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Vol. 2:
Furnishing fabrics waterfalls
Fabric sample making with Elebor GB devices
Elebor GB Sample making: furnishing fabrics books
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Table of Contents
Introduction to sample making
3
Introduction to furnishing textile
3
Introduction to Waterfalls sample
making
3 High volumes books sample making 19
Entry level books sample making
4 Taping process
Taping process
Step
Step
Step
Step
Step
0:
1:
2:
3:
4:
taping heads positioning
fabric spreading
tape heading
automatic taping
next fabric spreading
Cutting Process
Step 1: resizing to pinking machine
Step 2: fabric transferring to cut
Step 3: pinking machine cut
Assembling process
5
5
6
7
8
9
10
11
12
13
14
Step
Step
Step
Step
1:
2:
3:
4:
fabrics sticking in waterfall way
15
waterfalls cutting
16
waterfalls and headers assembling17
glue cooling
18
Step 1: fabric spreading
Cutting Process
Step 1: resizing to pinking machine
Step 2: fabric transferring to cut
Step 3: pinking machine cut
Assembling process
Step 1: fabrics labelling and sticking in
waterfall way
Step 2: waterfalls cutting
Step 3: waterfalls mounting
Step 3: glue cooling
Conclusions
20
21
22
23
24
25
26
27
28
29
30
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Elebor GB Sample making: furnishing fabrics books
Introduction to sample making
We define two levels of approach to the sample making business.
The first approach is an entry level approach, with the minimal set of
machineries to balance manual operations, quality and time needed.
The second is the advanced level for high volume productions, the state of the
art of sample making devices.
Introduction to furnishing textile
There are usually two main ways to display samples of furnishing fabrics:
catalogue books and waterfalls hangers.
They differ in many steps of preparation and in the machinery needed to
achieve the final product.
Introduction to Waterfalls sample making
To produce waterfalls you need to:
1.
2.
3.
4.
5.
6.
7.
8.
prepare labels or printed tapes for the fabric identification
prepare the fabric, spreading it on a table
tape the fabric to avoid threading
cut the fabric to the size to fit the waterfall machine dimensions
mount the fabric in waterfalls fashion
cut the waterfalls to the final dimensions
mount the waterfalls to hangers or headers
apply the labels for identification fabric
The symbol
 define a manual operation
Elebor GB Sample making: furnishing fabrics books
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Entry level books sample making
The entry level sample making solution proposed by Elebor GB is suitable for
low and medium volume production.
It is defined by the following set of devices:
–
–
–
–
–
–
–
–
–
spreading table
taping machine
tape holder
vertical blade cutter
pinking machine
waterfalls machine
hot melt dispenser
press
label and tape editor software
Elebor GB TS1000
Elebor GB CNL 1800
Elebor GB BIN 1000 clamps (faculty)
120mm (5”) blade
JEM TJ 110cm long blade pinking machine
Elebor GB semi automatic TIE
hand hold guns B300
Elebor GB manual clamps PD 2700
NSTLabelEditor
Elebor GB Sample making: furnishing fabrics books
Taping process
The taping process is performed in order to avoid the threading of the samples
after the cut, it is called edge fixing.
The tapes will be applied where the pinking machine will cut.
It means that the taping heads must be placed one each other at the same
distance of the cut dimensions.
Step 0: taping heads positioning
Before starting to tape, the operator must place the heads in the right position.
Each head is composed by a dispenser (the tape roll holder) and by an
applicator that sticks the tape over the fabric.
Usually the width of the waterfall machine is 0.9 meter, that mean it is smaller
than the fabric width, it is necessary to apply a double tape.
It permits to fix both edges of the slices of the prepared fabrics, further reading
will help to clarify the need.
Table
Fabric
Narrow gap heads
NSL 2040 IS
CNL
Dispenser
NSL 2240

Applicator
APN 4050
Elebor GB Sample making: furnishing fabrics books
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Step 1: fabric spreading
The fabrics have to be laid over the spreading table in the right sequence to
permit the taping of each fabric.
Two persons will lay down the fabric, and they have to unwind it over the
spreading table.
Spreading table
TS 1700
Table
Fabric

Fabric Roll


Longitudinal
taping machine
CNL
CNL
Elebor GB Sample making: furnishing fabrics books
Step 2: tape heading
The next step is to lock the tapes at the head of the table.
The clamp bar BIN 1000 will help you in sticking and it will reduce the tape
waste.
Table
Fabric
Narrow gap heads
NSL 2040 IS
CNL
Dispenser
NSL 2240
Applicator
APN 4050
Elebor GB Sample making: furnishing fabrics books

Clamp bar
7
Step 3: automatic taping
Now the longitudinal taping process can start. Automatically all tapes will be
stuck over the fabric.
CNL
Max = 90 cm
Max = 90 cm
Forward:
longitudinal taping
Note:
in this example the length of the pinking machine blade is shorter than the
fabric width.
The process needs to apply a double tapes, the following steps will clarify it.
Elebor GB Sample making: furnishing fabrics books
Step 4: next fabric spreading
The next fabric can be spread. The process repeats the sequence from step 1
for all the different fabrics that compose the display book.
Fabric
Roll

max = pining blade length


CNL
Elebor GB Sample making: furnishing fabrics books
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Cutting Process
Once the spread of all fabrics that compose the book is finished, it is time to
cut the samples in the dimensions of the book.
Using a vertical blade cutter the taped spread must be cut in slices fitting the
size of the pinking machine
Elebor GB Sample making: furnishing fabrics books
Step 1: resizing to pinking machine
The operators manually have to slice the fabrics spread to the size fitting the
pinking machine and the waterfalls machine dimensions.
Because of the inadequate dimension of the pinking machine blade and of the
waterfall machine the fabric must be cut also in the longitudinal way.
Max = 90 cm

Max = 90 cm
max = pinking machine blade max = pinking machine blade
In this step the application of the two tapes applied with the narrow gap
becomes clear: they save the new edges created by the cuts.
CNL
Elebor GB Sample making: furnishing fabrics books
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Step 2: fabric transferring to cut
Now the slices of fabric can be transferred to the pinking machine.
In this example four slices are obtained.
Pinking machine cuts
Elebor GB Sample making: furnishing fabrics books
Step 3: pinking machine cut
The cutting take place. The slices are cut into the dimensions of the waterfall
machine. In this example the cutting cycle must be performed four times.
JEM – TJ 110
JEM – TJ 110
X4
JEM – TJ 110
JEM – TJ 110
X2
Elebor GB Sample making: furnishing fabrics books
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Assembling process
The assembly process starts applying the fabric over a support.
The waterfall machine is used to stick with hot melting glues the fabrics over
the support.
Then the waterfall is reduced in dimension and it is insert and lock into the
header.
The last operation is to apply labels to identify the fabric.
Elebor GB Sample making: furnishing fabrics books
Step 1: fabrics sticking in waterfall way
The fabric slices are applied using the TIE waterfall machine.
An operator by hand picks a fabric and lay under a pressing clamp.
The clamp press the fabric over the support and it press the support over the
heater that melt the glue sticking the fabric.
The support is feed and the next fabric can be applied.
Waterfall machine TIE

Fabrics
Hot melted
not woven fabric
(black or white)
Elebor GB Sample making: furnishing fabrics books
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Step 2: waterfalls cutting
When all the waterfalls have been prepared it is time to cut the waterfall to the
display dimension.
The pinking machine is used once again to cut in one direction only.
JEM – TJ 110
JEM – TJ 110
Elebor GB Sample making: furnishing fabrics books
Step 3: waterfalls and headers assembling
Once prepared the slices of waterfalls it is time to assemble the waterfalls with
the header.
The header can mount an anchor, an holder or a hook.
The hot melt glue i the best solution to close headers over the waterfalls.
Fabric
waterfall
Header
Hot melt
Glue
Elebor GB Sample making: furnishing fabrics books
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Step 4: glue cooling
The only caution you have to follow while using hot melt glue is to press the
two sticking parts while the glue is still hot and melted.
The manual operated press PD 2700 holds the header closed over the waterfall
with a constant pressure.
It avoid the use of manual lifted weights and the onset of back pain.
Once the glue is become cold the waterfall is ready to be manually labeled.
Manual clamp
PD 2700
Product finished
ready to be labeled
Elebor GB Sample making: furnishing fabrics books
High volumes books sample making
The high volumes sample making solution proposed by Elebor GB is defined by
the following set:
System composition:
–
spreading table
–
hand drive spreading car
–
taping machine
–
transversal taping machine
–
vertical blade cutter
–
pinking machine
–
waterfall machine
–
–
–
Elebor GB TS1000
Elebor GB STT
Elebor GB CNL 1800
Elebor GB NTE 1000
120mm (5”) blade
JEM TJ 160cm blade long pinking machine
Elebor GB TIE2 waterfall and labelling
machine
hot melt dispenser
B4 melter with two pipes and two guns
press
Elebor GB pneumatic press PDP 1800
label and tape editor software NSTLabelEditorAdvanced
The need of managing great quantity of materials and of an high throughput of
finished products pushes the automation of the sample making a great step
forward.
All the steps are automatized to get the maximum in fabric usage efficiency
and time saving.
Elebor GB Sample making: furnishing fabrics books
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Taping process
The whole taping process is the same as in the entry level scenario, please
refer to it page 5.
We only suggest the use of the spreading car STT to speed up the fabric
spreading phase.
Elebor GB Sample making: furnishing fabrics books
Step 1: fabric spreading
The right sequence of fabric have to be laid over the spreading table to permit
the taping of each fabric.
A spreading car will help in this operation. Using the spreading car you need
only one person to lay down the fabric over table.
Table

Fabric Roll
Fabric
Fabric
Longitudinal
taping machine
CNL
CNL
Elebor GB Sample making: furnishing fabrics books
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Cutting Process
Once the spread and taping of all fabrics that compose the book is finished, it is
time to cut the samples in the dimensions of the book.
Using a vertical blade cutter the taped spread must be cut in squares fitting the
size of the pinking machine.
Elebor GB Sample making: furnishing fabrics books
Step 1: resizing to pinking machine
The operators manually must slice the fabrics spread to the size fitting the
pinking machine dimensions.
Max = 90 cm

Max = 90 cm
max = pinking machine blade
Manual
vertical
blade
cutter
max = pinking machine blade
The pinking machine blade 160cm long is larger than fabric width. It permits to
have less cut in the longitudinal direction.
CNL
Elebor GB Sample making: furnishing fabrics books
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Step 2: fabric transferring to cut
The squares of fabric can be now transferred to the pinking machine. In this
example two slices instead of four are obtained (cf pag 12).
Pinking machine cuts
Elebor GB Sample making: furnishing fabrics books
Step 3: pinking machine cut
The cutting take places. The slices are cut into the dimensions of the waterfall.
In this example two cutting cycle must be performed.
JEM – TJ 160
JEM – TJ 160
X4
Elebor GB Sample making: furnishing fabrics books
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Assembling process
The assembly process starts applying the fabric over a support.
The waterfall machine is used to stick with hot melting glues the fabrics over
the support.
Then the waterfall is reduced in dimension and it is insert and lock into the
header.
The last operation is to apply labels to identify the fabric.
Elebor GB Sample making: furnishing fabrics books
Step 1: fabrics labelling and sticking in waterfall way
The fabric slices are applied using the TIE2 waterfall machine.
The machine, while the operator is processing the fabric, prints and applies the
labels.
The operator by hand picks a fabric and lay under a pressing clamp.
The clamp press the fabric over the support and it press the support over the
heater that melt the glue sticking the fabric.
The support is feed and the next fabric can be applied.
Label printer
Label applicator

Fabrics
Hot melted
not woven fabric
(black or white)
Elebor GB Sample making: furnishing fabrics books
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Step 2: waterfalls cutting
When all the waterfalls have been prepared it is time to cut the waterfall to the
display dimension.
The pinking machine is used once again to cut in one direction only.
JEM – TJ 160
JEM – TJ 160
Elebor GB Sample making: furnishing fabrics books
Step 3: waterfalls mounting
Once prepared the slices of waterfalls it is time to assemble the waterfalls with
the header.
The header can mount an anchor, an holder or a hook.
The hot melt glue is the best solution to close headers over the waterfalls, the
use of an hot melt machine reduce the amount of glue needed to get a good
closing, and speed up the application.
Fabric
waterfall
Header
Hot melt
Glue
138-140
melter
Elebor GB Sample making: furnishing fabrics books
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Step 3: glue cooling
To speed up the header closing we suggest to use a pneumatic press like PDP
1800 STD.
It permits to dramatically reduce the time need to get the glue cold, and also
the quantity of glue can be reduced.
Glued waterfall
Pneumatic clamp
PDP 1800
Product finished
already labelled
Pressing time
Elebor GB Sample making: furnishing fabrics books
Conclusions
The use, in high volume solution, of a waterfall machine with automatic
labelling system permits, in one step, to create the waterfall and to apply the
labels.
It also permits to reduce the cutting cycles, reducing the time needed and the
waste of fabric.
In conclusion the use of the advanced set permits to save:
– material:
less fabric usage and less quantity of glue (thanks to
pneumatic press)
– time:
less manual cutting and less cutting cycle,
labelling phase avoided,
faster header mounting
– quality
a more sharp cut and a more precise labelling and tighter
mounting
Elebor GB Sample making: furnishing fabrics books
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© Elebor GB s.r.l. 2008-2012
review: 06/06/12
Elebor GB s.r.l.
Via B. degli Ubaldi, 9
20155 Milano
Italy
Produced in Italy
All right reserved
All trade marks are property of their owners
The data in the document way change
without any previous communication
Elebor GB Sample making: furnishing fabrics books
Elebor GB Sample making: furnishing fabrics books
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Elebor GB Sample making: furnishing fabrics books