The finishing of edges on blankets is essential to both their aesthetics and longevity as textiles. Selecting a sewing machine that is optimally suited to producing different types of blankets (fleece, quilts, wool throws or commercial fabrics) directly affects the efficiency of the production process, the quality of the stitches, and the financial sustainability of a manufacturing operation.
A huge variety of sewing machines are available, all with their own capabilities; therefore, it is important to know exactly what materials will be used, how much volume will be produced and technical specifications for appropriate machine selection, to determine what machine will be best for the job. This article lists some essential factors that should be considered when looking for a sewing machine that is appropriate for blanket edging in a manufacturing environment.
Before choosing equipment for edging your blankets, it is important to understand why we add edge finishes. The primary reason is not just to add decorative elements but to prevent the fabric from fraying, provide a finished and uniform appearance to the blanket and to give the blanket the ability to endure being laundered repeatedly. A well-finished edge on a blanket contributes positively to the durability and perceived value of the blanket. Therefore, there is a significant link between a business's customer satisfaction and the finished edge of their blankets, and ultimately their brand reputation.
Depending on the type of blanket to be edged, there are different techniques of edging a blanket; e.g., fleece blankets are often finished with an overlock stitch for flexibility and speed; wool blankets typically require a more robust stitching mechanism to accommodate the thickness of wool; decorated and bound edges are frequently utilized for quilted blankets to achieve a high-end visual appeal. As there are many different types of blankets requiring differing edging techniques, fabric type and desired appearance should be considered when choosing a sewing machine for edging any given blanket.
Choosing the right type of machine is the absolute key to achieving quality when edging blankets. Each type of machine is designed with a specific type of sewing mechanism, certain strengths and weaknesses, as well as limitations for use. This is a summary of the most commonly used sewing machines for finishing blanket edges (and their features and uses):
Overlock (Serger) Sewing Machines: Overlock sewing machines are used most in high-volume production for sewing edges and trimming at the same time. They create a clean edge as well as provide a secure edge in one step, allowing for more efficient production. They are also used very successfully to manufacture products with stretch, such as fleece, because they allow for the ability of the product to stretch in use.
Coverstitch Sewing Machines: Coverstitch machines are used for strength, durability, and finished appearance. They provide a clean, double-sided stitch, making them appropriate to use on the edge of a product when both sides of the edge will be exposed to view. Coverstitch machines provide a very strong and flexible seam and provide a decorative edge for the items being finished with a coverstitch.
Lockstitch Machines with Binding Attachments: Lockstitch sewing machines that have a binding attachment use binding (tape) to sew around the edge of the blanket. The raw edges are covered with the binding to provide a finished edge that has a more structured look than an unfinished edge. This approach to edge binding on blankets is a way to reinforce and enhance the finished product, especially if the blankets are heavy/thick or have multiple layers.
Zig-Zag Sewing Machines: Zig-zag sewing machines are good for a few products. Zig-zag sewing machines are flexible and lower-cost to manufacture products in low volume. Machines with adjustable width and multiple patterns are available and are used for securing fabrics together as well as providing decoration on their edges. Zigzag sewing machines are not as fast as the more specialized machines found in industrial applications; however, they can commonly be used in many different sewing applications where custom designs may be needed, or low production runs would be performed.
When selecting a machine, you must consider a number of factors that will affect the machine's ability to produce quality goods in an efficient manner over time.
The type and weight of the fabric you will use, each type of fabric has specific machine requirements. Lightweight fabrics (fleece and cotton) can be sewn on overlock machines, while medium-weight fabrics (polyester blend) need a more versatile industrial machine. Heavyweight fabrics (wool and layered quilts) require high-powered lock-stitch sewing machines with sufficient needle penetration to perform effectively.
To ensure you do not experience missed stitches, thread breaks or uneven seams, you need to have adequate motor power on the machine used to sew fabrics in your range to deliver a consistent level of quality and protect the machine from excessive wear over time.
Production volume will influence how much automation and machine performance is expected by the manufacturer. Manufacturers producing small-volume products can use either semi-industrial sewing machines (zigzag) or medium production products can be produced on standard industrial overlock machines and provide the best overall solution for price and efficiency.
Manufacturers producing large volume products typically use either automated or specialty edging machines (sewing machines) with many more features, such as automatic thread trimming, edge guiding and programmable controls, to maximize efficiency, reduce workforce dependency and provide consistent production output.
A good quality stitch must be used in order to create durable and good-looking products. Different types of applications require different configurations of sewing machines, like 3-thread, 4-thread, and 5-thread stitching configurations. The degree to which a stitch is tightly or loosely sewn affects the strength of the seam, as well as its appearance.
Control of the tension on a sewing machine is also important for producing high-quality stitches. If the tension is incorrect, the stitches can be uneven, which could result in the seam damaging the fabric or vice versa. Stitching that is high quality considerably reduces rework and thus increases product quality consistency, both of which are essential to maintaining a company’s good name.
Many industrial sewing machines are capable of sewing faster than 5,000 stitches per minute. While speed is key to fulfilling high production demands, it should also always be coupled with accuracy.
Servo motors use much less energy than other types of motors, produce little to no noise, and have automatic lubrication systems that require very little maintenance and thus have a longer life than other types of motors. Stability of operation with minimal vibration enables consistent stitch quality, even during high-speed operation.
Easy-to-use machines are very beneficial in helping increase production by reducing training time and operator error. Machines that have user-friendly controls and interfaces allow operators to be much more productive.
Maintenance is also just as critical as ease of use. Machines that are easy to thread, have easily accessible parts, and are readily available for replacement parts will be less likely to experience production downtimes. Having reliable technical support will be critical, especially when a company manufactures in high volumes, as any downtime will result in lost revenue.
The proper accessories for a sewing machine for blankets will make it much more versatile and increase production efficiency. Examples of accessories that increase sewing machine functionality and production efficiency include binding folders, edge guides, and tape feeders, all of which allow for a more accurate and consistent edge on the fabric being sewn.
Choosing the right sewing machine for a company is only half the equation. Finding a reputable and reliable manufacturer who can provide more than just sewing machines is also important for the successful long-term operation of a company. A good quality manufacturer will provide not only the equipment but also technical knowledge, personalized recommendations, and after-the-fact support.
A reliable manufacturer provides support through all aspects of operations, such as installation, training, preventative and ongoing maintenance, and supply of replacement parts. Depending on volume, interruption to production due to a machine malfunction can cost a high-volume manufacturer a large sum of money.
As a provider of industrial sewing automation equipment, TPEP specializes in providing high-performance, application-based solutions that provide productivity, durability, and accuracy to manufacturers that require reliable, consistent quality output and increased productivity in demanding materials in continuous production environments.
The decision of which sewing machine to purchase to edge blankets is an important decision for any textile manufacturer. The machine should be the most compatible with the type of fabric used to manufacture the blankets, volume of production, quality of production, as well as efficiency and long-term dependability.
No matter whether you choose to utilize an overlock sewing machine to sew the edges quickly, a coverstitch machine to create a more finished edge, or a lockstitch machine with a binding to create a more structured edge, the goal is to ensure that the capabilities of each machine will sufficiently meet your individual needs.
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