The range of Gemata products is expanding with a new machine with working width of 3400 and 3800 mm., designed by the company’s internal technical department, to finish any type of whole hides.
GREENSTAR is the new rollercoating machine that allows to finish any type of whole and half cowhides in reverse mode: the sectors in which it is most used are automotive, upholstery, clothing and footwear.
It joins the Megastar model, particularly appreciated by the automotive market for its coating precision and the effectiveness of covering, even on leathers with lows, guaranteed by big diameter rubberized counterpart roller.
Greenstar is the summary of Gemata’s thirty years of experience in the field. This new model guarantees coverage and extreme precision in all types of application, even on very defective leathers and with high thickness variations. With Greenstar it is possible to apply the entire range of chemicals for finishing: resins for impregnation, oils and waxes, fillers and pre-bases, bases, coatings and water-based fixatives.
The machine consists of three structural elements: Spreader for stretching and insertion in the work area of the hides, machine body for spreading the chemical product on the surface of the leather and the Puller for spreading and conveying the hides to the drying tunnel.
Greenstar combines and condenses the advantages of previous models. The stiffness and precision of a large diameter counterpart roller is combined with the advantage of conveyor belt at constant pull. This engineering solution makes it possible to detach the hides without any type of detaching rollers or other mechanical device and consequently eliminates any contamination of the flesh side of the hides.
The improvement of the hides detachment process was possible thanks to the innovative geometry of the machine, which is composed of a motorized rubber belt, a large diameter chromed counter roller and a small diameter return roller conveyor, that favours the detachment at exit of the hides from the machine and its deposit on subsequent transport.
Specifically, the special rubber conveyor belt can be positioned at 4 different angles at the exit from the coating point. This:
- allows the processing of all types of leather,
- ensures greater and better application of the chemical product,
- increases the spreading precision,
- increases the quality of the
Moreover, a system that keeps the tension of the belt constant in all its different positions, extending its duration and reliability over the time, preventing the carpet from deforming or losing its shape for the variation of the tension due to the change of angle, as it happens with the traditional machines with the rubberized belt, has also been patented.
GREENSTAR features a new movement of the doctor blades: this technology, with horizontal and calibrated movement, keeps the engraved cylinder capacity constant throughout its life cycle, ensuring uniform coating and automatically compensating the wear and tear of the doctor blade itself.
The chromium-plated steel counter-roller is constantly kept clean by a scraper blade which prevents dirt residues from adhering to the chromed roller and to the inner face of the rubber belt, which would spoil the quality of the coating. The combination of a large diameter counter-roller and a thick rubber belt guarantees an optimal coverage of the surfaces and a precision that had never before been achieved by any machine with a rubberized conveyor belt.
As far as the ergonomic aspects, the 3400 model features a more intuitive and simple blade adjustment system: the introduction conveyor belts are slightly inclined and ease the operator’s work.
The machine is equipped with Long Life cylinders, available in several dozen incisions and capacities: these improve and optimize the unloading of the chemical product from the engraving, make applications much more uniform, shorten the cleaning operations at the end of processing (about 15 minutes to wash the machine) and speed-up colour change time.
Unique and innovative feature of the Greenstar machine is the data storage and management system of the engraved cylinders. The machine is equipped with a data reading and writing system directly in the engraved cylinder by means of an RFID tag, inserted integrally into the cylinder.
With this technology, can be written and read information that uniquely identifies the engraved cylinder, the type of engraving and the production date. The actual working hours of the cylinder are automatically stored on the relevant machines in which it is mounted. It is possible to memorize the duration of the cylinder in advance for scheduled maintenance, linked to the estimate of wear.
Like all Gemata products, GREENSTAR is equipped with control systems that allow remote identification of problems and remote assistance.
Gemata, with this new model 3400 and 3800 for whole hides, completes the new series of ecological and sustainable machines, inaugurated in 2020 when the GREENFINISH and GREENSTARs 1800 and 2400 lines were launched, ensuring its customers an offer of machinery always more complete to meet their needs.
