ZARIF 2025 Sewing Technology

Introducing the world's first ideal ZARIF 2023 double thread chain stitch technology with rotary looper.

For the first time in human history, the revolutionary ideal ZARIF 2023 double thread chain stitch technology with a rotary looper has transformed the process of straight stitch sewing.

We achieved this global breakthrough after about 26 years of perfecting our original ZARIF sewing technology, in which a rotary looper was used for the first time to form a double thread chain stitch type 401. This innovation was granted US Patent No. 6095069 in 2000.

The ZARIF technology, using a double thread chain stitch with a rotary looper, enabled us for the first time to create a new double thread chain stitch type 401, where the loops of the top and bottom threads are rotated 180 degrees. As a result, the underside of the chain stitch is very similar to the lockstitch type 301, which uses a thick bottom thread.

Thanks to our new ideal ZARIF 2023 double thread chain stitch technology, it is now possible to replace lockstitch type 301 with the new double thread chain stitch type 401 on a large scale, eliminating the need for frequent bobbin changes in hook systems.

The world's first ideal ZARIF 2023 double thread chain stitch technology with rotary looper.

We are thrilled to announce the 2023 invention of the ideal ZARIF double thread chain stitch technology, specifically designed for straight stitch sewing. Building upon our pioneering 1994 technology, which first introduced the rotary looper to create double thread chain stitches (type 401) and was granted US Patent No. 6095069 in 2000 (https://patents.google.com/patent/US6095069A), we have now perfected this method.

Our prototype innovative ZARIF double thread chain stitch sewing machine with rotary looper, based on our ideal ZARIF 2023 double thread chain stitch technology with rotary looper, sewing with the new double thread chain stitch type 401.

Early Prototypes and Initial Innovations.

In 1997, to advance the research of our 1994 technology, we developed the world’s first prototype of a ZARIF double thread chain stitch sewing machine with a rotary looper. This was achieved by reconstructing the 1022-class industrial lockstitch machine from the Belarusian company Orsha.

By utilizing the rotary looper on this prototype, we successfully created a new double thread chain stitch (Type 401), where the top and bottom thread loops rotate 180 degrees. This results in a chainstitch seam with an underside that appears more like a thick, continuous thread than a chain of loops.

Overcoming Challenges and Achieving Perfection in 2023.

During experimentation with the prototype, we identified limitations in the original technology. From 1997 onwards, we invested in continuous R&D, incorporating advanced know-how to address these issues. In 2023, our efforts culminated in the development of the ideal double thread chain stitch technology for straight stitch sewing, which has now revolutionized the industry.

Key Innovations of the ZARIF 2023 Double Thread Chain Stitch Technology.

1. Revolutionary Rotary Looper:

The first technology globally to use a rotary looper that makes two full revolutions per needle cycle, forming a double thread chain stitch with unprecedented precision.

2. Advanced Chain Stitch Structure:

A new double thread chain stitch (type 401) with loops rotated by 180 degrees, as a result, the underside of the chain stitch is very similar to the lockstitch type 301, which uses a thick bottom thread.

3. Needle Collision Prevention:

Eliminates needle collisions with the looper and minimizes contact with the needle plate, preventing breakage and prolonging needle life.

4. Enhanced Stitch Reliability:

High stitch reliability is achieved without the need for needle guards, streamlining the mechanical design of the sewing machine.

5. Optimized Needle Design:

Incorporates a standard single-groove needle, which offers greater resistance to bending, improving overall durability.

6. Innovative Twin-Disc Cam Thread Take-Ups:

The use of rotary twin-disc cam mechanisms allows precise control of both the top and bottom threads, ensuring smooth tightening of the top and bottom threads.

7. Error-Free Stitching:

The new technology eliminates skipped stitches and thread breakages, provided the threads are knot-free, enhancing both productivity and seam quality.

8. Expanded Material Compatibility:

Capable of sewing materials up to 8mm thick with a short needle bar stroke of 32mm, this technology accommodates a wider range of materials.

9. Versatile Adjustment-Free Operation:

The machine can seamlessly sew materials of varying thickness, density and elasticity without any adjustments by simply setting the normal thread tension for all threads.

10. Increased Needle-to-Looper Gap:

The maximum allowable gap between the needle and the tip of the looper has been increased to 0.5 mm, allowing needle sizes from needle Nm. 130 to needle Nm. 60 without having to adjust the looper in relation to the needle.

11. Reducing the Length of the Double Thread Chain Stitch to 0.5 mm:

For the first time in the world, it is now possible to reduce the length of a double thread chain stitch to 0.5 mm, making it possible to tack the end of a chainstitch seam more securely against unravelling due to stitch condensation at a stitch length of 0.5 mm.

12. Our Know-How Capabilities:

For the first time in the world, our know-how makes it possible to adjust the degree of tightening of the top thread loop in a stitch, without changing the normal thread tension of the top thread: if the top thread loop is tightened strongly in the stitch, a normal stitch is obtained, which is used to join materials tightly; if the top thread loop is tightened loosely in stitch, an elastic stitch is obtained, which is used to obtain a smoother seam on light materials and an elastic seam on elastic materials.

13. Simplified Mechanical Design:

For the first time in the world, a prototype of the ZARIF double thread chain stitch sewing machine was made, which had the simplest mechanical design in the world due to: a rotary looper; two rotary twin-disc cam thread take-ups; the simplest crank-slide needle mechanism; the absence of needle guards.

14. Reliable Long-Term Performance:

The machine maintains high reliability in forming double thread chain stitches over long periods of operation, ensuring consistent stitching quality.

History of ZARIF double thread chain stitch technology with rotary looper.

In 1994 we came up with the idea of creating a double thread chain stitch type 401 using a rotary looper. We applied for a patent for this new ZARIF double thread chain stitch technology and in 2000 US Patent No. 6095069 was granted (see https://patents.google.com/patent/US6095069A).

Before our invention, the rotary looper was used in the single thread chain stitch technology, type 101, on single thread chain stitch sewing machines and button machines. History records that the rotary looper was invented in 1857 by the American inventor James Edward Allen Gibbs for his single thread chain stitch sewing machine, based on the single thread chain stitch technology, type 101, where the rotary looper makes one revolution per needle cycle (see U.S. Patent No. 17427 https://patents.google.com/patent/US17427A ).

A rotary looper is a unique and the only tool in sewing technology that can rotate loops of thread around its body, by turning them 180 degrees with its tail.

As is known, the rotary looper is made in one piece and has three zones: the head zone with a front tip to catch the thread and a rear tip to release the thread loop from the body of the looper; the tail zone for rotating the thread loop through 180 degrees; and the shaft zone for attaching the looper to the machine.

The use of the rotary looper in the ZARIF double thread chain stitch technology has enabled us to create the world's first new double thread chain stitch type 401, in which the loops of the top and bottom threads are rotated by 180 degrees.

The ZARIF double thread chain stitch technology forms a double thread chain stitch type 401, where the rotary looper makes two revolutions per needle cycle.

VIDEO: SINGER single thread chain stitch sewing machine, using a rotary looper, manufactured in the 19th century.

New double thread chain stitch type 401 in which the loops of the top and bottom threads are rotated 180 degrees.

ZARIF double thread chain stitch technology with rotary looper, invented by us in 1994 (see US Patent No. 6095069).

In the ZARIF double thread chain stitch technology, the top thread is fed to the looper by a needle with a vertical reciprocating motion, as is usually done.

To feed the bottom thread to the looper, a bottom thread pusher is used, which makes oscillating movements in the horizontal plane.

Since the rotary looper can loop thread around its body in the form of a loop, once the bottom thread, fed by the bottom thread pusher, is caught by the front tip of the looper, the top thread loop leaves the looper body and, as it tightens, forms loop from the bottom thread which the looper can now wrap around its body.

As the rotary looper only uses a small length of the thread loops and the thread loops are released from the rear tip of the looper, the thread loops can be tightened very smoothly.

The needle does not collide with the looper body as it moves downwards, and, the top and bottom threads are smoothly tightened with the two rotary twin-disc cam thread take-ups.

Where: 1- top thread; 2- needle; 3- material; 4- needle plate; 5- bottom thread; 6- bottom thread guide; 7- rotary looper; 8- pusher of the bottom thread.

Attention: Our revolutionary ideal ZARIF double thread chain stitch technology from 2023 with rotary looper will be published after the Patent for Inventions is issued for it.

Therefore, the ZARIF double thread chain stitch technology uses a two rotary twin-disc cam thread take-ups to feed and tighten both the top and bottom threads, with each thread being controlled separately.

And the needle will never collide with the looper body on its way down, even if it is deflected.

Revolutionary ideal ZARIF 2023 double thread chain stitch technology with rotary looper has made the following technological revolutions in the field of sewing.

For the first time in the world, a rotary looper is used to form a double thread chain stitch.

For the first time in the world, the length of a double thread chain stitch can be reduced to 0.5 mm.

For the first time in the world, thanks to the use of a rotary looper, a new double thread chain stitch type 401 was obtained, where the loops of the top and bottom threads are rotated 180 degrees.

For the first time in the world, a needle with one long groove is used to form a double thread chain stitch.

For the first time in the world, the collision of the needle (1) with the body of the looper (2) is completely excluded when the needle moves down in the formation of a double thread chain stitch.

For the first time in the world, high reliability of stitch formation without the use of left and right needle guards.

For the first time in the world, the simplest needle mechanism (crank pin-crank mechanism) is used to form a double thread chain stitch.

For the first time in the world, the top and bottom threads are smoothly shortened and tightened using two rotary twin-disc cam thread take-ups.

For the first time in the world, sewing materials with a thickness of 8 mm with a small needle bar stroke of 32 mm.

For the first time in the world, the maximum allowable gap (a) between the looper point and the needle has been increased to 0.5 mm, and the height (b) of the needle lifting from the lower position is constant for all stitched materials.

History of the prototype development of the ZARIF sewing machine based on ZARIF double thread chain stitch technology with a rotary looper.

In 1997, we decided to build a prototype sewing machine to test our new ZARIF double thread chain stitch technology with a rotary looper, which we had invented in 1994.

Industrial lockstitch sewing machine 1022 class of the «Orsha» company (Belarus), from which the thread take-up mechanism, the hook and the thread winding mechanism on the bobbin have been removed.

We chose a class 1022 lockstitch industrial sewing machine from the Belarusian company «Orsha» because it was widely used in Uzbekistan at the time and was relatively affordable. The machine had a needle bar stroke of 32mm and was designed to sew fabrics of medium thickness.

After a thorough review of the machine's design, we successfully integrated our new ZARIF sewing technology into the machine, retaining only the mechanisms of the material feed, presser foot and needle. Thus, in 1997, we produced the world's first prototype of the ZARIF double thread chain stitch sewing machine with rotary looper.

Trials on a prototype ZARIF sewing machine allowed us to identify some of the shortcomings of our new ZARIF double thread chain stitch technology developed in 1994. We then set ourselves the goal of improving our new ZARIF sewing technology until it became the world's first ideal technology for straight stitch sewing.

We have reached our goal in 2023. For about 26 years we have been researching and developing, successfully implementing many innovations and testing them on a prototype ZARIF sewing machine. And so, step by step, we have come closer to our world's first ideal ZARIF double thread chain stitch technology with rotary looper for straight stitch sewing.

Stitch type, working units and technical specifications of the prototype ZARIF sewing machine based on the ideal ZARIF 2023 double thread chain stitch technology with rotary looper.

Prototype ZARIF 2023 double thread chain stitch sewing machine, based on ideal ZARIF 2023 double thread chain stitch technology with rotary looper.

Industrial lockstitch sewing machine class 1022 of the company «Orsha» (Belarus), on the basis of which the prototype of the revolutionary ZARIF 2023 double thread chain stitch sewing machine was made.

TYPE STITCH: NEW DOUBLE THREAD CHAIN STITCH TYPE 401.

The new double thread chain stitch type 401, in which the top and bottom thread loops are rotated 180 degrees, is obtained by using a rotary looper.

For the first time, without adjusting the normal tension of the threads, the tightness of the top thread loop in the stitch can be adjusted with know-how: if the top thread loop in the stitch is tightened strongly, a normal stitch is obtained; if the top thread loop in the stitch is loosely tightened, an elastic stitch is obtained.

A normal new double thread chain stitch type 401 in which the loop of the top thread is strongly tightened, which allows a tight join of the materials, reduces the thickness of the stitch seam and increases the wear resistance of the stitch seam.

Elastic new double thread chain stitch type 401, in which the loop of the top thread is loosely tightened, giving a smooth seam on light materials and an elastic seam on elastic materials.

WORKING UNITS:

Rotary looper.

Needle with one long groove.

Pusher of the bottom thread.

Take-up of the top thread.

Take-up of the bottom thread.

Bottom feed.

TECHNICAL SPECIFICATIONS:

Application: For all materials.

Platform type: Flat.

The maximum speed of sewing: 5000 s.p.m.

Length of a stitch: From 5 mm to 0,5 mm.

Needle bar stroke: 32 mm.

Lift of the presser foot: 9 mm.

Maximum thickness of sewing material: 8 mm.

Type and number of needles: DPx5 or DPx17, from Nm.60/8 to Nm.130/21.

Type feed material: Bottom feed.

The world's first prototype of the ZARIF 2023 double thread chain stitch sewing machine has an extremely simple mechanical design and forms stitches with high reliability and durability.

Kinematic diagram of the prototype ZARIF 2023 double thread chain stitch sewing machine.

Where:

1- main shaft;

2- needle;

3- rotary looper;

4- thread guide of the bottom thread;

5- pusher of the bottom thread;

6- feed dog;

7- presser foot;

8- nut for regulation of pressure of a press foot on a material;

9- rotary twin-disc cam thread take-up of the top thread;

10- tension device of the top thread;

11- rotary twin-disc cam thread take-up of the bottom thread;

12- tension device of the bottom thread;

13- lever for regulation of length of a stitch and reverse feed.

The use of three rotary working units in the machine, such as the rotary looper and two rotary thread take-ups, together with a simple crank-slider mechanism for the needle and the absence of needle guards, has made it possible to create the world's first prototype of the ZARIF sewing machine with a very simple mechanical design.

In addition, the machine is the first in the world to allow easy switching between different needle sizes, from needle Nm. 130/21 to needle Nm. 60/8, without having to adjust the position of the looper relative to the needle, thanks to the world's first increase of the maximum allowable gap between the needle and the looper tip to 0.5 mm.

In addition, the machine is very easy to maintain as all working units are mounted on the ends of the shafts and can be removed without dismantling other parts of the machine.

Our automatic thread trimming technology for the ZARIF double thread chain stitch technology with rotary looper.

It is well known that most modern industrial sewing machines are equipped with automatic thread trimming, and all automated sewing systems require automatic thread trimming.

With this in mind, we have long been researching and developing automatic thread trimming technology for our ZARIF double thread chain stitch technology with rotary looper.

Thanks to these efforts, we successfully invented the automatic thread trimming technology for our ZARIF double thread chain stitch technology with rotary looper in 2020, and further improved it in 2021 and 2023.

The advanced version of our automatic thread trimming technology, which we invented in 2023, has not yet been physically manufactured to ensure its practical functionality.

However, the drawings of our automatic thread trimming technology prove that it works in theory.

At present we cannot disclose the details of our automatic thread trimming technology as it is not yet patented. However, we can say that the top and bottom threads are trimmed under the needle plate, with the bottom thread end remaining clamped under the needle plate after trimming. This eliminates the need to re-thread the bottom thread when moving to the next sewing operation.

If the sewing process is finished with condensed stitches of 0.5 mm stitch length and manual thread trimming, the resulting chainstitch seam will be difficult to unravel from the end of the seam.

If the sewing process is finished with condensation stitches at a stitch length of 0.5 mm and with automatic thread trimming, the resulting chainstitch seam cannot be unraveled from the end of the seam, as the end of the top thread passes through the last loop of the bottom thread.

Chain seam is difficult to unravel from the end of the seam and is obtained by manually trimming the threads.

Chain seam that does not unravel from the end of the seam is obtained by automatic thread trimming.

Our ideal ZARIF 2023 double thread chain stitch technology with rotary looper opens a new era in the development of automated straight stitch sewing.

It is well known that the future of mass production in various sewing industries is closely linked to automation, and the automation of sewing processes plays an important role in this transformation. Currently, some sewing operations are already being automated using robotic manipulator controlled sewing systems. In the future, these robotic manipulators may be replaced by more advanced humanoid robots.

When it comes to automated sewing, it is essential that the process is performed to a high standard, ensuring that there are no skipped stitches, thread breakage, needle breakage and deformation of the needle point. Efficient sewing of different materials without the need for adjustments is also critical to the automation of the sewing process.

Our ideal ZARIF 2023 double thread chain stitch technology with rotary looper for straight stitch sewing is the perfect solution to meet all these requirements.

Our prototype ZARIF sewing machine has proven this in practice, but only when the material is fed in one direction. This allows us to create different automatic sewing systems based on this technology, where the material is fed in a single direction.

However, there are many sewing operations where the stitch must follow a complex path. In such cases, stitch formation must be independent of the material feed direction.

With this in mind, we have been working for a long time to develop a device that would allow our ZARIF double thread chain stitch technology with rotary looper to produce stitches regardless of the direction of material feed.

As a result of our efforts, we were able to invent this device in 2020, improve it in 2021 and complete the final refinements in 2023. Although we have not yet built and tested the device, our drawings show that it theoretically works.

Patent protection for our inventions that we invented in 2023.

We intend to secure patents in several countries around the world for all our inventions developed in 2023, including the ideal ZARIF double thread chain stitch technology with rotary looper, automatic thread trimming technology and the device that allows stitch formation with material feed in any direction.

Application of the revolutionary ideal ZARIF 2023 double thread chain stitch technology with a rotary looper.

Application of the revolutionary ideal ZARIF 2023 double thread chain stitch technology with a rotary looper that forms stitches in only one direction.

Our prototype ZARIF sewing machine, based on the ideal ZARIF 2023 double thread chain stitch technology with rotary looper, has proven its ability to perform straight stitching with material feed in only one direction and a stitch length ranging from 0.5mm to 5mm. In addition, we have developed a technical solution that allows the stitch length to be increased to 10 mm.

Based on our ideal ZARIF 2023 double thread chain stitch technology, which forms stitches in only one direction, the following machines can be designed and manufactured:

1. Various industrial sewing machines with different types of platforms and material feed mechanisms.

Flat bed.

Long arm flat bed.

Cylinder bed.

Post bed.

Bottom feed.

Bottom feed and pull roller.

Bottom feed and pressure roller.

Needle feed.

Differential feed.

Top and bottom feed.

Unison feed.

Roller feed.

2. Various automated sewing systems with material feed in one direction only.

3. Programmable automatic pattern sewing machines with a 360° rotating head with material feed in any direction in the X and Y axes according to the programme, where the head and the lower part with the needle plate rotate together synchronously in the material feed direction according to the programme.

Application of the revolutionary ideal ZARIF 2023 double thread chain stitch technology with a rotary looper, forming stitches in any direction.

If the device we invented in 2023, which enables our ideal ZARIF 2023 double thread chain stitch technology with a rotary looper to form stitches with material feed in any direction, works successfully in practice, the following automated machines can be designed and manufactured on the basis of it, enabling the production of complex stitch patterns:

1. Various conventional programmable automatic pattern sewing machines, without a 360-degree rotating head.

2. Various automated sewing systems.

3. Single and double head quilting machines.

Can our revolutionary ideal ZARIF 2023 double thread chain stitch technology with a rotary looper become obsolete in the future?

We are confident that this will not happen. Our confidence is based on the following undeniable facts. The «eternal» disadvantages of the existing sewing technologies currently used for straight stitch sewing, such as the lockstitch type 301 and the double thread chain stitch type 401, prevent them from becoming the ideal solution for straight stitch sewing, no matter how much they evolve in the future.

Furthermore, the invention of an ideal straight stitch sewing technology can only be achieved by creating a new double thread chain stitch technology that eliminates the "eternal" disadvantages of existing sewing technologies. Since it is technically impossible to invent an ideal straight stitch sewing technology by developing a new lockstitch technology without using a hook.

However, the task of inventing a new double thread chain stitch technology and making it the ideal solution for straight stitch sewing is a very challenging one.

All previous attempts to invent a new double thread chain stitch technology and make it the ideal solution for straight stitch sewing were unsuccessful. For example, the new double thread chain stitch technology using a special hook (see US Patent No. 3811392, 1974, https://patents.google.com/patent/US3811392A/) was never commercialized. We believe that any new double thread chain stitch technology using a special hook cannot become an ideal solution for sewing due to the complexity of the special hook design and the need for lubrication.

We were the first in the world to invent the new ZARIF double thread chain stitch technology with rotary looper in 1994, which was granted US Patent No. 6095069 in 2000. It took us about 26 years to make this new ZARIF sewing technology the world's first ideal straight stitch sewing technology.

Threaded material joining is known to be the most universal method, as it allows for high quality joining of different types of materials and their combinations in multiple layers, something that cannot be achieved with threadless material joining methods such as welding and bonding.

Therefore, threading is likely to remain the main method of joining different materials in the future, as it is today. Our ideal ZARIF 2023 sewing technology aims to make thread-based joining more attractive and universal.

A Transformative Advancement in the Sewing Industry.

These innovations have been thoroughly tested and demonstrated using our prototype ZARIF sewing machine. For a visual demonstration of how our technology works, please visit our YouTube channel here.

Our ideal ZARIF 2023 double thread chain stitch technology represents a significant breakthrough in the sewing industry, offering unmatched advancements in straight stitch sewing. We are confident that this innovation will lead to higher quality products, greater productivity, and enhanced performance for manufacturers around the world.

VIDEO: Ideal ZARIF 2023 sewing technology this revolution in straight stitch sewing_ Threads #40 S/2.

VIDEO: 2_ZARIF 2023_Revolution in sewing_ Sewing different materials_Threads #40 S/2_Foot-roller.

VIDEO: 3_ZARIF 2023_Revolution in sewing_ Sewing different materials_Threads #20-40 S/2_Foot-roller.

VIDEO: 4_ZARIF 2023_Revolution in sewing_ Sewing different materials_Threads #20 S/2_Foot-roller.

VIDEO: 5_ZARIF 2023_Revolution in sewing_Sewing elastic and light materials_Threads #40_Foot-roller.

VIDEO: 6_ZARIF 2023_Revolution in sewing_Sewing denim materials_Threads #20_Foot-roller.

VIDEO: 7_ZARIF 2023_Revolution in sewing_Sewing furniture materials_Threads #20_Foot-roller.

VIDEO: 8_ZARIF 2023_Revolution in sewing_Sewing furniture materials_Threads #210-150_Foot-roller.

VIDEO: 9_ZARIF 2023_Revolution in sewing_Sewing leather materials_Threads #150_Foot-roller.

VIDEO: 10_ZARIF 2023_Revolution in sewing_Sewing leather materials_Threads #210-150_Foot-roller.

VIDEO: 11_ZARIF 2023_Revolution in sewing_Sewing heavy materials_Threads #210-150_Foot-roller.

VIDEO: 12_ZARIF 2023_Revolution in sewing_Sewing different materials_Threads #40_Teflon foot.

Page updated

Google Sites

Report abuse