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Innovative Carrier Exchange System: Automatic Color Change in Braiding without Splices

We are proud to present our Carrier Exchange System, designed to revolutionize the thread braiding process by enabling color changes without splices and with total automation. This system meets the needs of demanding sectors such as security, medicine, and customized textiles, providing great versatility in design and functionality.

Main Features of the System

This advanced system consists of carrier exchange stations integrated within the braiding machine, allowing for automatic color changes in the rope at programmed intervals. Each station has carriers (also known as spindles) that can alternate between the central position and the outer layer of the rope, creating a color change on the surface without the need for splices. This way, the thread that was in the core moves to the exterior and vice versa, allowing for a unique and uninterrupted braiding aesthetic.

In our model 48B-E115 8I braiding machine, equipped with 48 carriers, the system allows for precise configuration of color transitions. Below, you can see a sample rope where 8 carriers in red and yellow thread were exchanged for 8 carriers of blue thread to achieve a distinctive color pattern.

Photo of a rope produced with the exchange system in the model 48B-E115 8I, showing a change of colors in the braiding.

The 48B-E115 8I braiding machine in operation, producing ropes with color changes every 20 cm.

Photo of the system presentation at the ITMA 2023 fair, highlighting the interest generated by its unique capabilities.

Presentation at ITMA 2023

Our Carrier Exchange System applied in a 48-carrier braiding machine was successfully presented at the ITMA 2023 fair in Italy, where it was received with great enthusiasm.

Attendees had the opportunity to see firsthand how this system transforms the design of ropes and textiles by offering complete customization without compromising quality.

Space and Machine Configuration

Given the limited space in the center of the machine, the exchange system is optimized for machines with a minimum of 16 carriers and a maximum of 48. Each machine can be adjusted to production needs based on the number of carriers, providing the adaptability required by different industries to customize their products.

Diagrams of the upper plate of the 16 and 48-carrier braiding machines, showing the exchange stations and internal design. One station in the case of the 16B-E80 I1 and 8 stations in the case of the 48B-E115 I8.

Specialized Applications in Model 16B-E80 I1

For the medical sector, the 16B-E80 I1 model specializes in marked surgical thread, allowing for clear and precise visual differentiation that facilitates use in high-precision surgical procedures. This feature responds to the growing demand for customization in medical products.

Photo of white surgical thread with a discontinuous black marking pattern on 16 threads.

Photo of Ratera’s booth at TechTextil North America in 2022 in the USA showcasing the 16B-E80 I1 model.

This model was previously presented by Ratera in 2019 at the ITMA in Barcelona and subsequently promoted at technology fairs such as TechTextiles and in its sector at MD&M West and Medtech China, with its respective software and mechanical evolutions.

The concept of the carrier exchange system is undoubtedly an innovation in the world of braiding, conceived, created, and exclusively manufactured by Ratera.

Flexibility and Specialized Applications

In addition to producing high-quality ropes and medical products, the system opens up a world of possibilities for products in different sectors:

  1. Brand Identification and Exclusivity: Allows brands to create unique patterns in their products, reinforcing the identity and distinction of their designs.
  2. Rope Making and Smart Textiles: With applications such as personalized shoelaces and technical ropes, the system can incorporate patterns and technical fibers into smart textiles, opening new possibilities for functionality and style.
  3. Medical Applications in the 16B-E80 I1: This model allows healthcare professionals to have surgical threads with visible markings to facilitate measurements during surgical procedures.
  4. Safety Ropes and Mountaineering: The option to mark every X meters allows users to count the length of the rope on-site, ideal for applications where precision is critical.

A System That Evolves with You

This Carrier Exchange System is much more than a production technology: it is a tool for personalization and innovation. Each final product, from a safety rope to a surgical thread, can benefit from unique precision and flexibility, helping every company stand out in its sector with customized and functional solutions.

If this system inspires you and you envision how it can be applied to your products, please do not hesitate to contact us to discuss customization possibilities or to adapt a machine to your specific needs. Our team is here to help you transform your ideas into unique products and take your business to the next level.