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Mtuft

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Mtuft

The Mtuft range of machines are for product development of Tufted Carpet.

The combination of conventional tufting machine components with a highly sophisticated control system means that one machine can sample a large range of gauges, stitch rates and constructions. This gives a single machine the sampling capability for many production machines. Only one package of yarn is required for each color in the sample. Up to eight different yarns can be included in a sample.

The Mtuft includes a control PC and design software.

Features

The Mtuft range of machines is an innovative solution for product development of Tufted Carpet. The combination of conventional tufting machine components with a highly sophisticated control system means that one machine can sample a large range of gauges, stitch rates and constructions. This gives a single machine the sampling capability for many production machines. Only one package of yarn is required for each color in the sample. Up to eight different yarns can be included in a sample. With over 50 units sold around the world, the Mtuft has set the benchmark for performance and flexibility, whilst saving our clients time and money.

Performance

The best practice cycle time to produce a new carpet sample, including setup time is now 20 minutes! The Mtuft innovation enables carpet manufacturers and carpet designers to get to the same end point as with traditional tufted carpet sample machinery but much quicker and with less cost.

Sample Cycle Times

The current response time of Carpet Designers and manufacturers to the "custom/contract" market segment is typically 2 weeks. For those who have not streamlined their creative design process "end to end" cycle times can be 3 to 4 weeks, just to produce one sample.

For the conventional tufted carpet sampling machine or running samples on a production machine, the setup time for one sample could take up to one full day with setup of up to 200 cones of yarn. This is a lot of non value added work just to setup the sampling machine. The value adding time to produce 1 carpet sample is less than 1% of the total cycle time.

The Mtuft produces a new carpet sample including the setup time, in 20 minutes. This capability enables a 2 day response time for new designs to be offered to clients. A same day service for urgent sample requests is now possible.

Product Development

The Mtuft gives the designers the capability to develop new products (ie. New construction development, dye developments, etc.) and perform diagnostic work with immediate feedback.

It enables product development in miniature and the results can be seen immediately. It therefore gives the capability to perfect new product ideas before committing them to the production plant.

This exploratory stage is critical in the creative design process.

Flexibility

Traditional carpet sampling machines are based on production technology and can therefore only produce samples to match the gauge or type of the individual production machine.

The Mtuft has remarkable flexibility in that one machine has the capability to sample any type of tufted carpet.

  • Full Repeat Scroll (FRS)
  • Single, double and unequal Sliding Needle Bar
  • Fine Line
  • Cut Pile
  • Cut & Loop Pile

All types can be produced at a wide range of gauges and stitch rates without changes to any gauge parts.

The Mtuft can produce samples of 1.0m or 2.0m by any length. It also has the capability to produce miniature samples which enables the Designer to perfect their product ideas quickly, without wasted investment in yarn and set-up time. For colour work, the designer can simply batch multiple design files of up to 8 colours and leave them to run overnight. Upon return to work next day, all 8 coloured samples will be waiting for you.

Saving you money

Reducing Total Sample Making Labour by up to 90%

The total cost to produce a tufted carpet sample inclusive of labour and yarn is reported to be US$110. The labour cost includes the setup time and the sample producing time, with the setup time being a non-value adding cost of up to 90% of the labour time.
The Mtuft will reduce the labour costs by 90% and the designers will be able to perform other activities when the Mtuft is running as it requires no supervision. The Mtuft can even be set up to produce samples overnight.

Mtuft uses a single package of yarn per colour - up to 8 colours

Traditional tufted carpet sampling machines need between 30 to 50kg of yarn, which is then fed onto approximately 200 cone, just to make one carpet sample. If this quantity of yarn is not available then it has to be specially made.

A skilled operator can reduce the amount of yarn wastage, but it can be up to 0.25kg at a cost of $5 to $10 per kg. The calculated minimum yarn wastage is estimated to be $1.25 to $2.50 per sample.

The Mtuft requires only 1 package of yarn per colour so there is no wastage. The cost saving is estimated to be US $2/sample.

Cost per sample US $

Current

Mtuft

Comments

Labour 100 10 Direct cost allowance
Yarn and materials 10 8 Direct cost allowance
TOTAL 110 18 Saving you over 80%


Freeing the Production Facility from Sample Making

Making carpet samples on the production plant is advantageous because the samples will accurately replicate the production quality. However it comes as a great cost to the business in terms of significant production downtime.

The Mtuft can produce samples that accurately replicate all tufted production lines and designs from your production plant.

Cost of a traditional sampling machine

Traditional sampling machines are based on production technology and can only replicate samples with the same gauge and style of tufted carpet that the production machine can produce. These sample machines can cost up to $1.5 million. The Mtuft can produce samples for all tufted production lines and designs at a fraction of this cost.

Specifications

Model Standard Stroke
TMS
Long Stroke
TMSL
Extra Long Stroke TMSXL Single Needle
TMSSNXL
Max Speed Straight Stitch Up to 20 per second Up to 30 per second
Max Speed Shifted Stitch Up to 10 per second Not available
Max Loop Height 3/4 “ / 19 mm 2 “ / 51 mm 3 “ / 75mm
Min Loop Height 1/16 “ / 2 mm
Range of Gauge 1/16 “ to 1/4 “
Range of Stitch Rate 4 – 16 stitches/inch (16 to 64 stitches/10 cm)
Number of Colours Max 8 colours Single colour
Variable High-Low Cut Not available Available as option Not available
Software Included Machine control software and NedGraphics OEM Tuft Modra Advanced Controller Machine control software only,
set of standard pattern
(no NedGraphics Advanced Controller
Design Format Open Tuft format (exported by Vision Tuft)
Machine Sizes 101 201 551
Max Sample Width 1 m 2 m 2.5 m
Mass 750 Kg / 1650 lbs 975 Kg / 2150 lbs 1100 Kg / 2425 lbs
Dimensions WDH (without creel) 2300 x 930 x 1340 mm
91 x 37 x 53 inches
3300 x 930 x 1340 mm
130 x 37 x 53 inches
3800 x 390 x 1340 mm
150 x 37 x 53 inches
Machine Requirements and Environment
Power 220 / 240 volts AC 50 /60 Hz 10A max, single phase
Air Supply 150 lit/min @ 7 bar, 5 cfm @ 100 psi
Environment Normal operating temperature 10 – 25 degrees Celsius, in a clean & dry environment (5 – 95% humidity, non condensing)

All specifications subject to change without notice

Samples

Testimonials

Market Positioning

  • We are now proactive in meeting our customer requirements. We can give a guaranteed response time to our Customers of only 2 days for a new design
  • We have an enhanced belief in our product development team, their innovative capability and their ability to meet the custom business market's requirements
  • The Mtuft also enables you to structure your business processes to best meet the custom / contract market segment

Creative Design Process

  • Our sample cycle time has been reduced from 3 to 4 weeks, down to the same day, with available yarn
  • It use to take us up to 2 weeks to produce a 10 colour palette range for one of our new designs; now we can setup the Mtuft to run overnight and produce this one design with 8 different colours. We just set the Mtuft to run at 5pm and it is finished well before we arrive to work the next morning
  • We have saved over 20% of our design team time by eliminating the non value adding setup times. This time is now spent on creating more innovative designs for our customers
  • Previously when I had a new idea, I could only produce 1 sample. Now I can try many variants in the creative process and make a better choice on the best option. This is because the design interface is on the Mtuft; so I can stop it, make a change, then restart it, and see the results immediately
  • We are now producing more designs and samples, with a faster turn around time. The lead time for a sample can be 20 minutes, so we can give a guaranteed response time to our Customers of only 2 days
  • We can fully cost a new range based on our Mtuft samples; we weigh and measure the amount of yarn used, then we apply our standard costs to determine the overall production costs
  • The Mtuft enables us to perfect our new product ideas before we commit them to our pilot production plant i.e. theoretical construction development, dye development and diagnostic work. This exploratory stage is critical in the creative design process

Ease of Installation

  • We produced our first Customer sample on day 3 of owning the Mtuft machine

Risk Management - Production

  • The Mtuft helps our Manufacturing Team access the production risks with new ranges

Sample Quality

  • The Mtuft sample quality is approximately 95% aligned to our production machinery
  • The sample quality is far superior to samples produced by hand trialists

Sampling Costs

  • We have had a 90% reduction in the cost to produce our Tufted carpet samples
  • Since our sample costs have come down; we now no longer need to consider the cost of making a sample, we just do it.

Business Justification

  • Our business justification was based on an 18 month payback period, with the financial savings based on labour costs. We achieved this payback in less than 18 months
  • A change of mindset is required to maximise the benefits from the Mtuft

Videos

Mtuft for Tufted Carpet Development.

This video demonstrates the following features -

  • Variable Height Loop
  • Cut Pile
  • Cut and Loop
  • Cut and Multiple Height Loop
  • Single Sliding Needle Bar
  • Double Sliding Needle Bar
  • Servo Scroll
  • TMSL Long Stroke (to 50mm Pile Height)
  • 251 Model (2.5m Width)

Mtuft for Tufted Carpet Development.

This video demonstrates the following features - TMSXL Long Stroke (to 75mm Pile Height)

Brochures

ENGLISH Mtuft Brochure Mar09_Page_1.jpg
Mtuft Brochure - English

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ENGLISH Mtuft Brochure Mar09_Page_1.jpg
Mtuft Brochure - Chinese

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Mtuft White Paper - Jan 09_Page_1.jpg
White Paper

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Mtuft Reference List Mar 11 2009.jpg
Mtuft Reference List

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