Barco supplies production monitoring systems to major carpet manufacturers

Barco’s TUFTMASTER system provides production management information and makes a planner’s task more transparent and easier to handle. In addition to machine production monitoring, the system offers operator traceability and a user-friendly plan board. Barco has made substantial investments to optimize its monitoring software to meet the specific needs of the carpet industry. The link between TUFTMASTER and the customer’s IT infrastructure now allows real time data feedback to the ERP system on the order status of the produced carpet rolls.

Each tufting machine is equipped with a data unit type DU8 to allow the capturing of production count and stop signals which are available at the machine. The collected information is automatically transmitted to the server of the TUFTMASTER system, which allows a detailed analysis of production as well as down time.



With Barco’s new data transmission technology, it’s no longer a requirement to wire from the various production machines to the server. Each DU8 data unit uses Bluetooth wireless RF communication to transmit and receive information to and from the TUFTMASTER server. Bluetooth access points are installed in the production area. This allows wireless communication within a 50-meter perimeter around each access point. Contrarily to the use of a wireless LAN, a Bluetooth network is extremely secure. Outsiders to the organization will not be able to tap into the network. More than 20 textile operations are already using Barco’s RF technology for their monitoring system. The quality of the data communication has been reported as just perfect.

Collins & Aikman already purchased a TUFTMASTER system three years ago for their operation in Dalton (GA). Recently this company decided to install an identical monitoring system in their operation in Nova Scotia/Canada. J&J Industries, another tufting company based in Dalton, GA, decided to monitor production with TUFTMASTER and during the ATME show, Beaulieu of America confirmed their decision to install TUFTMASTER. In Belgium, Barco just finished the installation of a TUFTMASTER system at Ideal Floor Coverings.

Barco also offers systems for manufacturers of rugs. Recently Orian Rugs in Anderson, SC purchased an upgrade of their 12 years old installation. With the new WEAVEMASTER software, the data units on the machine remain in use to form a state of the art monitoring system. In Belgium, Mc Three Carpets, the mother company of Orian Rugs, also decided to purchase a WEAVEMASTER system for their 25 Van De Wiele carpet looms. Wireless data units will be used to transfer the collected data. With a new system installed in each plant, the performance of the production can be viewed from both sides of the ocean. Through a VPN (virtual private network) the systems are connected and a manager in Belgium can consult the system in the USA without any additional telecommunication cost.

From the feedback given by these Barco system users, it has become evident that TUFTMASTER and WEAVEMASTER allow an increase in productivity between 5% and 7%. This magnitude of savings assures a short return on investment period.


About Barco
Barco, an international company headquartered in Kortrijk, Belgium, is active in three key areas of imaging technology. Barco designs and develops solutions for large screen visualization, display solutions for life-critical applications, and systems for visual inspection. Barco has a network of subsidiaries, distributors and agents in almost 100 countries. Barco is quoted on Euronext Brussels and is a BEL 20 and a Next 150 company.

For more information, please contact

Johan Schepens
Vice President Marketing & Sales
BMS bvba

Telephone + 32 56 262642
sales.bv@visionbms.com

Herman Dewitte
Sales Executive
BMS bvba

Telephone + 32 56 262693
sales.bv@visionbms.com