Smooth Fuse SF10 - Contents
Introduction
Smooth Fuse SF10 – The route to smoother fusing

Introduction

Smooth Industrial Products Ltd, producers of Smooth-Fuse, the unique cleaning and lubricating product used on garment fusing presses around the world, have appointed Triglo Limited and its associates as its exclusive Worldwide Licensee, to manufacture and distribute Smooth Fuse SF10 and other chemical products of Smooth Industrial Products for the world garment manufacturing industry. Smooth Industrial Products Ltd will continue to develop its range for Triglo introducing several new products for garment manufacturers over the next 18 months.

The new distribution arrangements for Smooth Fuse SF10 coincide with the launch of new Smooth Fuse SF10 which offers an improved formula with more effective results. By providing increased active ingredient and a higher content of quick release additives in a formulation with both preventive and cure chemical configurations Smooth-Fuse SF10 is designed to eradicate many of the problems commonly associated with fusing operations in garment production. The SF 10 formulation provides simultaneous advantages of encouraging the break up and absorption of existing accumulated adhesive resin contamination on the PTFE surface conveyor belts (and covers) while maintaining a fine lubricating film which prevents further contamination building up. (dia 1)
The problem of fusing press Contamination top

Conveyor Fusing presses (and flat platen fusing presses) use PTFE (Teflon) surface conveyor belts (covers) designed to withstand temperatures of up to 230C and have non stick surfaces. In the same way that domestic PTFE surfaces used in fusing equally require a form of lubricant/cleaner. Smooth Fuse SF10 is a unique product which provides both cleaning and lubrication elements.

Stage 1 Smooth Fuse SF10 breaks up, loosens and absorbs resin contamination

Stage 2 Smooth Fuse SF10 provides a barrier film to reduce further contamination

Result – Smooth Fuse SF10 achieves clean conveyor belts and smoother fusing production
Why Smooth Fuse SF10 top

Smooth-Fuse SF10 has been specially developed to meet the specific problems of garment producers in the processing of fusible interlinings during the manufacturing process. Reducing or eliminating the problems attributable to adhesive and dirt contamination can open significant improvements in productivity, reductions in machine downtime, reduce the level of wastage experienced from garment damage and improve overall quality.
Fusing press adhesive/material Contamination top

Most contamination of fusing press surfaces initially arise from fusible interlining adhesive getting onto the conveyor belt (or platen) surfaces. ‘Strike through’ and ‘strike back’ of adhesive arises when the fusible interlining adhesive becomes too viscose is often due to too high overall fusing press temperatures or where one conveyor (or platen) temperature is significantly higher than the other . A mismatch between the specification of the fusible interlining and the fabrics can also be a cause. Poor quality fusible interlinings are prone to ‘strike back’ problems. In ‘strike through’ the adhesive flows through to the ‘good’ side of the fabric and then onto the surface of the lower PTFE conveyor belt (or platen). In ‘strike back’ the adhesive flows back through the interlining onto the upper PTFE conveyor belt (or platen).

Strike through of adhesive

Strike back of adhesive

Another major cause of adhesive contamination is overlap of fusible interlining on the fabric to which the lining is to be fused. This can arise as a result of oversize interlining cutting against the top fabric size or through poor positioning of interlining on the fabric by the fusing press operatives. The result is for adhesive to be transferred directly onto the lower conveyor belt (platen) where the overlap of interlining arises.

Adhesive resin contamination and other debris from materials cause a wide variety problems for garment producers resulting in elements of reduced productivity, greater downtime, quality problems and increased wastage. Smooth Fuse SF10 has been formulated to address these detrimental elements and thus to smooth the whole fusing process.
Smooth Fuse SF10 - The Route To Smoother Fusing top
Smooth Fuse SF10 - Improving productivity top

Reductions in adhesive and resin contamination of fusing press conveyor belts arising from the regular use of Smooth Fuse SF10 can result in a direct improvement in fusing production levels.

Smooth-Fuse SF10 improving productivity by eliminating slow downs from sticking fabrics/interlinings missing the offload position

Contaminated conveyor belts cause fabric/fusible interlining sections to miss the offload systems as they become attached to the belts and the offload guides cannot force them to detatch. When this occurs machine operatives have to stop the fusing press and extract the stuck interlining/fabric from inside the press. When this occurs regularly, often on lightweight fabrics, production levels can drop by as much as 50%.

Smooth-Fuse SF10 improving productivity by reducing downtime from sticking fabrics/interlinings contacting offload guides causing a concertina effect on the materials

Another common production slow up problem arises when the fabric/interlining sections stick to the conveyors but do not bypass the offload guides which have become contaminated themselves by adhesive and resin. The fabric/interlining will normally concertina against the offload guides often damaging the garment section irrecoverably. This problem is reduced or eliminated entirely by the correct use of Smooth Fuse SF10. Some Smooth Fuse SF10 will transfer naturally from the belts to the offload guides and the non-stick surface thus provided will reduce the instance of this occurring. Spraying Smooth Fuse SF10 directly on to the offload guides and thus keeping them lubricated with a non stick coating will further act to avoid this problem

Fabric concertina effect

Reduced incidence of concertina effect with Smooth Fuse SF10
Smooth Fuse SF10 - Reducing costly machine downtime top

Smooth Fuse SF10 extends the life of PTFE conveyor belts by lubricating the non stick PTFE surface and the woven fibre glass or Kevlar base cloth. In some applications belt life can be doubled by regular use of the Smooth Fuse SF10.

Conveyor belt replacement on conveyor fusing presses is an expensive business. There is the cost of the specialised belts themselves which is substantial. The cost of engineer’s time; either internal service staff of the manufacturer or external contractors. There is the machine downtime of anything up to 14 hours and the related lost production. The total cost of replacing both belts on an average 1.8 metre fusing press can be up to £5000 depending on the model and manufacturer. It speaks for itself that the regular use of Smooth Fuse SF10 as a belt lubricant and cleaner can pay substantial dividends in reducing costs.

How does Smooth Fuse SF10 extend the life of conveyor belts?

Lubricated belt surfaces avoid abrasion of PTFE coating from a number of sources. Offload guides by necessity run against the belts. Even with the commonly used PTFE non stick edge covering significant abrasion and scouring of the conveyor belt surfaces takes place from this source.

Smooth-Fuse SF10 reducing machine downtime by minimising the number of conveyor belt replacements arsing from PTFE surface line abrasion from hard adhesive contamination

Hard resin deposits collect from PTFE belts on non lubricated fusing press guides/scrapers. These deposits are accumulate from adhesive resin, dust, material and other debris which attach to virtually any surface running against the PTFE belts.

These harden into abrasive fragments which scour the non stick PTFE surface causing indentations and eventually crease marks. Abrasion indentation and/or crease marks can commonly be seen in the form of lines running in the direction of the conveyor even if the belt is recently new. The PTFE surface is gradually worn away by the conveyor belt running against the hard fragment and the impression crease in the belt becomes deeper and more noticeable. If the fragment (s) is (are) not cleaned away the line wear to the belt will become acute and eventually conveyor belt base cloth can show through with the belt loosing its non stick properties along the abrasion line. The lines and crease mark may start to leave leave an impression in the top fabrics being fused. Continuous exposure to hard fragment abrasion is a common cause of premature termination of the conveyor belt, its necessary replacement and the resulting production stoppage while this is taking place.

Smooth Fuse SF10 - Minimising hard deposit line abrasion on PTFE conveyor belts

As well hard resin fragments building up on fusing press guides/scrapers they also commonly build up on fusing press built in wiping cleaning systems. These cleaning systems are designed to wipe away the adhesive and other debris away and normally require frequent replacement. . Smooth Fuse SF10 will normally impregnate these wipers so that once saturated they provide a continual coating of SF10 film to the belt and minimises the build up of hard deposits.

Smooth-Fuse SF10 reducing machine downtime by minimising the number of conveyor belt replacements arsing from adhesive debris on conveyor rollers

Adhesive resin contaminating conveyor rollers will normally form into hard raised lumps on the rollers which force the conveyor to stretch each time the lump of resin on the roller comes in contact with the underside of the belt. This causes additional wear to the underside of the belt, can cause conveyor tracking systems to fail and puts stress on the weave of the conveyor base cloth. This can be minimised if Smooth Fuse SF10 is used to keep the machine clean and to ensure that the build up of copious amounts of adhesive does not spread from the conveyor belts to conveyor rollers.

 

Smooth-Fuse SF10 reducing machine downtime by minimising conveyor belt replacements arsing from joint damage

Most fusing presses use joined conveyor belts, the most common type of join being the scarf overlap type. A large percentage of belt failures arise in the joint area


Joint surface abrasion:

The overlap creates a section of the belt against which, because of its greater thickness guides/scrapers, rollers and wiping systems press with greater force than the rest of the conveyor belt. The friction on the raised area and the resulting high level of abrasion, causes the PTFE to wear faster on the joint than the rest of the belt. Smooth Fuse SF10 acts as a lubricant on the joint to reduce the general abrasion to its PTFE surface and base cloth.

Without using Smooth Fuse SF10


Using Smooth-Fuse

Joint ‘catching’ problem:

The joint edges are also prone to ‘catching’ as guides/scrapers ride over them. If a guide catches the leading edge of the overlap joint it can easily damage the joint. Any damage to the raised overlap will quickly spread at each revolution of the belt. The lubricating effect of Smooth Fuse SF10 reduces the likelihood of catching problems on the belt joint.


Using Smooth Fuse SF10

Conveyor belt joint softening:


One of the beneficial effects of Smooth Fuse on the belt joint itself is its softening effect on the woven base cloth belt material . Because of its double thickness the belt join itself is comparatively rigid and does not easily mould itself to run around rollers, through pressure systems and around guides. The ‘softening’ effect of Smooth Fuse SF10 allows the belt to quickly mould to roller diameters and guides the greater flexibility reduces the amount of wear and tear on the belt.

Without Using Smooth Fuse SF10

Using Smooth Fuse SF10

 

Smooth-Fuse SF10 reducing machine downtime by minimising wear and tear to drive systems and other parts of the machine.

If adhesive contamination is allowed to spread without the use of a cleaner/lubricator the fusing press will become generally contaminated causing strains to its operating systems. Tests show that the drive systems of a heavily contaminated machine with strong belt abrasion, contaminated wipers, guides, rollers and a generally sticky belt will have to work up to 30% harder than a clean machine using Smooth-Fuse SF10 to lubricate working surfaces
Smooth Fuse SF10 - Improving quality and reducing wastage top


Smooth Fuse SF10 reducing wastage by minimising the incidence of stain marks on fabric occurring during the fusing process.

Greatest wastage during the fusing process is experienced from dirt getting on to the top fabric from a number of different sources. In most cases stains are caused by a mixture of adhesive resin combined with debris from fabrics. Because of the adhesive nature of the staining it is extremely difficult to recover garment sections contaminated in this way. The cost arising from this can, therefore, be substantial.

By keeping conveyor belts and other parts of the fusing machine clean and adding non neutral non staining Smooth Fuse lubrication to the parts of the machine which fabrics come in contact Smooth-Fuse SF10 can substantially reduce the level of wastage experienced due to fabric staining.


General wear to the PTFE coating of the conveyor belts, line abrasion and abrasion to the conveyor belt joint causes adhesive resin contamination to attach more aggressively to the conveyor belt which in turn will make it more likely that fabrics will become contaminated. As shown in sections ----- by providing continuous cleaning and lubrication to the conveyor belts Smooth Fuse SF10 substantially reduces PTFE wear.


Fabric staining from worn conveyor joint

Reduced staining using Smooth Fuse SF10

Smooth Fuse SF10 reducing wastage by minimising the incidence of stain marks on fabric occurring along belt abrasion lines.

As described under section impression lines in conveyor belts are mainly caused by hard adhesive deposits causing abrasion as the belts run. The damaged PTFE surface within the lines allow adhesive deposits to collect sometimes forming into accumulations where line abrasion has been more pronounced. It is common for dirt contamination to transfer to the top fabric from abrasion lines. Another problem effecting quality is that the indentations in the conveyor belt surface can sometimes transfer to the fabric in the form of an impression mark. This problem can be reduced significantly or potentially eliminated altogether by the correct and frequent use of Smooth Fuse SF10

Fabric staining from abrasion lines Reduced staining using Smooth Fuse SF10

Smooth-Fuse SF10 improving quality and reducing wastage from sticking fabrics/interlinings contacting offload guides causing a concertina effect on the materials

As shown in section concertina effect affecting fabrics and fusible interlining are caused by adhesive contamination to conveyor belt and or scraper system. Fabrics affected this way are often irrecoverable and the problem can cause serious quality difficulties. Smooth Fuse SF10 can substantially reduce this occuring.

Smooth-Fuse SF10 improving quality by improving fabric ‘handle’ .

Certain fabrics fused directly on heavily contaminated conveyor belts can become stiff and loose their original ‘handle’ and feel. This is sometimes caused by microscopic specks of contamination transferring from the belts to the top fabric. The board like feel to the fabric, which sometimes will only be noticed in the final checking stage of the garment, represents a potentially major quality problem which can be very costly. Smooth-Fuse SF10, as well as conditioning the conveyor belt surfaces to avoid microscopic contamination, can also have a beneficial ‘conditioning’ effect on some fabrics which cvounteracts stiffening and loss of feel effect and protects the fabric from damage.

Smooth Fuse SF10 is formulated not to mark most fabrics top

Smooth Fuse SF10, based on the original Smooth Fuse formulation has been proven over many years of use in different parts of the world not to mark most fabrics (see note below).

Safe to use – no dangerous vapors or CFCs top

Smooth Fuse is formulated to be safe to use as described in user instructions and information sheets. It contains no solvents of CFCs. It is regarded as an environmentally friendly product

(The following section can be expanded and added to with suitable diagrams)

Advantages of Smooth Fuse SF10 over alternatives top

Comparison of advantages of Smooth fuse against powder cleaners and aerosols cleaners
(Page 1)

No. Feature Smooth Fuse Powder Aerosol sprays Comments

1 Removes adhesive and resin contamination to PTFE surface conveyor belts used in laminating machines
+
+ Aerosol types are generally ineffective on resin contamination. Because of the fine spray it is impossible to put a heavy enough coating onto the conveyor belts for effective cleaning
2 Prevents adhesives sticking to PTFE surface conveyor belts.

+ Powder is a cleaning system. It does not leave a coating on the belts to prevent sticking after cleaning. Aerosol coating is too light and evaporates too quickly at normal operating temperatures. Smooth Fuse remains on the conveyor belts as a barrier film to prevent future sticking problems and to facilitate easy cleaning
3 Protects materials being processed from damage caused by dirty conveyor belt surfaces

+ Powder is a cure for dirty belts but does not protect materials from dirt contamination during fusing operations. Smooth Fuse is cure and a prevention by continuing to work after the belts are cleaned
4 Extends conveyor belt life by lubricating conveyor surfaces and reducing the amount dust, dirt and other contamination attaching to the belt
++ By continuing to prevent resins and dirty adhering to the belt during the fusing operation Smooth fuse extends belt life. Aerosols and powders do not work during normal fusing operations
5 Improves effectiveness of laminating machine’s built in cleaning systems
+ By lubricating surfaces during fusing operations the machine s cleaning systems work more effectively. The competitive products only work as cleaners, not as lubricators
6 Eliminates ‘stick up’.ie materials sticking to conveyor surfaces and point of exit mechanical systems
+ Continual lubrication by Smooth Fuse avoids sticking problems
7 Smooth Fuse contains additives which provide a ‘stick free’ PTFE surface which by reducing ‘drag’ improves the efficiency of laminating machine drive systems and some types of peripheral processing equipment such as non driven unwinds
+ Smooth fuse when used in continuous laminating applications reduces problems associated with ‘drag’ on materials running through the machine. Competitive products do not offer continuous lubrication necessary to achieve this advantage

8 The improved cleaning of the conveyor belts achieved by using Smooth Fuse reduces the amount of dirt and adhesive contamination getting into the mechanics and onto the rollers of the laminating machine.

+ Downtime caused by mechanical failure of the fusing machine is reduced by the lubricating effect of Smooth Fuse
9 The neutral Smooth Fuse formulation avoids marking of most types of materials being processed in laminating machines.

+ The Smooth Fuse formulation is designed to be neutral in colour and thus to reduce the instance of visible dirt contamination on materials being processed. Competitive products are not used while the machine is in operation.
10 Ensures clean exit from the laminating machine of non continuous sections being laminated. Foam/textile panels, non woven sections, head liners, composite panels etc
+ In non continuous laminating applications Smooth Fuse ensures clean exit from the laminating machine of panels.
11 Smooth Industrial Products supply very cost effective spray systems for coating conveyor surfaces direct from 5 litre or 25 litre containers
+ Smooth Fuse is available in cost effective and handy 5 litre containers with spray devices available straight from the container. None of the competitors offer industrial quantity containers
12 Smooth fuse is very competitively priced in a volume for volume comparison
+ On a comparison of volume of chemical, Smooth Industrial Products is probably the most competitive product on the market especially when sold in 5 litre containers. A large percentage of the contents of aerosols is the propellant itself and not the useful chemical
13 Smooth fuse is environmentally friendly and safe to use
+ Smooth Fuse does not create CFC or toxic emissions and does contain solvents. Aerosols contain CFCs and the airborne particles can be harmful. Powder contains solvents which can be hazardous in certain circumstances.
A full 500ml bottle of active cleaner/lubricator and all the fluid is active to the last drop top


Easy to use pump action spray containers which deliver a direct even spray of liquid every time top


Smooth Fuse is unique in that it is supplied in various containers sizes to meet individual requirements. All containers come with or are available with pump action spray systems which allow direct and wide spread application to the fusing surfaces. All 500 ml bottles have built in pump action spray devices. 5 litre industrial size containers can be supplied with heavy duty spray devices which allows direct from the container application to the fusing surfaces.

 

Trials

NB Where new untried fabrics are to be processed through fusing machines we recommend that before production commences tests are carried out to ensure that the new fabrics are not effected by Smooth Fuse SF10

Smooth Industrial Products Limited

(The information contained herein is confidential. All information, data and technical diagrams contained in the above documents are the copyright of D. Weisfeld - Smooth Industrial Products Ltd (Smooth Industrial Products). The information and diagrams contained herein are to the best of Smooth Industrial Products’s knowledge and belief correct at the time of writing. Details contained above are for information purposes only and are given without any legal liability)
© David Weisfeld-Smooth Industrial Products Ltd October 2004