Fabric fusing machines provide consistent heat and pressure so factory workers can focus on high-value tasks.
The global garment industry is growing with revenue expected to exceed USD $1.7 trillion by the end of 2022, up from 1.5 trillion in 2013. This shows an annual increase of 10.59 percent during 2022. To keep up with demand and stay competitive, garment manufacturers need to look for innovative ways to enhance production efficiency. One of the best ways they can do this is by investing in machines that simplify the manufacturing process. Automating fabric fusing is one such way that manufacturers can streamline the production process.
A crucial step in garment production, the process turns separate pieces of fabric into complete wearable garments ready for display in warehouses. But how do garment manufacturers know which type of fabric fusing machine to invest in? Is bigger always better, or are small-sized continuous fusing machines good enough?
Fusing creates an unbreakable bond between fabric pieces
Garment manufacturers use fabric fusing to attach pieces of interlining to areas of clothing fabric for increased durability and shape retention. Cutting out this part of the production process would lead to limp clothes that easily wear out.
The fabric fusing process involves applying an adhesive resin to one side of an interlining, then bonding it to another piece of fabric using heat and pressure. The bond becomes stronger as the adhesive cools. Before fabric fusing machines were invented, garment manufacturers had to sew fabrics together by hand, as there was no way human force could apply sufficient pressure to melt an adhesive resin. Fabric fusing machines have made garments more durable while enhancing efficiency.
What are small-sized continuous fusing machines and why do garment manufacturers need them?
Continuous fusing presses with a width above 1400mm are suitable for fusing long fabric strips. Anything under 1400mm is ideal for smaller fabric pieces like shirt collars and cuffs. Operating continuous fusing presses is convenient and low-maintenance compared to other fusing machines, as they operate continuously as long as they are fed with fabric. Their continuous processing capability helps garment manufacturers produce high-volume orders. In fact, using small-sized continuous fusing machines is up to five times more efficient than manual fusing.
What are the benefits of small-sized continuous fabric fusing machines?
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Robust machines require fewer workers
Manually sewing and fusing fabrics isn’t just time-consuming, it’s also monotonous work that requires multiple workers. Small-sized continuous fabric machines enhance production time while cutting down on labor costs as they only need one operator per machine. And of course, machines don’t get tired like human workers do, meaning they can operate all day without burning out.
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Wide feeding belts over 1400 mm long optimize long fabric fusing
Continuous fusing machines come in a range of sizes. Small-sized machines with a feeding belt over 1400 mm long are suitable for long fabric pieces like sleeves or pant legs, meaning garment manufacturers can set up a production area dedicated to these types of clothing. This boosts productivity, as workers won’t have to reset specifications each time new fabric is loaded into the machine. Some machines also come with adjustable feeding belts to accommodate even longer fabric pieces.
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Consistent heat and pressure application prevent damage to clothing
Garment manufacturers would be hard-pressed to perform high-quality fabric fusing without applying adequate heat and pressure. Machines must apply just the right amount of heat to melt the resin without burning the fabric. Most small-sized fabric fusing machines have a temperature control function with separate upper and lower areas that apply heat only where it’s required. Some machines even have a temperature control sensor directly on the belt to ensure consistent heat is applied every time.
Specific pre-heated zones remove the risk of a sudden heat increase that can damage clothing. Furthermore, many small-sized continuous fusing machines have a separate belt for cooling and an automatic shutdown feature in case of overheating.
Moreover, continuous fabric fusing machines apply consistent pressure over the entire garment, which would be impossible to achieve manually. Some machines are fitted with a pneumatic cylinder system to ensure consistent pressure is applied throughout—and they can apply up to 10 kg of pressure at once. This optimizes the fabric fusing process and creates a stronger bond, ensuring final products consistently meet a high standard of quality.
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Wide-running belts cut production time
Just a few years ago, clothing stores adhered to two main fashion seasons, Spring and Summer, and Fall and Winter. But that isn't acceptable for today’s consumers. Fast fashion is in, and many stores have implemented 52 micro-seasons, meaning new trends are added to shelves every week. Given the demands of the industry, garment manufacturers must optimize the production process to avoid wasting time. Small-sized continuous fusing machines can process 2 to 10 meters of fabric per minute. They have multiple heated zones and take 10-34 seconds to fuse fabric, so garment manufacturers can accept bulk orders knowing their machines can handle them efficiently.
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Small-sized continuous fusing machines are easy to maintain
Working with adhesive resin can be messy. Leftover glue can stick to other fabrics, causing damage that is hard to resolve. Dried resin can be difficult to remove from the machine belt, meaning workers have to spend valuable time doing what they can to remove it. To combat these difficulties, some fusing machines have an upper and lower dual-scraper system that helps remove adhesive resin and laminates from the production belt. This means factory workers no longer have to spend time removing messy resin themselves.
Moreover, many small-sized continuous fusing machines are fitted with casters so they can be easily transported to other factory areas, allowing managers to restructure the factory layout as they please.
Conclusion
Small-sized continuous fusing machines bring consistency and efficiency to the factory floor. Without them, factory workers would spend time applying glue and bonding fabric themselves, which can only lead to uneven results stemming from human error. Small-sized continuous fusing machines can handle high volumes of fabric—perfect for factories with high production output. With feeding belts over 1400 mm long, these durable machines are ideal for fusing long fabric pieces. They’re equipped with intelligent features like multi-zone heating, an automatic shutdown function, and temperature control systems to ensure high-quality fusing every time. Oshima’s small-sized continuous fusing machines come in various sizes and incorporate additional smart features to enhance the fabric fusing process. Get in touch today to learn more.
