From the idea...to the product!
The need to define a product takes shape in Mapel Textile with its Processing cycle,
which is the orderly and rational succession of operations (or PHASES),
necessary to transform one or more raw materials or semi-finished products into a finished product.
The Processing Cycle constitutes one of the planning activities of the production process, it arises from the need to translate the specifications of the product design into actions involving a series of decisions concerning in particular: - the starting material (typically in bill of materials); - the choice of the processing system; - the execution parameters; - tools and equipment to produce; - the definition of the operating sequences that must be followed to process the materials; etc. It can therefore be considered as a technical document, drawn up on paper or electronically, containing a multiplicity of data relating to the production of a single item or a batch of products. But also a first database for decision-making activities, having as objective the creation of different alternatives among which to make a choice based on certain optimization criteria of the pre-established objective functions. The examination of the design of the detail, combined with the Company's experience and the production policy adopted, will influence all the consequent choices.
Design
All raw materials and semi-finished products, made up of yarns, are uniquely encoded in the company management system, through a process that guides users through all phases and allows for the assignment of all the characteristics involved.
In the design phase, the sketches are defined, the materials are chosen and all the requirements of the desired product are prepared.
Marketing
Everything is fine sales orde rof our products is immediately included in the company management system and linked to the related Datasheet by the Commercial Office (or Sales Office).
Loaded orders, marked with a unique number, determine the creation of a requirement of goods for sale, which is immediately sent to the Production Office and the Research and Development Office, for the control of the related requirements, needs and production planning.
In relation to the needs and resources to be used, we finally proceed with the calculation of supplies necessary, the realization of any prototypes, and starting internal and external production orders.
Purchase of Raw Materials
The purchase of raw material is carried out among the selected and tested production chain of our Suppliers, equipped with the most extensive certifications recognized worldwide for quality, price and sustainability. The products purchased are chosen to satisfy the broadest expectations of customers (for physical, chemical, aesthetic-functional characteristics, etc.), in compliance with the most stringent capitulated existing. Our supply capacity allows us to contain the delivery times of all the most requested products, constantly replenishing the warehouses set up at each lowering of the minimum thresholds set up.
Twisting
The phase of Retwisting (or Binature) takes care of stabilizing the yarns, giving them greater titration (thickness o diameter of the resulting yarn) and consequently resistance, thanks to the coupling, by torsion, of two or more ends of yarn. The characteristics of the twisted yarns depend on the materials of the fibers and their initial treatments (which provide for the initial diversification betweenplain, shiny, textured yarns, etc.), but also by the precautions we adopt in this process, in order to exclude the formation of "knots", in order to obtain a more homogeneous product.
Dye (in yarn)
The phase of Tincture is the operation that allows to give or change color to materials through a liquid bath in which dyes are dissolved.
Our company only uses Yarn dyed yarns (to allow greater homogeneity compared to "in piece" or "in garment" dyes) and in almost all of the colors it prefers the "reactive dyes", to ensure the highest quality and durability over time. The class of reactive dyes has a vast spectrum of hues, shades and colors available, especially among the brightest ones (such as turquoise, violet and scarlet), with a strong color fastness, even in the different environmental conditions and methods of use of the ennobled product.
Our color charts already include thousands of colors (in the different materials proposed), even if it is possible to recipe new colors "randomly" (in this specific case, however, the delivery times are extended by a few weeks).
Storage
Storage constitutes the collection of all our yarns in the different materials, counts and standard colors available. Through this archive and the constant control of the minimum stocks is possible to quickly satisfy the production of any product that is allowed by our machinery.
Warping
The phase of warping is responsible for defining the warp (or chain), which is the yarn that extends along the entire length of the tape (longitudinal thread) and together with the texture (transversal or horizontal thread, beaten by a comb at each passage, which goes from one end of the warp to the other, to reach the selvedge), constitutes the armor. To prepare the yarn for the weaving operation, the warp threads are laid up metallic beams (cylinders) and placed in the rear part of the frame of each machine, in the colors envisaged by the article to be made, according to the motif of the design defined by the relative planning.
Weaving
The Weaving phase takes care of making the fabric (ribbon) through the systematic weaving of the threads of texture and warp (overall called armor), scrupulously observing the previously designed colors and motifs.
The graphic representation of the armor is named "put on paper" and consists of a pattern in which small squares alternate whites and blacks, where the thread of texture is represented by the black one (when the warp passes behind it) or the thread of warp is visible (white square) because it dominates the texture one.
The capabilities of our Research and Development department allow to combine tight sequences of black and white squares which, suitably alternating, allow to define complex motifs, logos and drawings with embroidery effect.
Example of Motif and corresponding "put on paper" ("Canvas" weave):
Ironing and Wrapping
The stages of Ironing and Wrapping allow to dimensionally stabilize the produced ribbon (by regulating the temperatures in order to respect the different yarn fibers used) and to quantify the relative production.
For ease of storage and preservation, the ribbon is usually wound on 50-metre rolls, with the help of automatic meter counters.
Control, Packaging and Shipment
The stages of Control, Packaging and Shipment
close the Processing Cycle of all our processes
and essentially envisage ensuring that:
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all the previous phases have been carried out in compliance with the operations envisaged by the Production Order;
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on each product, for each phase, the Control Plan of the required characteristics has been carried out;
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each material has been traced throughout the production process (internal and external) and in the warehouses;
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all the documentation required by the Orders and Specifications in place with the interested Customers exists;
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the products are packaged in the manner and shipped within the agreed times (through a efficient network with the main agreed couriers, which daily collect from our offices);
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Customers are informed of the fulfillment of their Orders, by sending the corresponding Transport Documents.
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