Designers and Manufacturers of Custom

Automated Machinery and Equipment Since 1985

A History of Our Automatic Rug Packaging Machines

Our Custom Rug Packaging Systems provide a cost effective approach to the packaging of rugs, rolled face-in or face-out and wrapped with a variety of packaging materials. The product can be rolled and banded with a clear polyethylene material, or clear stretch film, leaving the ends of the rug exposed. This approach to rug packaging, rolled face-out, reveals the rug's true color, texture, and pattern to the consumer while protecting the rug and label for retail display. The product may also be banded with clear adhesive back tape or non-adhesive stretch tape.

A narrow version of our rug packaging systems, it can package rugs up to 24" wide and 120" long. This can be done with the aid of a layout table, accumulator "J" box, or feed conveyor to deliver the rugs to the machine.

Another version of our rug packaging systems is capable of packaging rugs in widths from 24" to 96". It packages the rug with two or three clear tape bands then pushes it into an open ended bag flat-rolled, which is closed using a pneumatic wire clip system on the entrance end of the bag, and a flat heat seal and cut on the other end. The middle photo shows a close-up of our custom designed adhesive tape dispensers. Contact to the tape head is maintained by a vacuum generator. The tape is cut to length by a rotating knife assembly.

Customers have added our bagging fixture to their existing rug machines.  This fixture allows a poly bag to be slipped on the end of it.  As the rolled rug exits the rug machine it goes through the bagging fixture into the poly bag for shipping.

Rug sizes are operator selected via an operator interface panel or optional touch screen controls. Systems can be configured to package a range of rug sizes from narrow runners to larger area rugs. There were 128 pre-programmed rug sizes depending on our customer's specifications.

Designs Incorporated : Custom automatic label feeder designed to insert your label into the package Remote PLC monitoring, program editing, data retrieval - accomplished from our office via an optional panel installed modem. Festo pneumatic components, Allen-Bradley operators, Siemens PLC, TOSS heat seal system, 80/20 extruded aluminum sub-assemblies, Rittal enclosure, Acme transformers, Siemens inverters, Sew-Eurodrive inverter duty gearmotors and Meech static-eliminators.

This wide system was custom designed to package rugs with dimensions in excess of 72" wide and 120" long. It is equipped with a "layout-table" for visually inspecting the rug prior to packaging.

This system (left) shows a mobile layout table for soft-back rugs.

Our newest machine (right) for soft-back rugs and mats included an Automatic Mandrel Lubricator for Latex-back rugs.  This system rolls rugs 24"-30" wide 2 at a time or one rug up to 60" wide.  Allows 1 or 2 rolls of film and independently operated automatic label dispensers. 

The above systems demonstrates a stainless steel accumulator " J " box feed for hard-back rugs.

A later machine design includes a pulsed AC/DC static eliminator film feed dispenser, tape heads, packages rug sizes from 22" to 96" wide and up to 120" long, an operator interface panel with full machine diagnostics locating any faults that may occur on the machine automatically, programmable up to 128 rug sizes, a resetable counter with contacts for plant data acquisition, and a feed conveyor to deliver rugs flat folded from a confection line.

New technology includes an Allen-Bradley  touch screen, PLC, and drives.  This system will hold as many rug sizes as needed.  We program the touch screen to allow the customer to edit existing or create new rug recipes.  This system also controls the length of film that is inside the rolled rug and the number of layers of film that are on the outside of the rolled rug.

A 2005 design included an optional Automatic Rug Feed System which allows the operator to insert the rug up to the rug stop.  The Rug Feed System then automatically inserts the rug into the roll up system.

A 2006 design incorporated a staging conveyor, rug unfolding conveyor, rug inverter, and rug feed system.   This system accepts folded rugs up-line, automatically unfolds the rug, inverts the rug (optional equipment) to be packaged face-in or face-out, and feeds it into the rug machine to be rolled up for packaging.   The rug packaging system is supplied with 2-Automatic label dispensers, 3-bands of tape 10.5" wide, and the film (belly band dispenser) is sealed with a Ropex Heat Seal Controller.

To see our variety options that customers have requested on the Rug Machine, click on Rug Packaging on the side menu to the left.

If this page has helped you determine your needs for our custom equipment give us a call or you can send us an email for a quote!