1

I N S I D E R
Customer Magazine of Lindauer DORNIER GmbH / No. 11 / December 2001 / January 2002
Flanders Tapestries weaves for the new
cathedral in L.A.
Woven Saints
A further step in automation
Optimizing shed geometry with
DORNIER AutoWarp

Changes in management structure

Contents
Technical textiles for highest demands
SEAL S.p.A., Legnano, Italy 3/4
A good feature further improved
New in 2002:
EFC Electronic Filling Tension Control 5
Woven Saints
Flanders Tapestries weaves for the new
cathedral in L.A. 6/7
Optimizing shed geometry with
DORNIER AutoWarp

A further step in automation 8/9

Success factor called team spirit
Grupo Txtil Riopele,
Famalico, Portugal 10/11
Less parts =
reduced maintenance + increased
performance
Disc-O-Leno

with motor- and belt-drive

compacted into one single unit:
DORNIER MotoLeno

12/ 13
Changes in management structure 13
Transparency stimulates business
DORNIER weaving machine system family
successful also in curtains 14
Strong growth thanks to distinctive
export strategy
Quaker Fabric Corp., Fall River, USA 15/16
New DORNIER India liaison office
opened in Mumbai 16
Projectiles, knife cuts, fire fabrics
from the Italian textile company SEAL
provide reliable protection and their
advanced technology earns world-
wide acclaim. SEALs second main
area is prepreg elements and modern
materials for all kinds of lightweight
designs. Advanced chemical treat-
ments as well as weaving-techno-
logical methods are used to manufac-
ture such products developed in the
test laboratories of SEAL S.p.A.
As part of the Grupo Snia Viscosa, SEAL
was able to gain specific know-how on
processing polypropylene fibers which
generated great response in the packaging
industry. Joint ventures with companies
involved in similar products resulted in a
comprehensive competence in the areas of
industrial textiles and composite materi-
als. SEAL has recently also won customers
from the automotive, aircraft and defense
industries and provides complete soluti-
ons for human body protection as well as
lightweight elements for sports cars,
trains, aircraft, cruise ships, speedboats
etc. Other areas for SEAL products are
the construction industry, biomedical
engineering and manufacturing of preci-
sion tools and robots.
SEAL always works closely with custo-
mers when producing highest quality
fabrics with advanced properties. Mate-
rials such as carbon and glass fibers, ara-
mids, polyethylene and PBO fibers are
used. Prepreg synthetic laminates comple-
ment the fibers and fabrics produced by
the company. The product range can be
separated into two main areas with the ge-
neric definitions:
1. Body protection products consisting of
fibers and fabrics to efficiently safeguard
persons or objects.
2. Prepregs and novel materials for light-
weight designs with the highest strengths.
Technological lead and unique, highly
specialized performance in the respective
areas of application are common factors
for all products. Characteristic for fibers
used is high resistance against pressure
and tension combined with comparative-
ly low weight. This is of great significance
for the design of construction elements
and vehicle components as well as for the
wearing comfort of protective clothing.
Examples of final products are modern
bullet- and knife-penetration proof vests,
riot shields and helmets for police and mi-
litary, protective suits and blankets, armo-
ring of vehicles, tanks, aircraft and ships.
Prepregs are developed for bodywork and
hulls in automotive and ship construction.
For example, SEALs know-how was on
board the Luna Rossa yacht during the
prestigious off-shore ocean regatta, the
Americas Cup.
SEAL technology is also used in bodywork
and chassis design for the famous Italian
sports cars of Ferrari and Lamborghini.
New location, new potential
The various subsidiaries were united at
the present location in Legnano in 1990
SEAL S.p.A., Legnano, Italy
TECHNICAL TEXTILES FOR HIGHEST DEMANDS
SEAL was involved in designing the Luna Rossa hull for the Americas Cup
This INSIDER as well as various other
information can also be found under http://
www.lindauer-dornier.com
Contents
Technical textiles for highest demands
SEAL S.p.A., Legnano, Italy 3/4
A good feature further improved
New in 2002:
EFC Electronic Filling Tension Control 5
Woven Saints
Flanders Tapestries weaves for the new
cathedral in L.A. 6/7
Optimizing shed geometry with
DORNIER AutoWarp

A further step in automation 8/9

Success factor called team spirit
Grupo Txtil Riopele,
Famalico, Portugal 10/11
Less parts =
reduced maintenance + increased
performance
Disc-O-Leno

with motor- and belt-drive

compacted into one single unit:
DORNIER MotoLeno

12/ 13
Changes in management structure 13
Transparency stimulates business
DORNIER weaving machine system family
successful also in curtains 14
Strong growth thanks to distinctive
export strategy
Quaker Fabric Corp., Fall River, USA 15/16
New DORNIER India liaison office
opened in Mumbai 16
Projectiles, knife cuts, fire fabrics
from the Italian textile company SEAL
provide reliable protection and their
advanced technology earns world-
wide acclaim. SEALs second main
area is prepreg elements and modern
materials for all kinds of lightweight
designs. Advanced chemical treat-
ments as well as weaving-techno-
logical methods are used to manufac-
ture such products developed in the
test laboratories of SEAL S.p.A.
As part of the Grupo Snia Viscosa, SEAL
was able to gain specific know-how on
processing polypropylene fibers which
generated great response in the packaging
industry. Joint ventures with companies
involved in similar products resulted in a
comprehensive competence in the areas of
industrial textiles and composite materi-
als. SEAL has recently also won customers
from the automotive, aircraft and defense
industries and provides complete soluti-
ons for human body protection as well as
lightweight elements for sports cars,
trains, aircraft, cruise ships, speedboats
etc. Other areas for SEAL products are
the construction industry, biomedical
engineering and manufacturing of preci-
sion tools and robots.
SEAL always works closely with custo-
mers when producing highest quality
fabrics with advanced properties. Mate-
rials such as carbon and glass fibers, ara-
mids, polyethylene and PBO fibers are
used. Prepreg synthetic laminates comple-
ment the fibers and fabrics produced by
the company. The product range can be
separated into two main areas with the ge-
neric definitions:
1. Body protection products consisting of
fibers and fabrics to efficiently safeguard
persons or objects.
2. Prepregs and novel materials for light-
weight designs with the highest strengths.
Technological lead and unique, highly
specialized performance in the respective
areas of application are common factors
for all products. Characteristic for fibers
used is high resistance against pressure
and tension combined with comparative-
ly low weight. This is of great significance
for the design of construction elements
and vehicle components as well as for the
wearing comfort of protective clothing.
Examples of final products are modern
bullet- and knife-penetration proof vests,
riot shields and helmets for police and mi-
litary, protective suits and blankets, armo-
ring of vehicles, tanks, aircraft and ships.
Prepregs are developed for bodywork and
hulls in automotive and ship construction.
For example, SEALs know-how was on
board the Luna Rossa yacht during the
prestigious off-shore ocean regatta, the
Americas Cup.
SEAL technology is also used in bodywork
and chassis design for the famous Italian
sports cars of Ferrari and Lamborghini.
New location, new potential
The various subsidiaries were united at
the present location in Legnano in 1990
SEAL S.p.A., Legnano, Italy
TECHNICAL TEXTILES FOR HIGHEST DEMANDS
SEAL was involved in designing the Luna Rossa hull for the Americas Cup
This INSIDER as well as various other
information can also be found under http://
www.lindauer-dornier.com
4
and they utilize 30.000 m
2
of production
space. 55 DORNIER rapier machines
with nominal widths between 180 and
410 cm are installed. The total annu-
al production of woven fabrics amounts
to almost 3,5 million m
2
. SEAL expects
a turnover of approx. 26 million Euro in
2001, realized with a total of 120 employ-
ees. 70% of the production is exported.
The export share of ballistic materials
reaches even 89%. The company is mar-
ket leader in this sector in Italy and Euro-
pe, and sales are also strong to the Middle
East and Far East, South America and Af-
rica. The combined location in Legnano
brought the desired shorter, simpler flow
of manufacturing processes with faster
reaction times. It also created synergy ef-
fects within personnel and operational
resources. The company concentrates on
developing new generations of industrial
fabrics and safety restraint systems. The
acquisition of the share majority by the
SAATI group in 1993 increased this fo-
cus and opened up new market opportu-
nities. For example in 1998, SEAL suc-
cessfully developed and marketed a new
CONCREFLEX product line which ser-
ves to strengthen structural elements of
buildings. Especially for the renovation
and restoration of historic buildings this
system offers a great potential. Bridge and
building support elements made of car-
bon are also in the planning stages.
Apart from production facilities in Legna-
no, SEAL has its own test laboratories for
textile and mechanical development. A se-
parate ballistic laboratory is available to
test the products with various types of
hand weapons.
With a well developed sense for the de-
mands of the market and an emphasis
on the corporate strategy of the 5 Cs
(Communication, Confidence, Coopera-
tion Coordination, Competition), SEAL
feels well prepared for the challenges of the
future.
SEAL product lines:
SAATILAR

Bullet and fireproof fabrics for protective

clothing
TEXILAR

Laminate for bullet and knife protection

TEXINDUSTRIA

Fabrics made of carbon, glass, aramid and

hybrid fibers
TEXIPREG

Fabric and prepregs from various chemical

components
CONCREFLEX

Fabrics, tapes and straps to strengthen

and restore buildings
Technical fabrics at SEAL S.p.A.
55
New in 2002: EFC - Electronic Filling Tension Control
A GOOD FEATURE FURTHER IMPROVED
DORNIER rapier machines are very often
used by customers who process delica-
te yarns, typically characterized by
very low tensile strengths. Gentle yarn
processing is therefore very significant.
This has a direct influence on thread
break frequency, which in turn has a di-
rect impact on productivity and, indirect-
ly, on fabric quality. The entire area fil-
ling tensioner/ filling stop motion was
redesigned for the P-model to increase
the technological lead of DORNIER as
regards to careful handling of yarns.
The new electronic filling control device
EFC is a compact unit with the filling stop
motion integrated into the tensioner. This
means:
1. One single filling stop device per step-
per-motor-operated tensioner. Each single
filling stop unit can be set electronically to
a different sensitivity at any time during fil-
ling insertion. This means improved mon-
itoring and supports functional reliabil-
ity for multiple filling insertion. Also the
Anti2 function (elimination of inadvertent
double-picks) is guaranteed electronically.
All settings can be easily entered with the
keys of the Dialog Panel, individually for
each filling color.
2. Integrating the filling stop motion into
the tensioner holder resulted in fewer
deflections in the yarn path, a straighter
thread feed with less friction points and
a shorter yarn length between prewinder
and feeder needle. Reducing the free yarn
length also reduces the basic filling th-
read tension and makes it more even. This
lower base tension reduces the already
low filling thread break level even further,
which the DORNIER machine is known
for. Reliable monitoring per filling color
improves fabric quality.
The opportunity of a complete redesign of
the filling tensioner area was used not only
to integrate the electronic filling stop mo-
tion into the compact unit. By turning the
entire tensioner assembly upside down, fi-
berfly and friction dust can drop out of the
braking area, which has a positive effect on
performance.
The complete tensioner holder assembly can
be tilted upwards to simplify maintenance
work on the rapier insertion elements.
This device will be available for P-model
rapier weaving machines with up to 8 co-
lors from middle of 2002 onwards.
New EFC filling thread control integrated in the thread tensioner
6
One of the most impressive sacral buil-
dings for the Catholic church, the new
Our Lady of the Angels cathedral in
Los Angeles, is taking shape. Not least
because of the 57 large tapestries from
Flanders Tapestries BVBA woven on
DORNIER rapier weaving machines.
The surface dimension of this church
of around 16.000 m
2
is as overwhelming
as the record construction time. The cor-
nerstone was laid in May 1999 and the
cathedral is planned to be dedicated in
September 2002 as the largest sacral buil-
ding in the USA with room for 2.400 vi-
sitors. To eliminate any undesired acoustic
effects possibly arising from the modern
concrete construction, large tapestries will
be hung on the walls of the new cathedral.
Theme of these tapestries: A long impres-
sive procession of 133 saints consecrated by
the Catholic Church.
Walking in procession forwards while
looking at the altar one can clearly iden-
tify, among others, Mother Teresa, Joan
of Arc and Pope John XXIII. After com-
pletion, the new cathedral in Los Angeles
will become the worlds largest exhibition
area of woven tapestry.
The American artist John Nava provided
the initial photo-realistic image-outlines
of the groups of saints. He took his inspi-
rations from existing sacral paintings as
well as from the faces of ordinary people.
Flanders Tapestries, the Belgian company,
signs responsible for the production of the
sound absorbing artistic tapestries, woven
in a so-called 3-layer technique. Each of
these unique tapestries, approximately 2,3
meters wide and between 4 and 14 meters
high, represents a very special challenge as
regards to weaving technology.
Flanders Tapestries BVBA
Flanders Tapestries is a family owned
company that has been in the market
for 20 years and is part of the very small
international group of highly specialized
tapestry weavers. The company has its
own collection of around 100 base de-
signs, but is also specialized in repro-
ducing antique Gobelin tapestries and,
as shown in this example, in producing
unique, single tapestries to order. Flanders
Tapestries was recently successful in manuf-
acturing a replica of an invaluable, 16th
century Japanese Gobelin. The copy be-ca-
me necessary to protect the original
which was carried during procession
through the streets of Otsu every year.
The most difficult task was to match the
antique color tones and, at the same time,
give the copy an aged appearance, in-
cluding the places yellowed by the light of
the centuries.
Our Lady of the Angels
Flanders Tapestries weaves for the new cathedral in L.A.
WOVEN SAINTS
Tapestry presentation in August 2001 during an exhibition in Brugge, Belgium
7
Around 4 million Catholics live in Los
Angeles. Masses are held in 42 different
languages every Sunday. The new ca-
thedral was financed by donations and
designed by the Spaniard Jos Rafael Mo-
neo. It is being built in the middle of
Los Angeles. Alabaster in a warm yel-
low color tone covers the concrete con-
struction. This color shade however
represented an additional problem for
the designing of the tapestry, because
the background wall was to simulate
Italian frescoes. In order to attain the cor-
rect color in dampened yellowish alaba-
ster light, samples had to be measured in
the original light conditions with a color
spectrometer and the yarn color was then
adapted accordingly.
We would never have been able
to complete this order without our
DORNIER rapier weaving machines
The companys own CAD archive, con-
taining around 60.000 patterns impressi-
vely demonstrates the weaving technolo-
gy know-how of Flanders Tapestries. The
uncounted number of interlacings com-
bined with a multitude of colors of warp
and filling threads allow to duplicate
even the finest color hues of any photo-
graphic or painting original. Flanders Ta-
pestries demands were fulfilled with the
DORNIER rapier weaving machine fit-
ted with three warp systems and twelve
filling colors. Combined with a Jacquard
machine with 20.000 lifting hooks, this
installation is one of the most complex
weaving machines in the world. Three
warp systems with a total of 17.800 th-
reads provide even tension of the yarn
material for all weaves across the entire
width of 2,3 meters. The oversized Jum-
bo Jacquard drive on the DORNIER
weaving machine with its reliable start
and stop function is of special importance,
when such multi-layer, heavy Gobelin ta-
pestries are woven.
Another decisive factor was the wide fil-
ling yarn range that can be inserted, from
Ne 6/2 to Ne 60/2, with up to 64 color
shades. Filling density is variable between
60 to 160 threads per centimeter. The
three warp systems allow to change bet-
ween two and three layer fabric techni-
que, which will play an important role in
the final acoustics of the cathedral. 250
different color hues were used by the ar-
tists and designers for the tapestries in the
new cathedral.
This example shows that smaller compa-
nies with a lot of know-how covering se-
veral areas combined with high specializa-
tion in manufacturing can complete pre-
stigious tasks.
The construction progress of the Our
Lady of the Angels cathedral in Los
Angeles can be observed by visiting:
http://cathedral.la-archdiocese.org
Artist John Nava, on the left, with Roland De Keukelaere, one of the two owners of Flanders Tapestries BVBA
Improving machine efficiency and the
resulting increase in productivity were
the driving factor that led again to a new
DORNIER development. AutoWarp

, the
automatic rear shed adjustment system,
not only satisfies both points but also
improves fabric quality. The device
is currently being introduced on the
market.
The need to reduce costs and support
faster production cycles is often a some-
what negative side effect of globalization.
The pressure can be especially felt when
producing standard articles of high qua-
lity with typically low margins, as well
as with those fabrics dependent on fast
changing fashion trends. The increasing
shortage in qualified personnel available
in the textile industry altogether has to be
compensated at the same time.
Since this environment will probably not
change in near future if ever the pro-
duction machines have to be improved
and adapted. DORNIER AutoWarp

,
the automatic rear shed setting system
for DORNIER rapier and air-jet wea-
ving machines, is such an adaption. It
uses modern stepping motor technology
to adjust the back-rest roll vertically and
horizontally, the warp stop motion hori-
zontally and vertically, as well as the tilt,
to precise positions. All these settings can
be made by pushing respective buttons
on the machines Dialog Panel, either
during a style change when the machine
is stopped or even while the machine is
running. Precise positions can be stored
with the style master data. They remain
re-producible as required for any other
ma-chine, for example.
Scientific investigations at the German In-
stitutes of Textile Research in Denkendorf
and Aachen revealed clearly the impor-
tance of correct rear shed settings. These
tests show unequivocally that the relation
of tension between lower and upper shed
has a very strong influence on warp thread
breaks. The curve in the graph demonstra-
tes clearly that setting changes with positi-
ve or negative values increase warp thread
break frequency. Only a relatively small
setting tolerance is available to optimize
warp thread breaks to the lowest level.
This optimum back-rest and warp stop
8
A further step in automation
OPTIMIZING SHED GEOMETRY WITH
DORNIER AUTOWARP

Stepping motor arrangement for automatic back-rest roll and warp stop motion adjustment
9
The single advantages are:

reduction in thread breaks and set-up
times

style development with less waste and
shorter evaluation times

reproducible settings and setting data
availability

style optimization while machine is
running

checking improvement of fabric
appearance while machine runs
Automatic rear shed setting also reduces
the workload for operators and makes the
weaving machine easier to use. The data
recorded can also serve for possible future
simulation programs.
motion setting is often not searched for
during practical day-to-day work because
of the lack of time of the technicians. An
average standard setting is used and high-
er warp break frequencies are just accep-
ted, either consciously or not.
Correct rear shed adjustments can have
also a decisive effect on the surface ap-
pearance when producing sensitive fa-
brics. Raising the back-rest roll position by
4 cm and tilting the warp stop motion by
2 cm eliminated the cracky appearance
with visible reed marks to a great degree
(see picture). In summary it can be safely
stated, that productivity and quality are
decisively improved when the rear shed
adjustments are made with reproducible
precision utilizing the AutoWarp

auto-
matic rear shed adjustment system.
The current AutoWarp version is avail-
able as an optional on rapier and air-jet
weaving machines up to 220 cm nominal
width with standard type back-rest roll
assemblies. An extension to cover larger
machine widths and different back-rest
roll configurations is in preparation.
9
0,5 1,0 1,5 2,0 2,5 3,0 3,5
0
10
20
30
40
50
60
Relation between warp tension and warp thread breaks
Influence on fabric appearance by rear shed changes
Nothing is left to chance at Grupo Txtil
Riopele. Companies at the main premi-
ses in Famalico include a spinning mill, a
weaving mill and a finishing plant, reliab-
ly operated by the companys own power
generating station. The group also inclu-
des the dye works Olicilor and the two
spinning mills Olifil and Filatex. Only
part of the 10.000 tons of raw fiber ma-
terial processed to yarns annually is used
in the own weaving mills. The majority is
sold to international weaving and knitting
operations. Yarn counts range from Ne 20
to Ne 80.
Strong enough for Asia
80 % of the turnover is realized in Europe
and in the USA. Interest exists also in
entering the Asian market - as explained
by the Director responsible for Technol-
ogy, Dr. Gonalves de Oliveira - but de-
pends on free access to the markets. He is
strongly favouring open trading conditi-
ons which should offer however both si-
des the same opportunities. Dr. Oliveira is
convinced that according to my opinion,
our position as a European textile manuf-
acturer makes us competitive enough for
the Asian market. He emphasized the
European power of innovation combined
with that of our suppliers of textile machi-
nery is the very basis to secure us a decisive
advantage in winning market shares with
new fabrics.
Personnel as most important resource
Market closeness is not only expected and
appreciated from suppliers of Riopele but it
is also practised by themselves. High flex-
ibility and tangible, committed entrepre-
neurial spirit characterizes Riopele. We
should never forget that the customer
is our real boss stated Dr. Oliveira. This
approach must not only be followed at
management level but also by all employ-
ees in every department. Personnel then
becomes the most important factor within
the company in attaining consequent, ad-
aptable market orientation through flexi-
bility and outstanding individual perfor-
mance. For Riopele this means ongoing
training combined with breaking away
from old work habits and structures. Em-
phasis in the weaving mill is on employ-
ees with all-round knowledge and cross
training. Working in teams is common-
place. This is the key to success, says
Dr. Oliveira. These all-rounder teams are
given clearly structured tasks. They mainly
work independently. One obvious advan-
tage of this team concept is the use of
the DORNIER system family of rapier
and air-jet weaving machines with identical
user surfaces for the operators. Many sub-
assemblies and accessories are interchange-
able between both machine types, which
simplifies work tremendously and contri-
butes to the first priority: readiness for pro-
duction, anytime.
10
Grupo Txtil Riopele, Famalico, Portugal
SUCCESS FACTOR CALLED TEAM SPIRIT
Founded in 1927 by the grandfather and father of the present owners, the Por-
tuguese Grupo Txtil Riopele comprises today a group of independent textile com-
panies under one roof. With a production volume of 70.000 m
2
of fabric per day,
Riopele is one of the most innovative and important European textile companies
of private ownership, catering to the needs of the fashion clothing sector. 80 % of
the fabrics delivered are yarn-dyed and 20 % are piece-dyed.
DORNIER rapier and air-jet machine plant at Grupo Txtil Riopele
11
Higher efficiency, better performance
The results of ongoing training and such
all-rounder teams cannot only be seen
in employee satisfaction but also in above-
average machine availability for produc-
tion. An average efficiency of 95 % is
reached despite of the production of very
fashionable fabrics for shirts, trousers and
ladies outer wear. Wool and angora in yarn
counts from Ne 17/1 to Ne 30/2 are used
as well as cotton, cotton-polyester blends
and 100 % viscose in yarn counts from
Ne 20/1 to Ne 80/1 and fancy yarns and
Lycra, single and twisted from Ne 24/2
to Ne 40/2 and Ne 58/2. Over 1.000 de-
signs are offered per season, whereby the
share of fabrics containing Elastan has
been constantly increasing. Air-jet machi-
nes are used when weaving styles with
up to 8 shafts and rapier machines are
applied for everything requiring more
than 8 shafts. In order to achieve such
efficiency levels despite of the diversifica-
tion and warp length between 400 and
2.000 meters, Riopele concentrates on
maintaining an overall thread break level
as low as 0,5 stops per machine hour. A
maximum of only 30 minutes is allowed
for style and warp change. Preventive
maintenance is carried out meticulously,
and the annual maintenance is performed
during the summer vacation shutdown.
The low stop level combined with a
perfect selvedge using the DORNIER
EcoLeno

devices and the excellent

employee team spirit have all a positive
effect on product quality. The percentage
of seconds recorded after final inspection
is at a very low level of 0,5 %. Quality is a
overriding criteria across the entire Riopele
company, where the turnover reached 100
million Euro in the year 2000, and where
70 million Euro have been invested over
the last four years in new technologies.
Riopele was successful to achieve certi-
fication according to ISO 9002, and
presently an application for certification
according to ISO 14001 (Environmental
Management System) is under way.
The excellent teamwork between textile
and machinery manufacturers is based on
quality and consistency. Only a well func-
tioning partnership guarantees success and
a secure future for both.
Insider IMPRINT
Publisher and copyright:
Lindauer DORNIER GmbH
Rickenbacher Strasse 119
88129 Lindau
Germany
Telephone ++49 83 82 70 30
Telefax ++49 83 82 70 33 86
Editor:
Egon Wirth
Graphics and realization:
Werbeagentur Thomas Vetter
CH-8030 Zrich
Print:
REPRO-TEAM GmbH
D-88250 Weingarten
Issued:
Once a year
Date of this edition: December 2001 /
January 2002
Reprinting:
Permitted only with our previous written
consent, even for extracts

Printed in Germany
11
Grupo Txtil Riopele fabric collection
Time still means money, and optimizati-
on efforts still must concentrate on saving
time. The first priority for this is elimina-
tion of production interruptions by thread
breaks and reduction of maintenance in-
terruptions of machine elements - in this
case of the leno device. Rotating mechan-
ical parts have to be checked from time to
time for function. Fewer mechanical parts
mean less maintenance time. The Moto
Leno

is based on this simple principle.

The motor itself serves as the disc, which
means a considerable reduction in mechan-
ical parts, as illustrated. Conventional sa-
tellite lenos still widely used on other type
airjets account for over 50 moving compo-
nents. The MotoLeno

consists of just one
single rotating part. The result is that this
new DORNIER leno de-vice has hardly
any wear point, which improves the rela-
tion between machine operat-ing time to
machine down time immensely.
During operation of the machine the direc-
tion of rotation and the number of revolu-
tions in each direction as well as the timing
of each one of the discs in relation to the
weaving machine, can be electronically mo-
dified. Thus it is possible to adapt the func-
tion of the device to the requirements of the
fabric as regards to pick density and yarn
material.
On the Dialog Panel of the machine, the
leno function and the specific settings for
any particular style can be entered, prepro-
grammed and stored in the master data of
the style.
12
Disc-O-Leno

with motor- and belt-drive compacted into one single unit: MotoLeno

LESS PARTS
=
REDUCED MAINTENANCE
+
INCREASED PERFORMANCE

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80
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71
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75 80
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34
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76
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50
70
86
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107
96
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88 89
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105
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51 1
Conventional leno selvedge devices on weaving machines are often the cause of
time consuming leno thread breaks and the source of a creeping degradation in
the running behavior of the machine. This applies particularly on higher machine
speeds, for example on airjets. Performance and quality suffer as a consequence.
Our patented Disc-O-Leno

, a 2-thread leno device, has been on the market since

1997. Gentle treatment of the leno threads and the easy handling for operators had a
decisive effect in reducing thread breaks. A considerable improvement of the leno
selvedges on DORNIER weaving machines was achieved. The new MotoLeno

represents a further development of this successful concept. A patent secured this
idea already a number of years ago. Realization however, was a long-term project
because of the evaluation time required for a new roller bearing technology.
Because of this, the MotoLeno

first became available in September 2001.

Comparison between mechanical wear parts on MotoLeno

and conventional satellite leno

13 13
A further advantage: The use of double
discs with independent rotors allows to
adjust a different shed closing time for
each leno cord. Also the consequence and
frequency of rotation of each disc is indi-
vidually adjustable. This is of great impor-
tance for fabrics with high pick density. The
name MotoEco

was chosen analogue to

the existing double disc EcoLeno

. It eco-
nomizes on filling yarn waste and elimi-
nates the use of catch selvedge spools, thus
economizing again on yarn material.
The MotoLeno

offers the same

proven advantages of the DORNIER
Disc-0-Leno

generation:

Modular design

No need for catch selvedge spools

No winding of catch selvedge spools

required

No storage of spare selvedge spools

Fewer leno thread breaks

Lower weaver and technician work-load

Reduced set-up times

Finer and better appearance of fabric

selvedges

No speed restrictions from leno unit

Extremely long operating length of

leno spools

Fast width changes with Jacquard

For MotoEco

, reduced filling and

catch selvedge waste
(certain limitations of application exist)

Filling waste is reusable

Filling waste sorted by fiber material

Lower spare parts and maintenance

costs

Unit can be retrofitted to all

DORNIER weaving machines
with CAN Bus control.
Changes in management structure
Significant personnel changes were made
in management in the latter part of 2001
which led to a restructuring of various areas
of responsibility.
Dipl.-Ing. Peter D. Dornier, in charge of Marke-
ting, Sales and Customer Service in the wea-
ving machine sector for many years, took now
over from his father, Dipl.-Ing. Peter Dornier,
the position of Chairman of the Executive
Board as from the beginning of 2001.
Weaving Machine Engineering Design and
Development has been added to his areas
of responsibility.
The previously independent offices of Me-
chanical and Electronic Engineering were
combined into the new area of responsibi-
lity named Weaving Machine Technolo-
gy under the direction of Dr. Dietmar von
Zwehl, to ensure closeness to markets and
customers, and speak mechanically and
electronically with one voice.
These changes have become necessary
because Dipl.-Ing. Horst Kerner will be
retiring in the fall of 2002. His responsibi-
lity encompassed the entire manufacturing
area in the company as well as weaving
machine development and engineering.
Mr. Kerner created the new manage-
ment area Production and Logistics for
his successor. This new sector is defined
"to combine the responsibility for costs,
schedules and quality into one manage-
ment position for ensuring a high level of
avail-ability and flexibility and ultimately
guarantee a more effective fulfillment of
customers requirements.
Combining the responsibility for Weaving
Machine Marketing and Technology under
the management of Peter D. Dornier corre-
sponds to the management structure of the
Division for Special Machines, in which
Dr. Andreas Rutz has been responsible for
Marketing and Technology since the be-
ginning of 2001.
Dr. Heinrich Ahner retains management
responsibility for Finance, Accounting, Ad-
ministration and Human Resources.
MotoEco

double disc leno for fabric selvedge and catch selvedge

Leading European manufacturers in this
trade use the DORNIER system family
of rapier and air-jet weaving machines
to be able to meet production demands
for the wide range of curtain and drapery
fabrics.
These DORNIER customers are, in al-
phabetical order:
ADO Gardinen-Werke GmbH & Co.
KG, Aschendorf, Germany.
Creation Baumann Weberei und Frberei
AG, Langenthal, Switzerland.
Cordima AG-International, Greven,
Germany.
GARDISETTE GmbH, Eystrup,
Germany.
Joh. Hohmann GmbH & Co. KG,
Helmbrechts, Germany.
Keller AG, Wald, Switzerland.
Unland GmbH & Co. KG,
Saterland, Germany.
Altogether they have more than 700
DORNIER machines in operation.
When reviewing the areas of application
of both DORNIER machine types, the
following general pattern becomes visible:
Voile curtains in plain weave, usually
ordered with substantial production yar-
dages are produced most economically
on fast running air-jet machines. High
speeds and the resulting fast throughput
are of great importance to keep the custo-
mary short-term delivery schedules. Tech-
nical advantage of these air-jet machines
are the movable tandem nozzles which
provide better air distribution during
yarn acceleration. The reed-drive- cam
design in both gear boxes provides a wi-
de filling insertion window. Consequent-
ly sufficient time for gentle insertion of
a large range of filling yarns is avail-able.
This again means that, depending on the
order-yardage, voile curtains with certain
fancy yarns in the filling can also be effec-
tively and economically woven on DOR-
NIER air-jet machines.
Marquisette leno curtains are an establish-
ed product on the market. They have the
lowest production yield at highest sales pri-
ces, but they provide better visual effects,
finer drape and interesting shades. Large
wholesale dealers have to serve various
market segments with differing qualities
and therefore must offer leno curtains
along with raschel-produced fabrics. The
optics of the curtains de-mand using the
most varied fancy yarns in filling, but
unfortunately the leno technology limits
speeds to 200 rpm approximately. DOR-
NIER rapier weaving machines are the
p e r f e c t p r o d u c t i o n
means for this type of specialty weaving.
The positively controlled thread feed and
transfer of the filling by the rapier heads
eliminates the risk of stripping back or
displacing of fancy effects and avoids
stretching of the core yarn and yarn break-
age. The low thread tension level during
insertion, typical on the DORNIER
rapier machine, helps to avoid these
defects. The marquisette weaving busi-
ness typically works with short yardages
so that the fast re-starting after style chan-
ges with a wide variety of filling yarns
is of significant importance. Time-consu-
ming resetting and adjustments for new
fancy filling yarns are not necessary, which
accelerates production to a great degree.
Exact, sensitive warp tension and reliable
adjustment for automatic start-mark pre-
vention, called ASP feature, are of im-
mense importance for fine curtain fabrics,
especially when producing with the so-
called clip-spot technique.
ASP is equally valid for DORNIER rapier
as well as for air-jet weaving machi-
nes.
14
DORNIER weaving machine system family successful also in curtains
TRANSPARENCY STIMULATES BUSINESS
Woven curtains with special effects
Modern curtain weavers can no longer just concentrate on the fancy and stylish de-
coration of windows as a single element, but, more and more, have to integrate the
whole room into their design visions. This not only demands diversification in using
various yarns in the filling but also requires adaptions in machine widths. Curtains
are now available in widely differing widths whereby the trend towards room height
is not so strong as for decorative fabrics. The latter is still part of the production
range of curtain weavers which altogether has led ultimately to standard weaving
machine widths of 290 cm and 330 cm.
Anyone asking for outstanding designs
and materials on the American market
of high quality upholstery fabrics will
invariably hear one answer: QUAKER
FABRIC. The company is not only known
for its creativity it is also one of the
largest manufacturers of furniture and
decorative fabrics in the world.
Unusual for an American textile compa-
ny is, that Quaker operates as a global
player, who exports a great portion of
its production to more than 40 countries
around the world.
There are many reasons for Quakers
success. Larry Liebenow and his partners
bought the company 1989 which was
ori-ginally founded 1945 as Providence Pile.
A fresh wind was soon blowing through the
vast multistory manufacturing facilities in
Fall River, Mass. The new management first
analyzed the product range and then de-
termined to specialize in the production
of yarn and fabrics for the furniture and
decorative business. Over time approx.
160 million US-Dollars have been invested
in the years between 1990 and 2000 in
modernizing production plants and install
the most advanced technology. The num-
ber of employees working presently in the
eight production locations in Fall River
rose in this period from 1,100 to 2,600
associates. They achieved a turnover of
around 300 million US-Dollars in the year
2000. This was an increase of 330 % com-
pared with 1990.
Consequent export strategy
A new export strategy adopted in the
early nineties was decisive for Quaker
Fabrics growth during a business cyc-
le in which the turnover of competitors
stagnated or showed contractions. This
foresighted sales policy of exporting -
normal practice for European and Asian
companies - is still rare in the USA. Ame-
rican textile companies traditionally made
comparatively weak appearances on the
international markets. It was common-
place to withdraw from a foreign market
if results were not convincing very quik-
kly. A new management team supported
Larry Liebenow, who had gained vast in-
ternational experience by living in various
foreign countries. Early on he empha-
sized for long-term continued relation-
ships and connections with foreign com-
panies. Today Quaker has distribution and
demonstration centers in Mexico and Bra-
zil. Sales offices are maintained in Lon-
don and Dubai and sales agents are ac-
tively presenting the comprehensive, very
diverse Quaker product collections in
all important countries. Quaker is not
only impressive because of its size and
its progressive, export oriented strategy,
15
Quaker Fabric Corp., Fall River, USA
STRONG GROWTH THANKS TO DISTINCTIVE EXPORT
STRATEGY
DORNIER rapier weaving machine plant at Quaker Fabric Corp.
Larry Liebenow, President of Quaker Fabric Corp.
16
but has also an excellent reputation for
modern fabric designs. State of the art
computer-controlled systems serve to
develop patterns and prepare and moni-
tor production. The own manufacturing
capacity for chenille yarns, the largest in
the world, plays a significant role in the
success story of Quaker.
Employee motivation starts with under-
standing
Quaker Fabric is regarded as a very reli-
able and flexible partner of the furniture
industry. This has a lot to do with the
above average motivation of the multi-
national labor force. The forefathers of
a large number of Quakers employees
emigrated from Portugal to the USA,
so Portuguese has become the second
official language at Quaker. All bulle-
tin board messages, all safety posters and
training manuals are displayed in two
languages. All Dialog Panels, the user sur-
face of the over 400 DORNIER rapier
weaving machines installed, display their
functions in two languages, English and
Portuguese.
CEO Larry Liebenow also wants to find
a common language with China. Unlike
many American companies, he supports
Chinas entry into the World Trade Orga-
nization. He looks at this as an opportu-
nity to avoid isolation and he promotes
marketing efforts in China in an aggres-
sive, proactive manner. A sales office has
already been opened in Beijing and a task
force on management level is developing a
strategy for the future business penetration
of the Peoples Republic of China.
Quaker design teams work continually on
developing the product range further, eit-
her with new yarns, new production and /
or finishing methods in order to maintain
their strong market position.
The decision to utilize DORNIER rapier
weaving machines with 180 cm nominal
width was already made as early as 1983
in order to keep the enormous diversity
of the existing product range. Today 372
Jacquard machines and 36 dobby type
machines, equipped for up to 12 filling
colors are installed. The modular color
cassette system allows changing rapidly to
the particular number of filling yarn types
or colours required.
Quaker produces chenille yarn of all kinds
on a large scale and the company in fact
dominates in this sector of furniture ma-
terials. Reliable insertion of coarse fancy
yarns alternating with fine binder threads
for interlacing and support of the fabric
construction is of major importance.
DORNIER rapier weaving machines with
their positively controlled filling transfer,
the low filling tension and the
open shed weaving feature are the perfect
solution for the requirements of this de-
manding customer.
DORNIER is proud that its machines are
playing a significant role in the success of
Quaker Fabric.
New DORNIER India liaison office
opened in Mumbai
Whether Bombay or today Mumbai:
DORNIER is now local. Our excellent
experience with the opening of our
DORNIER Beijing office in 1998 suppor-ted
our decision to open our own, permanent
office in India in the year 2001. This step
was the logical consequence of conside-
ring the impressive number of customers
and the distribution of over 2000 DOR-
NIER weaving machines in this territory.
Indian customers can now benefit from
the advantages in competent advice, tech-
nical support and timely maintenance re-
sulting from this local presence in the cen-
ter of the Indian textile industry.
Quaker Fabric Corp. fabric collection
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