ChromoJET Carpet Book 2012 - J. Zimmer Maschinenbau GmbH

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DIGITAL JET PRINTING SYSTEM 

... more products 

... more innovations 

... more flexibility 

ZIMMER AUSTRIA | DIGITAL PRINTING SYSTEMS

Zimmer Maschinenbau GmbH 

... the World Market Leader in Digital Jet Printing 

Since 1874 Zimmer is working hard to develop, design and manufacture the best finishing machinery for textile, 

carpet, non woven, paper and other roll to roll substrates. 

The activities in the carpet industry started in the early sixties and nowadays this is a major part of Zimmer‘s 

business. 

In 2006, the company structure has been optimized by establishing two competence centres: While Kufstein is the 

location for digital printing machines and carpet machinery, the production site in Klagenfurt covers the industrial 

production of screen printing machines, coating machines, dryers and steamers for the textile industry. 

In keeping the tradition Zimmer Kufstein has designed, delivered and installed more than 400 ChromoJET units 

worldwide, and our satisfied customers have produced millions of meters of their products. 

Modular machine design is not just a word for us. One of the outstanding characteristics of our machines is their immense 

flexibility. All systems are custom built from standardized elements in order to keep our manufacturing cost 

down and to give the customer short payback time due to a high R.O.I. factor. 

Productivity is most important for every customer. Therefore all machine models are especially designed for fastest 

design change, shortest possible colorways and non-stop production. 

Think global – act local. Customer service is one of our main objectives. Permanent availability via remote control 

service tools and on-site service is a must to satisfy our customers’ requirements. 

Digital Printing and Coating Equipment for Carpet 

Delivery Program 

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ChromoJET | Digital Jet Printing Systems page 04 - 27 

• ChromoJET 400 - 25 dpi page 06 - 13 

• ChromoJET 800 - 76 dpi page 14 - 23 

• Lab and Sample Equipment page 24 - 25 

SupraMIX | Color Preparation page 26 - 27 

SupraFOAM | Coating & Impregnation page 28 - 29 

Carpet Back Coating Lines for Secondary Backing and Gel Foam page 30 - 33 

PVC Carpet Tile & Mat Back Coating Lines page 34 - 39 

02 03

25 dpi 

Halbmond Teppichwerke GmbH, Oelsnitz 

04 

ChromoJET 400 Basics 

Function 

ChromoJET is a printing system using high speed valves which are computer 

controlled. The pre-mixed pressurized spot colors are injected with high 

precision deep into the face of the pile without any machine parts touching 

the fabric. 

Deepest color penetration and excellent print definition are the result. 

Print Speed 

Production speed is almost proportional to the number of jets used per color. 

More jets offer higher production speed. 

Modes of Operation 

Single Speed Mode (SSM) 

Each group of jets is used for one individual color. 

Double Speed Mode (DSM) 

Two groups of jets are combined and filled with the same color. The linear 

production speed is almost doubled in comparison to single speed mode. 

Production per year 

at 2 shift operation (16 h) 

0 - 25.000 

25.000 - 50.000 

50.000 - 100.000 

100.000 - 250.000 

250.000 - 500.000 

0.5 - 1 mio m² 

1 - 2.5 mio m² 

2.5 - 5 mio m² 

Advantages of ChromoJET 400 

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Selector | ChromoJET 400 printer with 25.4 dpi resolution 

Piece by Piece operation 

Mats Carpet tiles 2 m print lines 4 m print lines 5 m print lines 

CHR 400 2000 

16 c x 8 jets 

CHR 400 2500 

16/32 c x 16 jets 

CHR 400 2500 

32/48 c x 48 jets 

CHR 400 2000 

8/12/16 c x 32 jets 

CHR 400 2000 

8/12/16 c x 64 jets 

CHR 400 2000 

8/12/16 c x 128 jets 

CHR 400 2000 

8/12/16 c x 256 jets 

CHR 400 2000 

8/12/16 c x 32 jets 

CHR 400 2000 

8/12/16 c x 64 jets 

CHR 400 2000 

8/12/16 c x 128 jets 

CHR 400 2000 

8/12/16 c x 256 jets 

Roll to Roll operation 

CHR 400 4000 

8/12/16 c x 128 jets 

CHR 400 4000 

8/12/16 c x 256 jets 

CHR 400 4000 

8/12/16 c x 512 jets 

CHR 400 4000 

8/12/16 c x 1280 jets 

Besides our standard program we also build highly customized printing lines in various configurations. 

CHR 400 5000 

8/12/16 c x 512 jets 

CHR 400 5000 

8/12/16 c x 1280 jets 

• No screens – no limitation in pattern repeats 

• Design change „on the fly“ 

• Full penetration 

• Pile weight from 250 up to 1,500 g/m2 

• For polyamide, wool, acrylic and (up to a certain extent) 

polyester yarns 

• Complete print line from one supplier 

• High Resolution 

05

25 dpi 

Workflow of a Carpet Printline 

Carpet Sew-On (Butt-End Seam) 

Feeding from Roll or Trolley 

Accumulator or J-Box 

Lint Removal 

Pre-Steamer Padder 

Gum Layer 

Dye Applicator 

Anti-Stain 

Steaming 

Washing 

Flour-Carbon 

Centering Unit 

Steaming 

Washing 

Drying 

Backing 

Pre-Washing 

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ChromoJET 400 Printer for rugs & wall to wall carpets 

Specification 

CHR 400 4000 

c x 128 

Print width 415 cm 

Number of colors 8/12/16 c 

Jets per color 128 

Linear print speed at 25.4 dpi 

in single speed mode 


in single double speed mode 

0,7 - 0,9 m/min 

CHR 400 4000 

c x 256 

415 cm 

8/12/16 c 

256 

1,5 - 1,9 m/min 

CHR 400 4000 

c x 512 

415 cm 

8/12/16 c 

512 

2,7 - 3,4 m/min 

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CHR 400 4000 

c x 1280 

415 cm 

8/12 c 

1280 

6,3 - 7,6m/min 

1,4 0,7 - 0,9 1,8 m/min 1,5 3,0 - 1,9 3,8 m/min 5,4 2,7 - 3,4 6,8 m/min 10,3 5,1 - 6,2 12,4 m/min 

Requried Required space ~ 15 x 50 50 m ~ 15 x 60 m ~ 15 x x 70 m ~ 15 x 100 100 m 

ChromoJET printed rugs and carpets for the contract and hospitality markets are very popular. High flexibility in colors 

and no restriction in pattern repeats are the major advantages over woven and tufted carpets. 

No dyed yarn needs to be kept on stock – only white yarn or white tufted carpet. 

06 07

25 dpi 

Unrolling, J-box, lint removal, 

pre-steamer, edge guiding 

and pull roller 

08 

ChromoJET 400 printer with up to 16 colors and up to 5 m width 

Color kitchen with automatic 

thickener and water dosing 

Horizontal steamer, washing unit 

and dryer 

ChromoJET 400 4 m print lines 

for rugs & wall to wall carpets 

Stenter inlet to dryer Exit of dryer with cooling zone 

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Washing and vacuum unit Vacuum pumps of washing unit Foam application and impregnation 

Accumulator, inspection zone and 

roll-up unit 

09

25 dpi 

• Tile positioning unit for any size up to 205 x 105 cm 

• High resolution ChromoJET printer 

• Conveyor belt throughout the complete line 

• Special steamer construction with steam from 

top to avoid overheating of the backing 

• Sandwich washer with high power vacuum pump 

• Low temperature dryer with long drying time 

ChromoJET 400 Printer for carpet tiles, mats & runners 

Specification 

CHR 400 2000 

c x 32 


Number of colors 8/12/16 c 



in single speed mode 

0,3 - 0,4 m/min 

CHR 400 2000 

c x 64 

210 cm 

8/12/16 c 

64 

0,7 - 0,8 m/min 

CHR 400 2000 

c x 128 

210 cm 

8/12/16 c 

128 

1,2 - 1,4 m/min 

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CHR 400 2000 

c x 256 

210 cm 

8/12/16 c 

256 

2,2 - 2,7 m/min 


Linear print speed at 25.4 dpi 0,6 - 0,8 m/min 1,4 - 1,6 m/min 2,4 2,4 - 2,8 m/min 4,4 - 5,4 m/min 

in double speed mode 

Tiles Tiles per hour (50 x 50 cm) ~ 40 x 45 m²/h m²/h ~ 75 x 90 m²/h ~ 120 x 145 145 m²/h ~ 210 x 240 m²/h 

Carpet Tile Printing 

ChromoJET is perfect to print carpet tiles either on individual tiles or on slabs where tiles will be cut out after 

the printing process. 

Printing can be done either on pre-dyed tiles with a light base color or on white tiles. 

Sandwich washer for mats 

and carpet tiles 

Unrolling unit with integrated 

pre-steamer, edge guiding 

and pull roller 

Bath mat printing (2 m line) 

Carpet tile positioning device 

for a precise match of the print 

Positioned tiles during 

the print process 

10 11

25 dpi 

At the Cap‘Cinéma Le Carnot various playful colors show the way to the cinema halls whose 

numbers are also integrated into the design. 

Applications 

25 dpi Carpets by Halbmond Teppichwerke GmbH, Oelsnitz 

Hotel Royal in Eurothermen-Ressort Bad Ischl 

ChromoJET Exceeds All Expectations! 

ChromoJET allows sharp colorful and brilliant carpet designs. 

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12 13

76 dpi 

14 

ChromoJET 800 Basics 

How does process color printing work? 

In process color printing a set of 12 basic shades are used to 

generate all color shades on the carpet using small dots (just 

as in an office printer). 

This method has a lot of advantages against spot color printing, 

where each color must be pre-mixed in advance. 

• Easy sampling 

• Even orders for one piece can be realized 

• Unlimited design variety 

• Unlimited colors per design 

• No change of color - always run with same dyes 

(environmental friendly) 

Process Color Carpet Printing 

... creativity without limits 

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Selector | ChromoJET 800 printer with 50/76 dpi resolution 

Production per year 

at 2 shift operation (16 h) 

25.000 - 50.000 

100.000 - 250.000 

250.000 - 500.000 

0,5 - 1 mio. m² 

Mats Carpet tiles 

CHR 800 2000 

12/16 c x 32 jets 

CHR 800 2000 

12/16 c x 128 jets 

CHR 800 2000 

12/16 c x 128 jets 

CHR 800 2000 

12/16 c x 256 jets 

2 m print lines 

tiles and roll-to-roll 

CHR 800 2000 

12/16 c x 128 jets 

CHR 800 2000 

12/16 c x 256 jets 

Advantages of ChromoJET 800 

4 m print lines 

for roll-to-roll 

CHR 800 4000 

12/16 c x 512 jets 

• Maximum efficiency in short runs 

• No screens necessary - no limitation in repeats 

• Just in time delivery - lower cost for stock goods 

• Design change ”on the fly” 

• Low paste cost due to standard commercially 

available dyestuff 

• For polyamide, wool, acrylic and polyester 

• Pile weight from 200 up to 1500 g/m² 

• Brilliant shades with best fastness 

• No fabric pre-treatment needed 

• Full penetration 

• Less waste water 

• Complete print line from one supplier 

15

76 dpi 

16 

ChromoJET 800 2000, with 12 colors / 256 jets per color and color holding tanks 

Entry unit 

Horizontal steamer 

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Printer for mats, carpets tiles, rugs and wall-to-wall carpets 

Sandwich washer 

and vacuum system 

Specification 

CHR 800 2000 

c x 128 


Number of colors 12/16 c 


Linear print speed at 50 dpi 

(up to 500 g/m² pile weight) 

Linear print speed at 76 dpi 

(up to 1500 g/m² pile weight) 

0,6 - 0,9 m/min 

0,4 - 0,6 m/min 

Tiles per hour (50 x 50 cm) ~ 40 - 50 m²/h 

Dryer with conveyor belt 

CHR 800 2000 

c x 256 

220 cm 

12/16 c 

256 

1,2 - 1,7 m/min 

0,8 - 1,2 m/min 

~ 70 - 80 m²/h 

CHR 800 4000 

c x 512 

420 cm 

12/16 c 

512 

1,5 - 2,1 m/min 

1,0 - 1,4 m/min 

- 

Accumulator and roll-up 

17

25/50/76 dpi | Mat Printer 

18 

Top level advertising ... 

for exhibitions, conventions and clubs, point of sale 

for entrance, counter, office or advertising areas 

in front of machines and for many other applications 

ChromoJET 800 

Steamer 

Washer 

Dryer 

Logo & Promotion Mats 

Print width 

Number of colors 

Jets per color 

Linear Print speed 

Specification 

Mats per hour (90 x 150 cm) 

Color preparation Design processing 

- resolution 

- coloration 

- retouch 

Extended CMYK Prepared design 

Steaming, Washing and Drying 

CHR 400 2000 (25 dpi) 

c x 8 

215 cm 

16 c 

8 

0,1 lm/min 

~ 8 - 10 mats/h 

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CHR 800 2000 (50/76 dpi) 

c x 16 

215 cm 

8 c 

16 

0,1 lm/min 

~ 8 - 10 mats/h 

Application Laundry Mats Promotion Mats 

Advantages of ChromoJET 

• Maximum efficiency in short runs 

• Lower cost for stock goods – just in time delivery 

• No screens needed – unlimited repeat sizes 

• Design change ”on the fly” 

• Low paste cost (€ 0,30/kg) due to standard 

commercially available dyestuff 

• High fastness level 

• Brilliant shades 

• Perfect penetration 

• No fabric pre-treatment needed 

• Photo-realistic prints 

19

76 dpi 

ChromoJET printed carpet was used as bench cover at „Marketing + Services 2009“, exhibition, Frankfurt 

Exhibition Carpet 

ChromoJET printed carpet is perfect to get YOUR message across. 

20 

Use your floor space to attract people and to enhance your CI. 

Applications 

Event Carpet - „Red Carpet“ 

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Perfect for all events and shows. Why use plain „Red Carpet“, when ChromoJET printed brand image can be presented. 

Maximum marketing exposure is ensured in the print media and on TV. 

Carpet Tiles 

Carpet tiles printed over a repeat of 3 x 5 tiles. 

21

76 dpi 

Carpet for the contract and hospitality market Individual rugs and mats 

Contract carpet installation 

Exhibition booth, Milano 

Exhibition booth, Shanghai 

Contract carpet, sample Play carpet, sample 

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Individual rugs and mats printed on demand. Each rug has a different design and it‘s own color combination. 

Beside these typical 

applications there are 

a lot of other possibilities: 

• Game and play carpets for 

floor and tables 

• Seat covers 

• Car carpets and mats 

• Club rugs and mats 

• ... 

22 23

24 

ChromoJET 400 1200 

ChromoJET 400 500 (Mini) 

Lab and Sample Equipment 

Laboratory devices 

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Lab Steamer Sample Steamer Viscotester VT-04 

• 65 x 65 cm 

• electrical heating 

• 130 x 130 cm 

• electrical or steam heating 

Homogenizer and Mixer Lab Mixer 

• capacity up to 500 kg 

• drive with frequency 

converter 

• also for synthetic stock 

thickener preparation 


• air motor with variable speed 

• special mixing and homogenizing 

heads 

• easy to handle 

• transportable 

• for a wide range of viscosity 


• air motor with variable speed 

25

• Automatic dosing - no manual weighing and measuring 

• Modular system with various sizes of pumps 

• Adjustable speed of the mixer (1,000 - 6,000 rpm) to 

process a large variety of products 

• Wide range of viscosity of the individual components 

• Output pumping performance of up to 6 bar 

... thickener preparation system Color kitchen for production lines 

SupraMix Thickener Preparation 

In-line dosing, mixing and dispersing system to prepare 

synthetic stock thickener and chemicals for the carpet 

printing and textile industry. 

• On-line dosing of up to 8 chemicals 

• Full yield of thickener 

• Air free and lump free stock paste 

• Easy cleaning by integrated washing program 

• Full yield of thickener and better mixing and 

dispersion – higher yield of raw materials 

• Quick change of recipes and quantities 

• Fully automatic mode of operation 

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Semi-automatic color dissolving system and color mixing 

tanks built according to customer demand. 

• Pre-assembled tanks in various sizes 

• Automatic dosing of thickener and water using ultrasonic 

level control 

• Integrated dyestuff dissolving with „heat-up“ function 

26 27

28 

FOAM MIXING AND DOSING SYSTEM 

SupraFoam – 

Foam mixing and application system 

• to produce the multi-functional carpet 

• saves chemicals and energy 

• reduces errors and cost 

• improves quality and productivity 

Pressing roller and carpet in non-contact 

position (foam application inactive) 

SupraFoam for: 

• Stainblocker 

• Soil, water and oil repellents 

• Fluorcarbons 

• Anti static chemicals 

• Softeners 

• Flame retardants 

• Anti bacterial chemicals 

• Moth and beetle proofing agents 

• Pile stabilizers 

• Anti shedding agents crease resist and dimensions stability resins 

Pressing roller and carpet in contact 

position (foam application active) 

Technical Data DMF 50 

Foam volume 50 liter/min 

Liquid flow rate 2 liter/min 

Products FOAM MIXING AND DOSING SYSTEM 

1 - 8 chemicals + water 

Foam Generation & Application 

Foam Generator 

FOAM MIXING AND DOSING SYSTEM 

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SupraMix - Foam Generator 

Dosing and mixing various products is a permanent job in Dosing the industry. and mixing various products is a 

permanent job in the industry. 

Most of the automatic dosing and mixing units have a limited range set by the size 

and type of the dosing pump. Any change in range requires Most either of the automatic a new dosing system and or mixing 

SupraFoam – 

major modification of the pump and drive system. units have a limited range set by the size 

Foam mixing and application system 

and type of the dosing pump. Any change in 

• to produce the multi-functional carpet 

range requires either a new system or major 

• saves chemicals and energy 

• reduces errors and cost 

modification of the pump and drive system. 

• improves quality and productivity 

To keep the expenses Another low problem Zimmer is a fully has continuous devel- mode 

Water Chemicals 

of operation: Several pump scan only 

oped a special combination of a stepping motor 

operate in a ”pulse” mode or must run at a 

drive and a peristaltic pump. 

certain speed. 

With this combination it is possible to reach a 

Air 

dosing range per pump of about 1:100 within 

+/- 2% accuracy without using expensive and 

complicated flow meters. 

Dryer 

DMF 250 

250 liter/min 

5 liter/min 

Foam density 20 - 100 g/liter (higher density at lower flow rate) 

Dosing range 0.5 - 500 g/liter (1:100 with each pump) 

SupraFoam Applicator 

DMF 500 

500 liter/min 

7.5 liter/min 

Mixing head 

• Easy access and maintenance 

• Double slide-ring sealing 

• Variable speed drive 

SupraMix DMF 

• Dosing, mixing and foaming in one step 

SupraMix DMF 

• Fully computer controlled 

• Dosing, mixing and foaming 

• Easy to install, operate and maintain 

in one step 

• Up to 8 dosing pumps 

• Fully • Dynamic computer foam mixer controlled 

with variable speed 

• Easy • 20-100 to g/liter install, foam operate density and 

maintain 

• Up to 8 dosing pumps 

SupraFoam Applicator 

• Dynamic foam mixer with 

• up to 5 m in width 

variable • automatic speed width adjustment 

• 20-100 • full penetration g/liter at foam low wet density pick-up of 5-20% 

• easy to clean 

• low foam content - even distribution 

• instant on/off 

• in-line with coating or printing 

• up to 5 m in width 

• automatic width adjustment 

• full penetration at low wet pick-up of 5-20% 

• easy to clean 

• low foam content - even distribution 

• instant on/off 

• in-line with coating or printing 

29 

To k 

deve 

step 

With 

a do 

with 

expe 

usin 

tube 

add 

be e 

This 

1:10 

Tec 

Foa 

Liqu 

Foa 

Dos 

Pro 

Pres 

tact

30 

Secondary Backing - ActionBac, Jute 

Embossed Gel Foam Backing 

Carpet Back Coating Systems 

Secondary backing Systems ... 

... for ActionBac, jute or felt 

1 Direct application of a ”pre-coat” onto the back of the carpet. 

The pre-coat is needed for a good tuft lock and also determines 

the stiffness of the carpet. 

2 Latex foam with lower level of filler is applied on top of the pre-coat. 

3 Layer of secondary backing is joined together with lamination rollers. 

SBR Latex Pre-Coating Unit 

• roller over roller 

• adjustable pressure or gap 

• rubbing function 

• level control 

Latex Foam Application 

• roller over table 

• adjustable pressure or gap with digital read-out 

• rubbing function for excellent penetration 

• automatic level control of foam 

• automatic control of the application width 

Lamination unit 

• for secondary backing with pneumatic pressure control 

• Feeding unit for secondary backing with width control 

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face yarn 

primary backing 

SBR latex coat 

secondary ActionBac 

31

32 

Dryer 

• Individual temperature setting between top and bottom 

• Filters can be cleaned from outside 

• MAXON gas burners or steam heat exchanger 

• Round or slot type nozzles 

• Frequency controlled fans 

• Moisture control of exhaust air 

• Scanning pyrometer for carpet temperature measurement 

Exit and roll-up 

• Accumulator with electrical weight compensation 

• Space for shearing heads 

• Inspection area 

Stenter from KENYON or Brueckner 

• Individual width control for 

each compartment 

• Carpet floor detection 

Gel Foam Backing Systems 

5 6 

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Ammonium Acetate Gel Foam (AAG) together with a gelling agent and a vulcanization 

agent is used as secondary backing. 

Between the pre-dryer and the main vulcanization dryer there is the embossing station which gives a 

structure to the backing. 

Embossed gel foam has: 

• a very good mechanical quality 

• good water resistance 

• a no-slip effect 

1 Carpet unrolling 

2 Sewing machine 

3 U-Box 

4 Steamer 

5 Kiss coater 

6 Latex pre-coat 

7 Unrolling secondary backing 

8 Guiding secondary backing 

8 

7 4 3 2 1 

9 

10 11 

12 

An infrared gelling unit 

(gas or electrically heated) 

and a pre-dryer are used to 

create a skin on the gellified backing. 

13 14 

9 Lamination 

10 Pre-dryer 

11 Latex applicator / Gel foam 

12 Infrared zone 

13 Embossing station 

14 Dryer 

15 Cooling zone 

15 

21 20 19 18 17 

16 Edge cutting 

17 Accumulator 

18 Inspection area 

19 Accumulator 

20 Guiding frame 

21 Winder 

16 

33

Infrared Curing - 

The smart Way of PVC Backing 

• Carpet Tiles 

• Entrance Mats 

• Runners and 2 m/6 ft wide 

Broadloom Carpet 

Carpet Tile & Mat Back Coating Systems 

PVC Back Coating Line ... 

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Zimmer‘s Tile Back Coating Line (TBCL) with its infrared curing oven is the most efficient and 

revolutionary PVC coating line for carpet tiles, mats and runners available in the market. 

Infrared with the matching wavelength is a highly effective method to jellify PVC plastisol. Almost the complete 

energy is absorbed by the PVC and the curing time is much shorter in comparison to ovens with oil or gas 

heated plates. One major advantage is that IR emitters heat-up and cool-down very fast and therefore the 

process is much more flexible for short runs. 

Due to its modular concept the line can be built for runners and mats (using a single layer of PVC) or a line 

for carpet tiles using 2 layers of PVC and a glass scrim in the center. 

Latest technology and control systems makes the line reliable and productive. 

TBLC Process 

Carpet Tiles 

A first layer of PVC paste is applied 

on a Teflon conveyor belt. 

Onto this PVC layer a scrim of glass 

fiber is laminated (enforcement). 

A second layer of PVC (top layer) 

is added onto the scrim. 

34 35 

Mats 

A layer of PVC paste is applied onto 

the Teflon conveyor belt. 

Mats are manually positioned onto 

a conveyor belt which gently 

positions the mats onto the PVC 

layer. 

The whole construction is moving 

into the infrared curing oven 

followed by a cooling zone and a 

roll-up unit. 

Runners 

A layer of PVC paste is applied 

onto the Teflon conveyor belt. 

The carpet is put onto the 

layer of PVC and merged 

together by a nip roller.

Carpet Tile Manufacturing 

Starting from tufted carpets 

Fibreglass reinforced intertial backing system 

Starting from fusion bonded carpets 

Primary Backing 

PVC layer No.2 

Fibreglass layer (scrim) 


Yarn Fusion Bonded 

into polymer layer 

Primary Backing 


Fibreglass layer (scrim) 

Polymer layer No.1 

• Tufting of a carpet 

• Pre-coating the tufted carpet 

with a special emulsion of EVA 

or NBR pre-coat 

• Back coating on a tile back 

coating line 

• Tile punching 

• Bonding of a carpet 

• Back-coating on TBCL 

• Tile punching 

1 5 3 

10 

36 

2 

3 

4 

6 

7 

8 

9 

Back Coating with PVC 

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A PVC plastisol is a plastic, consisting of a polymer resin in homogeneous solution in a plasticizer oil. It can be 

compared with a solution of salt in water. The plastisol paste does not contain any water! 

In “wet” state it appears itself as a paste. It can be spread out easily, and scraped into a layer on the backside 

of the carpet. 

In “dry” state it appears a firm plastic film or layer, tightly bonded to the carpet. It gives the carpet a 

mechanical strength, a dimensional stability, a flat-lying capacity and a certain weight. 

Line layout and components 

1 Carpet unroll unit with synchronized drive and edge guiding 

2 Sewing machine 

3 Pull roller with servo drive for carpet for a tension free „lay-on“ of the carpet onto the PVC layer 

4 Scrim unroll unit with pneumatic lifting and manual side adjustment 

5 Relaxing iInfrared zone 

6 Applicator for PVC layer 1 

7 Nip roller for scrim 

8 Applicator for PVC layer 2 

9 Nip roller for carpet with precision gap adjustment 

10 Infrared curing oven with Pyrometers for temperature control 

11 Cooling panels for contact cooling 

12 Conveyor belt assembly with master drive, belt tensioning and belt guiding unit 

13 Winder for pile out winding - max. diameter 1200 mm 

11 

12 

13 

37

38 

Infrared Technology 

Radiation power (relative units) 

250 

200 

150 

100 

50 

0 

0 

1 2 3 4 5 

Wavelength (μm) 

Radiation oven 

Jellification is the physical process of enhancing the 

complete solution of resin molecules absorbed within 

the oil molecules into a solid jel-like state under 

influence of heat. The result is an irreversibly solidified 

plastic material. 

The process of jellification requires the addition of heat 

energy for a certain period of time. 

Infrared curing - the smart way: 

4 times more energy efficient than the classical 

hot-air oven, resulting in a lower energy bill. 

IR waves are heating up the medium and not 

the air and housing of the oven. 

A shorter line is sufficient at a given production 

capacity. 

No investment in boiler, thermal oil and piping. 

No waiting time during start-up and shut-down 

- the line is ready within minutes rather then hours. 

It allows unlimited stops and restarts without 

affecting the quality of jellification. 

Pyrometers, Thyristors and servo drives in 

combination with latest PLC technology are used 

to control temperature speed and the process. 

PVC Basics 

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PVC is an environmentally friendly material. PVC production and processing require comparatively few fossil 

fuels and resources (57% of PVC consists of native rock salt available in virtually unlimited amounts, oil comprises the 

other 43%). PVC construction products are light, low-maintenance, long-lasting, recyclable and are thus environmentally 

friendly. 

PVC is a high-quality, versatile material .Products made of PVC are resistant to weather, oil and UV radiation. 

Finished products are flexible or resistant to mechanical shock and can be pigmented in any colour. The material has 

absolutely no adverse effects on health. The versatility of PVC allows it to be used for a wide range of products. 

PVC is a crucial material. PVC constitutes some 30% of all plastics processed world wide. It is thus among the 

essential materials for industry and trade. The main PVC consumers by industry: construction, packaging, electronics, 

cables, automotive, transport, furniture, office and others. PVC sales are increasing world wide. 

PVC is a safe material. PVC is less flammable than most other materials and thus is a factor in fire prevention. 

PVC has no adverse effects on health. Today, PVC production and processing is not a health hazard to workers 

or consumers, according to the German Federal Ministry of Environment. PVC is used for medical equipment and 

engineering, food packaging and transport piping for drinking water. PVC is a crucial factor in modern medicine (blood 

pumps, blood bags, intravenous tubes, etc. consist of PVC). PVC is the only material authorized for use as blood bags. 

PVC paste production generally comprises the following stages: 

• Dosing of the individual components 

• Stirring, dispersing/homogenizing PVC and plasticizers 

• De-aerating and screening (filtering). 

Depending on the available equipment, some of these stages may be performed simultaneously. For example, pastes 

can be readily de-aerated during the homogenization stage, or pastes can be screened on in-line filters during pumping. 

PVC Back Coating line for mats, runners and carpet tiles: 

Technical Data: 

Carpet and scrim width max 2100 mm 

Production speed 2 - 6 m/min. with 12 m woven 

Mechanical speed range 0.5 - 10 m/min. 

Application system Doctor knives 

Type of backing PVC paste (plastisol) 

Curing sytem IR - Elements for a temperature 

range of 50° - 220° C (belt temp.) 

Cooling system Water chilled plates 

Electrical connected load 450 kW 

Power consumption per kg PVC ~ 0.2 kWh/kg of PVC compound

chromo 


Zimmer Maschinenbau GmbH 

DIGITAL PRINTING SYSTEMS 

Eibergstrasse 2-8 

6330 Kufstein | AUSTRIA 

Tel.: +43 (5372) 648 93 - 0 

Fax: +43 (5372) 648 93 - 851 

chromojet@zimmer-austria.com 

www.zimmer-austria.com 

MACHINERY FOR THE CARPET INDUSTRY 

• ChromoJET - Digital Jet Printing Systems 

• Rotary Screen Printing Machines 

• Finishing and Wet Processing Machines 

• Color and Thickener Preparation 

• Foam Mixers and Applicators 

• Backing Lines for Carpet 

• PVC back coating lines with IR technology 

• Lab Machines 

...from the leading company for digital 

carpet & textile printing systems 

Your local partner 

2012 skugler | ChromoJET Carpet Book (EN) V1

ChromoJET Carpet Book 2012 - J. Zimmer Maschinenbau GmbH

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