EasyLeno - Lindauer DORNIER GmbH

EasyLeno ®
2007

Titel… EasyLeno ® – EasyLeno ® 2T
New technology for innovative textile fabrics
Various final products produced
using the “drebbing” technique
on DORNIER air-jet and rapier
weaving machines with
EasyLeno ® and EasyLeno ® T
DORNIER air-jet weaving machine, fitted with leno device
EasyLeno ® T for “drebfabrics” from mesh-like up to 100 %
compressed structures
An innovation with potential
Globalization has made the hard-fought market for textile fabrics even tougher.
The difference made through innovation is therefore more important than ever
for many manufacturers. Bearing our customers in mind, DORNIER has reacted
to this challenge with groundbreaking technology for completely new leno fabric
structures, the “drebbing“ technique.
Leno weaves may be in demand due to their transparency and slip resistance
but the classical manufacturing technology with inverted leno heddles shows
significant disadvantages regarding productivity, flexibility and wear. DORNIER
took the task on and presented a new method: DORNIER EasyLeno ® .
This means: Weaving without superstructures, with needle bars instead of leno
heddles, without separate shedding devices, with speeds to over 700 rpm, less
wear and high efficiency during style changes.
The terms “drebbing“ and “drebfabric“ characterize this new style of leno weav-
ing. DORNIER‘s EasyLeno ® and EasyLeno ® 2T technology allows you to create
completely new high quality products in “drebbing” technique that cannot easily
be imitated and copied.

EasyLeno ® makes leno weaving easy ... ... EasyLeno ® 2T creates a new textile surface -
the drebfabric
Ground needle bar (blue) and movable needle bar (grey)
create the weaving shed for the leno weave. The reed
(green) beats up the filling thread into the drebfabric
DORNIER‘s drebbing technique EasyLeno ® - minimum material use, maximum productivity
Textile fabrics with leno weave are more slip resistant than fabrics with plain, twill or satin weaves.
Reason: The number of crossings within a binding unit is higher and the angle of wrap on thread
crossings larger. Assuming the same thread density, thread tension and friction coefficient for
a plain and a drebbing weave (drebfabric), the slip resistance of the drebfabric is up to 70 %
higher. This means, for example, plain weaves can be redesigned as drebfabrics so that material
usage can be reduced by up to 30 % and productivity increased by up to 40 %. Even more the
color brilliance of drebfabrics is impressive: Filling yarn colors dominate and overpower the warp
color so that standard warps can be used to produce different styles just through filling changes
or filling effects.
DORNIER‘s new drebbing technique achieves its advantages through innovative technology,
gentle to the yarn, user-friendly, self-cleaning as well as quick in gaining experience and style
changes - it´s easy.
Plain weave
interlacings in a weave repeat
(small crossing angle)
Leno weave
Drebbing technique advantages
• Higher weaving machine productivity with
speeds up to 450 rpm on rapier machines
and up to 720 rpm on air-jet machines
• Easy handling and maintenance through
needle bars without additional shedding
device
• Normal front and rear shed
• High warp densities up to 30 threads/cm
possible
• Slip resistance is up to 70 % higher than
plain weaves
6 interlacings in a weave repeat
(large crossing angle)
Drebfabric - universal in use - inherently stable,
brilliant colors and tear proof
Thread tension relative to
yarn count [cN/tex]
Carrier warp
Binder warp
EasyLeno ® 2T processes warp ends in two systems.
Different warp tensions then create an innovative dreb-
fabric. Warp ends are crossed on the rear side which
means a higher filling density can be set and the new
geometry creates new attractive optical characteristics.
Substituting finer threads for the binding thread allows
new designs with a double-face character. Filling threads
can be impacted so close to each other that a density
level of 100 % can be attained. The drebfabric thus
shows a mock plain weave on the upper side. An over 20
% increase in breaking strength has been proven thanks
to decisive improvements in the stress-strain ratio.
Stress-strain ratio for fabrics and drebfabrics
25
20
15
10
5
EasyLeno ® 2T
Filling thread
0
0 5 10 15 20 25
Elongation [%]
ε H
R H
ε H
L 1/1
R H
Filling density [1/cm]
EasyLeno ® T advantages
• Innovative double-face fabric
• Reduced structural elongation
(filling threads and carrier threads lay straight
in the drebfabric)
• Higher density level and distinctly superior
color brilliance
• Relief-type fabric surfaces through different
yarn counts
• Variable density level settings allow mesh-like
and compressed stripes
EasyLeno ® T is suitable to produce
fabrics with various densities because
no crimping capability is required in
filling direction independent of the
thread density. Temple cylinders with
only two needle knurls are sufficient for
fabric guidance in all density settings
Characteristic lines for drebfabric density limits
70
60
50
40
30
20
10
0
conventional
leno fabric
22 100 200 300 400
Filling yarn count [dtex]
EasyLeno ® 2T
500 600 700 800 900 1000 1100

Titel… Multifunctional and versatile - drebbing technique
High savings potential with excellent product features
Drebbing technology with a future - higher flexibility, new design options
Garments:
6
EasyLeno ® is suitable for all leno fabrics and drebfabrics - from very light curtains to the
heaviest glass roving. Drebfabrics open up new design options for clothing, household
textiles and technical textiles. Interesting tasks also open up in the carpet industry with clas-
sical carpet backings as well as manufacturing textile flooring, DrebCarpet ® , that can
be produced in just one process step. Weaving in leno and plain weave techniques will
also become more flexible; curtain weavers can produce leno fabrics and plain styles with
the same machine. There are no design limits - drapery and clothing fabrics with warp stripes
using plain or leno warp ends will be possible.
Plain and satin-like surfaces with definable air per-
meability in differentiated colors and high brilliance.
Multiple articles based on standard warps exclusively
by color selection and variable settings for filling den-
sities, e.g. for shirt fabrics
Decorative textiles:
Reduction in overall material usage for upholstery fab-
rics as compared to classical satin fabrics with better
surface coverage and equal abrasion resistance. The
high color brilliance is also suitable for curtain fabrics
Upholstery textiles:
Relief-type surfaces for better air circulation and anti-
slip behavior thanks to different filling thread fineness.
Formability through Elastan yarns in the ground warp
Technical textiles:
Constant warp density across the whole fabric width,
reproducible, different density levels, coarse and fine
mesh structures, high breaking strength; decisive, for
example, for coating fabrics, sun screening fabrics
and all kinds of glass fabrics
Carpets:
Ideally stiffened, velours-type surface structure, light,
environmentally friendly and economically producible
in just one workstep
From fabric to drebfabric
Filling density 36 threads / cm
The following example based on an upholstery fabric
compares economical aspects as well as product
features of drebfabric with a comparable fabric.
This example shows 125 % higher productivity and
28 % material savings in favour of the drebbed textile
achieving the same or better product features.
Fabric with 60 bindings / cm Drebfabric with 90 bindings / cm
Warp density 48 threads / cm
Fabric Drebfabric
Production data
Warp end PES 150 dtex 1 0/66 dtex
Warp density threads/cm
Filling density threads/cm
48 0
Chenille yarn Nm 4
12
1
(+ 1 % productivity)
PES 150 dtex
24
0
Fabric weight g/m² 552 0 (– 8 % material)
Filling density 13 threads / cm
Production features
Chenille yarn coverage Good Very good
Slip and seam resistance Good Good
Friction resistance Good Very good
Warp density 20 threads / cm
Technical Specifications
Type code
DORNIER EasyLeno ® air-jet weaving machine AWS4/ L 540
DORNIER EasyLeno ® rapier weaving machine PTS 4/ L 190
Number of filling colors
Leno device (Leno)
Nominal width cm
Air-Jet Weaving Machine
Machine
nominal width
cm
Rapier Weaving Machine
Machine
nominal
width
cm
Machine
width*
mm
Machine
width* with
4 colors
mm
Max. fabric
reeded width
mm
Max. fabric
reeded width
mm
Min. fabric
reeded width
mm
190 4810 1880 900
200 4910 1980 1000
220 5110 2180 1200
240 5310 2380 1400
280 5710 2780 1800
300 5910 2980 2000
320 6110 3180 2200
340 6310 3380 2400
360 6510 3580 2600
380 6710 3780 2800
390 6810 3880 2900
400 6910 3980 3000
430 7210 4280 3300
460 7510 4580 3600
540 8310 5380 4400
*Width valid for machines with 6 colors
Min. fabric
reeded width
mm
190 4975 1850 1044
200 5125 1950 1130
210 5275 2050 1230
220 5425 2150 1330
230 5575 2250 1430
240 5725 2350 1530
260 6025 2550 1730
280 6325 2750 1930
300 6625 2950 2130
320 6925 3150 2330
340 7225 3350 2530
360 7525 3550 2730
380 7825 3750 2930
*Add 100 mm for 6 colors
*Add 600 mm for 8 colors
Additional width on request
Please contact DORNIER for exact dimensioning of available
machine types
Subject to modifications

Lindauer DORNIER GmbH
881 9 Lindau/Germany
Telephone + 9 8 8 0 0
Telefax + 9 8 8 0 86
American DORNIER Machinery Corp.
P.O. Box 66886
Charlotte, N.C. 8 66, USA
Telephone +1 0 9 619
Telefax +1 0 99 018
DORNIER Machinery (Shanghai) Co. Ltd.
Area B G/F Block
99 FuTeZhong Road
WaiGaoQiao Tax Free Zone
Shanghai 001 1, China
Telephone +86 1 0 6 8 8
Telefax +86 1 0 6 1 8
Lindauer DORNIER GmbH
India Liaison Office
0 , Sangeet Plaza
Marol Maroshi Road
Andheri (East)
Mumbai 00 0 9, India
Telephone +91 9 06
Telefax +91 9 08 60
www.lindauerdornier.com
sales.wm@lindauerdornier.com
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