Pamantasan ng Cabuyao
Laguna Philippines 4025
COLLEGE OF ENGINEERING
MANUFACTURING PROCESS
A. PRE-PRODUCTION PROCESS
This stage includes receiving, validating and storing of raw materials and
production supplies needed by the company.
INCOMING QUALITY ASSURANCE
Items received will be check and validate for assuring that all items acquired
is in compliance and no foreign elements is mixed. Warehouse Staff will be
accountable for these matters.
WAREHOUSING
After the validation period, raw materials and other supplies where
temporarily stored in the warehouse area and at any moment items were
ready for processing.
B. PRODUCTION PROCESS
RAW MATERIALS PREPARATION (RMP)
Getting the needed materials from the warehouse area and prepares for
processing. This process is classified as two: the Denim RMP in which raw
material (trimmed denims) where palletize and prepares for fiber opening.
And, Polyester RMP where polyester from the warehouse will be endorse to
blending section for weighing.
DEFIBERIZING
The raw fiber arrives at the mouth of the opening machine and ingests
gradually until it passes to four opening rollers and reaches the desirable
cotton features of the denim. The main purpose of defiberizing is to loosen
the lumps of fiber and disentangle them.
Pamantasan ng Cabuyao
Laguna Philippines 4025
COLLEGE OF ENGINEERING
SOAKING
Opened denim fiber and polyester will be immerse on dissolve borax for 5
seconds then pull it up and proceed to oven for drying. Soaking serves as the
borax application for insulation that gives fire retardancy and termites-free
of the product.
DRYING
Subsequently, drying of opened fiber will be done on oven with the ideal
temperature ranging from 35
O
C - 40
O
C.
BLENDING
The opened fiber will be weigh sixty percent (60%) of the total weight of
product and forty percent (40%) for the polyester mixtures. Weighing will be
done using weighing scale for accuracy of the amount needed. After hefting
process, the opened fiber of denim will be mixed to polyester and ready for
soaking.
CARDING
The dry fiber will be feed to opening machine for assurance of fiber openness
and then direct process for carding through chute feeder and goes down to
carding machine. The output where now called Lap. This process is the
initial straightening process which puts fiber into parallel lengthwise
alignment.
NEEDLE PUNCHING
After the denim and polyester have been straightened and flattened it will
compressed and punched by thousand of needles using needle punching
machine. Now, it is called Textherm. Its main purpose is to form the
product firmly and to have a strong fiber compaction.
CUTTING
Endorsed Textherm from the needle punching process will be cut and
measure by semi-automatic cutting machine to form 1m x 2m of the
standard size of thermal insulation.
Pamantasan ng Cabuyao
Laguna Philippines 4025
COLLEGE OF ENGINEERING
ADHESION
It is the process of attaching one lap to another until it reaches the 5 layers
requirements or equivalent to 300mm thickness. Adhesion is manually
operated through the use fabric glue and applies on each edge of Textherm.
QUALITY INSPECTION
It is the product quality inspection such as adhesion characteristics and
accurate cut of the product. Textherm that passed quality inspection will be
adhere a sticker of company logo on the topmost right corner and ready for
storing.
WAREHOUSING
Thermal insulations will be stored on warehouse of finished goods and ready
for delivery.
Pamantasan ng Cabuyao
Laguna Philippines 4025
COLLEGE OF ENGINEERING
PRODUCT
Product Name: Textherm
Manufacturer: PADELE Manufacturing Company
Product type: Thermal Insulation
Description:
Textherm is made of sixty percent (60%) denim fabric obtained from trimmed jeans
and forty percent (40%) polyester fibers. Product has an area density of 4,203 g/m
2
,
thickness of 30.1 mm, 1 meter in length and width of 2 meters. It has a borax
content which makes fire retardant of 174.0 seconds from its length or 158.3
seconds of its width after the ignition source has been removed. It also shows that it
does not produce any glow after the removal of ignition source.
The product possesses also energy efficiency for it limits the leakage of heat or
conditioned air passes through a building with 34.6 cm
3
/cm
2
/s. Moisture content of
thermal insulation is lie on 6.1% only.
Pamantasan ng Cabuyao
Laguna Philippines 4025
COLLEGE OF ENGINEERING
SPECIFICATIONS
TOP VIEW
Figure 5: Textherm Standard size
Figure 6: Textherm width
2 meters
1 meter
30.01 mm
Pamantasan ng Cabuyao
Laguna Philippines 4025
COLLEGE OF ENGINEERING
PHYSICAL PROPERTIES:
PARAMETER METHOD RESULT UNIT
Air Permeability EN ISO 9237-1995 34.6 cm
3
/cm
2
/s
Flame Resistance
ASTM D 6413-99:
VERTICAL
After flame
Afterglow
Char Length
Length Width
174.0 158.3
0 0
300 300
second
second
mm
Mass Per Unit Area ISO 9073-1:1989 4,203 g/m
2
Thickness ISO 9073-2:1989 30.01 mm
Thermal Conductivity
CHEMICAL PROPERTY:
PARAMETER METHOD RESULT UNIT
Moisture Content ASTM D2495-07 6.1(6.5) % -