HOW IT WORKS
Robotic Cutting Center – one of the main parts of ICOL Smart Footwear Factory – is the hardware and software system, consisting of:
– technological cells;
– service cells;
– transportation system.
TECHNOLOGICAL CELLS
DEFECT DETECTION AND APPLICATION OF TRANSPORTATION FILM
The starting stage, where a skin is scanned to define edges and to detect flaws. Transportation film is applied right after.
MARKING
The robot marks a skin with dash lines (with the printer). Some other indications, like commodity, size, etc. can also be marked.
PRINTING
Full-colour printer allows application of ornaments and drawings to a skin. Parts of several shoe models can be placed to the same skin.
LASER STAMPING AND ENGRAVING
At the laser stamping and engraving cell engraving is applied and/or perforation is burned on the surface of the skin in processing. The system allows placing parts of several shoe models on the same skin.
EDGE SKIVING
Edge skiving is the reduction of skin thickness at the edges. It is necessary for proper sewing or gluing of parts. The robot, manipulating the grinding mill, processes the edges of parts laid out on a skin – not cutting the edges through, saving the skin’s integrity for further processing and transportation.
Traditionally, woven or nonwoven fabrics, leather, or pelage are used as lining materials. They are sewn on or glued to the upper components' insides. ICOL Group has developed and registered a brand new lining installation technology named ICOL Polycomposite Layer Sputtering (IPLS).
REINFORCING
Application of composite compounds that stiff, polymerize and provide the desired thermal insulation, air circulation, waterproof, absorption and comfort properties to footwear. The spraying injector is the patented technology of ICOL. This type of lining is far more resistant to friction, bending and stretching than the traditional materials. ICOL Polycomposite Layer Sputtering (IPLS) technology allows using up to 6 different compounds within one technological operation – including multi-layer application to the same part and variable layer thickness.
CUTTING AND PICKING
Cutting of parts in accordance with the digital scheme of cutting. The technological solution is patented under IICC (ICOL Intelligent Screening & Cutting) name.
SERVICE CELLS
INVERTATOR
While being processed, skins need to be rotated front to back and vice versa at certain moments. We’ve developed the special invertator for such rotations. AGV mobile robot moves a leather roll to the invertator, and it rotates a roll to its proper side. A roll goes for further processing afterwards.
ROLL-IN CELL
The cell is designed to roll-in a transportation film to a pair of special pulleys.
FILM REMOVAL CELL
The cell is designed to remove a transportation film from a pair of special pulleys.
TRANSPORTATION SYSTEM
AGV MOBILE ROBOTS
AGV mobile robots conduct all movements between the technological and service cells.
INNOVATIONS IN EVERY PRODUCT
ICOL Smart Factories use a variety of unique proprietary technologies:
– robotized cutting centers
– automatic sewing machines
– carousel racks
– lining layer sputtering
– tensioning claw members
– robotized adhesive lasting machines
– diaphragm presses
– claws
– technological equipment
– software
Our proprietary AGV mobile robots handle all the inbound logistics tied on ICOL Group.
Each ICOL Group product is developing within a single ecosystem.
THE DEEPEST DELVE INTO THE BUSINESS DOMAIN
The ICOL Smart Factory is a brilliant result of the painstaking teamwork of roboteers, chemists, coders and scientists, coupled with best-in-class technologists, designers and marketers working with footwear brands and manufacturers.
For each product development cycle, a mandatory step starts right after R&D. We always build a fully functional Proof of Concept, deliver it to one of the biggest European footwear factories and kickstart the production. Then we test the product thoroughly and comprehensively in the real context.
EFFECTIVE START
The ICOL company is heavily involved in the digital transformation of every single company from the very start. We’re assisting our clients even after the successful launch.
1. Our experts conduct audits of the transformation planning and help find the best fitting scenarios.
2. Depending on the need, we get leasing companies involved in funding the projects.
3. We’re in touch 24/7 during the start-up stage and after.
4. You can get even more advantages becoming a part of the ICOL Ecosystem. Send us a line to find out more about the program.