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Report | February 2019

Automatic D4S toe linking device for increased efficiency

The D4S toe linking device sews the toe closed while the sock-knitting machine simultaneously produces the next sock and the precise operation of the device ensures perfect linking quality.

The Asian knitting industry is constantly growing in importance. China, Vietnam, and South-East Asia are amongst the world’s leading export countries when it comes to knitted products. Whether recent applications such as sports shoes or traditional applications such as hosiery, virtually no household anywhere is without some sort of knitted good, the most basic example being socks. At the ITMA Asia 2018, Stäubli and its Deimo knitting solutions were giving visitors a chance to discover the very latest automation solutions for sock-knitting mills. These solutions allow mills to keep up with sock trends, maximise production efficiency, and meet the highest quality standards – and thus remain highly competitive.

The days of taking the sock off the knitting machine to close the toe are gone. The revolutionary new D4S closes the toes directly on the knitting machine – automatically, and without any operator intervention. The D4S toe linking device (patents pending) can be mounted on any new circular sock machine with a diameter of 3-½ to 4-½ inches and from 8 to 19 gauge.

Mills enjoy a wide range of benefits

The D4S toe linking device sews the toe closed while the sock-knitting machine simultaneously produces the next sock. The precise operation of the device ensures perfect linking quality. Thus, the D4S answers several key challenges in knitting: minimising idle time, delivering higher-quality and higher-volume output, and reducing waste material, the increasing price of which eats into profit margins.

Installing the D4S device on a sock-knitting machine promises a quick return on investment for the mill. In addition to the more efficient production, the mill will also benefit from enhanced operator convenience and expanded functionality, especially thanks to the independent 2900SL electronic controller.

Drastically shortened sock-knitting process

Two D4S toe linking devices were demonstrated in action on two circular sock-knitting machines at the ITMA Asia. One machine was equipped with a 3-¾-inch cylinder and 144 needles, and the other with a 3-¾-inch cylinder and 200 needles. Manufacturers were amazed to see for themselves how the device drastically shortens the sock-knitting process.

Stäubli knitting solutions for hosiery, medium-to-large diameter underwear, and seamless knitted goods: With the 2900SL electronic controller, the DStyler programming system for knitting patterns, and DData for process monitoring and data recording during knitting, Stäubli offers a complete solution for knitters who demand high overall performance and powerful, user-friendly equipment. Manufacturers that automate their knitting process with these Stäubli solutions enjoy a significant cost-return ratio and be equipped to deliver products that delight their customers.

Extensive range of weaving process optimisation solutions

Stäubli has been a leading supplier for the weaving industry for over a century. Visitors to the Stäubli booth in the weaving hall at ITMA Asia enjoyed a broad overview of the company’s machinery and solutions, which are perfectly adapted to the requirements of the Asian weaving industry:

  • Weaving preparation solutions for mastering warp preparation and warp tying
  • Shedding solutions for frame weaving for every type of weft insertion system (cam motions, dobbies)
  • Electronic jacquard machines with harnesses, in formats for every woven application
  • Weaving systems for carpeting and technical textiles
  • Original Stäubli spare parts

Stäubli’s extensive range allows mills to master the entire weaving process in order to produce excellent results and benefit from optimum cost efficiency. Stäubli is a global mechatronics solution provider with three dedicated activities: Connectors, Robotics and Textile, serving customers who want to increase their productivity in many industrial sectors. As an international company, Stäubli currently operates in 29 countries, with agents in 50 countries on four continents. The global workforce of 5,000 shares a commitment to partnering with customers in nearly every industry to provide comprehensive solutions with long-term support. Originally founded in 1892 as a small workshop in Horgen/Zurich, Stäubli is today headquartered in Pfäffikon/SZ, Switzerland.

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