaces. These are the types of markets where OEE can thrive. As 2020 unfolds, manufacturing and digital tech are set to become further entwined and OEE is is going to be right there with them.

Sewing Machine FAQs

A sewing machine is a device which manipulates thread to form a stitch.

What are the uses of a sewing machine?

The uses of a sewing machine are stitching garments, leather, green house covers, car covers, parachute, canvas, bags etc.

What are the two types of sewing machines used?

The two types of sewing machines are household sewing machine and industrial sewing machine.

What is an Industrial sewing machine?

Industrial sewing machines are used by textile manufacturers and customers who need a faster and professional job.

What are the differences between industrial and household sewing machines?

An Industrial sewing machine is faster and performs perfect stitches. They can perform only one operation at a time. While a household sewing machine can perform a straight stitch, a zig-zag, sew on a button or make a button hole with all operations built into the machine.

Whether a sewing machine can stitch heavy weight materials such as canvas etc.?

Yes, a sewing machine can stitch heavy weight materials such as canvas by using needle feed or walking feet or a combination of both with the sewing machine.

What are the classifications of sewing machines?

Sewing machines can be classified according to its usage. Its classification includes computerized sewing machines, embroidery sewing machines etc.

What are the names of companies who are famous in the market of sewing machine?

The companies which are popular in the production of sewing machines are Singer, Pfaff, White, Brother etc.

How can a sewing machine be purchased?

A new sewing machine can be purchased anywhere once the model is finalized by the customer. But a used sewing machine is best purchased from a trusted dealer. Dealers must have showroom and demonstration facilities.

How can one ensure about the right sewing machine?

By talking and asking questions to a local dealer of sewing machines. One can also get a free demonstration from the dealer.

What are the important points to be asked to the dealer while purchasing a sewing machine?

The important points to be asked to the dealer while purchasing a sewing machine are:

Are parts readily available?

Whether the dealer provides local service?

Whether the dealer maintains the list of customers who purchase sewing machine from them?

Whether the dealer provides any guide or video tape for learning the usage of sewing machine?

Five Tips to Buying a Sewing Machine

Whether you are buying a sewing machine for yourself or as a gift, you will need to ask yourself some questions to be a more informed consumer. Here are 5 tips to purchasing a sewing machine:

  1. Budget. Decide on how much you want to spend. The caveat is that if you spend too little, the machine will be worthless and you will never be able to get the sewing done you want. What’s too low a price? Do not purchase anything less than $100 new. Budgeting $200 will give you a good, basic machine. Sometimes you can find good machines used or refurbished for under $100. That would be fine, just don’t buy a “cheap” machine new.
  2. Sewing Requirement Level. Is this machine for a beginner? Or someone who only needs basic functions for simple sewing and mending? If so, look at the mechanical and more simple electronic sewing machines. Is this machine for someone who is going to run a small business or teach sewing? Look at the commercial grade, or industrial sewing machines. Is this machine for an advanced crafts person? Check out the embroidery and sewing combination machines. Is this machine for a professional tailor? Consider getting a serger as well.
  3. Don’t over purchase. The vast majority of sewing machine owners never use the multitude of fancy stitches available on their machines. A few extra decorative stitches is usually fine. Be sure that zig-zag stitch and some way of making buttonholes is available if the machine is going to be used for garment construction.
  4. Look for included accessories. Presser feet attachments, lint cleaning brushes, and the right machine oil can help you get the job done right. If you can find the same machine with accessories for the same price, get that one.
  5. Read the reviews. This is the age of the internet, even if sewing machines still need us to sit down next to them to do the mending. Read the reviews of the machine model you are thinking of purchasing. Pay careful attention if the same complaint comes up over and over again.
  6. Read the user manual. Many of the user manuals are available online, and you can download them to read. Make sure that the instructions make sense to you, because they are often what can make or break your experience.

Once you get your sewing machine delivered, re-read that user manual. Follow the instructions the first time through, even if you are an experienced operator. You’ll find it will save you time and frustration to just follow the instructions that come with the machine.

If you are purchasing a sewing machine as a gift, all of these points are exactly the same, just ask yourself from the point of reference of the gift recipient. And remember, don’t purchase a new machine under $100. You may be the lucky one to find one that stands up to decent use, but most of the really “cheap” sewing machines are too cheap to last with normal use.

Buying Industrial Woodworking Machinery: Tips for Saving Money

Industrial woodworking machinery is typically quite expensive. Consequently, many people prefer to purchase it as used woodworking machinery to save money. While buying the equipment secondhand is a great way to cut costs, there are additional measures you can take to ensure that you save the most money, such as not investing in too much capacity, buying hardware that has been operated for years, and buying refurbished equipment.

Do Not Invest in Too Much Capacity

If your business is growing, purchasing hardware that offers more capacity than you currently need is usually a good idea, especially if you need to increase production volume. The key, though, is to invest in as much capacity as you will need for the foreseeable future, not as much as you may need if your company continues to grow at the current rate for several years. Because the performance capacity of equipment has a major impact on its price, investing in the right amount of capacity is an important money saving measure.

Buy Hardware that Has Been Operated for Years

Unlike lesser grades of equipment, industrial woodworking machinery is designed to perform under strenuous conditions for decades. Consequently, buying it in well-used condition is a great way to save money while still receiving a product that performs at a high level. Instead of shopping for hardware that has been operated for less than five years, consider targeting products that has been operated for roughly ten years. The hardware will cost less, and provide the same performance as equipment that has less wear.

Buy Refurbished Equipment

How much you pay for used woodworking machinery involves more than the purchase price of the equipment; it also pertains to how much the hardware costs to repair and maintain over the course of its remaining lifespan. Refurbished products typically experience fewer breakdowns and unforeseen maintenance issues than pre-owned machinery that is sold as is. This is because the former is reconditioned by having worn and problematic parts replaced, and receiving a thorough cleaning inside and out.

Conclusion

If you need to buy industrial woodworking machinery for a bargain price, and spend as little as possible on repairs and maintenance issues, not overinvesting in production capacity, buying hardware that has been operated for years, and purchasing refurbished equipment are three ways to do it. For assistance choosing economical hardware that meets your company’s needs, contact a professional seller of used woodworking machinery today.

Is Your Company Ready For Industry 4.0 Transformation?

What is Industry 4.0?

Industry 4.0 is the 4th industrial revolution. To give a little history, industries used steam to make the machine work which increased production and reduced cost in the industrial revolution. The next phase of the revolution was the mass production with implementing electricity and assembly lines. The third revolution introduced automation and computers. We are now here in the fourth revolution through digitizing and networking where we can connect the digital world with the physical world.

With hassle free wireless networking you educate the machine. Earlier the intelligence lied with the humans and machines just helped with the physical work, but now we can educate the machine and the products itself, also get a virtual image. Using Internet of Things (IOT) you can connect all the physical machines with software, networks and censors and they would exchange data with each other making human life and production much more simpler.

How many hours have you spent to hire a mechanic because your machine stopped working and the mechanic failed to understand what went wrong with the machine? With Industry 4.0, the machine will tell you what part has been failed and what has to be replaced. With artificial intelligence, it also tells you which spare parts need to be fixed.

Why Transform to Industry 4.0?

The Cyber Physical systems enable your product to communicate with your machine. Your product will instruct the machine as to the quantity and the type of product that needs to be produced, and the machine is then produces and labels the products. After detecting the product, you can never go wrong with packaging, also your quality check has been performed by the machine while packaging itself.

Industry 4.0 allows you to have a flexible manufacturing process that will better react to customer demands. This new manufacturing technology reduces your cost of production, cost of wastage, reduces errors, increases efficiency due to usage of robotics, yields higher revenue, improves customer service and increases innovation. It also allows you to create a virtual image of the real world using 3D printers and help you test your product and know your contingencies beforehand which would allow you to change the process in order to avoid the contingency before you even start your production.

You don’t need to manually check your stock. You can add a censor to your forklift and your products, and while stacking up your goods, you get the data of the quality, description, weights and dimension as well as the location of the product. This would immensely reduce errors and damages.

Feed your machines, knowledge of automated systems with this new manufacturing trend and let them communicate with each other while you see your profits rise up high and costs go low.