Nowadays, with the growin energy and raw material prices, spinners are finding their ways to stay competitive and even to survive. One of the preferred ways is to save energy. Spinners are becoming increasingly more attentive to the energy requirements per kilogram of yarn produced, which makes energy savings one of the key criteria for their equipment choices.
The massive pressure has compelled textile manufacturers from around the world to boost their productivity in ways that are eco-friendly and sustainable. In discussing German textile machinery makers' exhibiting at ITMA 2011, VDMA Textile Machinery Association said in a recent press release that ecological design and energy efficiency are the subjects to which the textile sector is increasingly confronted both by legislation and by customers' requirements. The association, however, stressed that today, more than ever many new technical solutions are considered with regard to their ecological efficiency.
Germany is one of the major spinning machinery exporters. According to VDMA Textile Machinery Association, during January to June of this year, Germany exported spinning machinery amounting to 640 million euros, which registered a significant year-on-year increase of 61%. This has manifested how eager spinners are to enhance their competitiveness by employing the cutting-edge spinning technology.
Looking ahead
Spinning machinery makers noted that for the development of spinning technology, the leading direction is to introduce fully automated machinery - by exercising automation, spinners can slash their labor costs and enhance their production efficiency simultaneously.
Besides, how to improve yarn quality is also what textile machinery makers take into account. Guo Hua, Manager of Murata's Fiber Machinery Sales Department, told ATA Journal that the Japanese company's latest technology brings essential change for the worldwide spinning industry and textile manufacture industry. "We will always ensure high quality of each yarn because yarn will directly connect with our skin," he said.
In the spinning sector, chemical fiber has seen growing significance. Although natural fiber and chemical fiber are both seeing investment boom, chemical fiber obviously outperformed cotton textile in growth rate, said Wang Jun, President of Oerlikon Textile China said at the recent ShanghaiTex 2011.
He noted that chemical fiber grows faster than natural fiber because limited agricultural acreage in China has to meet the food demand, thus restricting large-scale cotton plantation. Besides, chemical fiber products are finding extensive applications from traditional garment to home textiles and technical textiles, such as geotechnical fabrics and chemical fiber products for building, medical and automobile purposes, added Mr Wang.
Some spinning machinery suppliers and their products
Spinning machinery makers have developed state-of-the-art technologies in attempts to help spinners tackle the hefty challenge with cost pressure. Presented below is what they have to offer.
Fadis Sincro technology
Italian machine maker Fadis has developed an innovative constructional philosophy of the Sincro range called "open platform", which makes it possible to create a machine which fully responds to users' technical and production requirements, and can be modified at any time to meet new market needs.
For the elastic yarn winding range, Fadis has Sincro M and Sincro RFM machines. Fadis notes that with the Sincro M machine, it is possible to produce FAPP low density packages (Fadis Precision Package) and hanks, which allow for wide retraction margins of the yarn during the dyeing phase, thus keeping a high residual elasticity percentage of the elasticized yarn.
Therefore, with this system, and the possibility of unwinding the FAPP hanks and bobbins with the Sincro RFM SW rewinding machine with its "on-line" tension control, users are likely to obtain perfect qualitative results but with the same simplicity and economy typical of yarn package dyeing, according to the company.
Lakshmi's LR60 Ring Frame series
The LR60 Ring Frame series introduced by India-based Lakshmi Machine Works (LMW) consists of LR60/A (without doffer) and LR60/AX (with doffer).
The automated and user-friendly LR60 series features spindleage upto 1200, inverter drive, servo drive for ring rail, and optional characteristics such as autodoffer, linkconer and compact spinning.
Higher productivity combined with quality is the key criteria for the ring frame. The series drafts the roving until the required fineness is achieved Impart strength to the fiber by inserting twist. It winds up the yarn in a form suitable for storage, transportation and further processing. The Ring Frame LR60 Series is designed with contemporary technologies and automation to deliver high quality yarn with optimum characteristics, especially with regard to structure and strength.
The automated and user-friendly LR60 series features spindleage upto 1200, inverter drive, servo drive for ring rail, and optional characteristics such as autodoffer, linkconer and compact spinning.
Higher productivity combined with quality is the key criteria for the ring frame. The series drafts the roving until the required fineness is achieved Impart strength to the fiber by inserting twist. It winds up the yarn in a form suitable for storage, transportation and further processing. The Ring Frame LR60 Series is designed with contemporary technologies and automation to deliver high quality yarn with optimum characteristics, especially with regard to structure and strength.
Besides, the principle of compacting is to minimize the width and height of the spinning triangle. The fibers are aligned in the yarn with uniform twist with fixed path. The company's RoCoS Compact spinning system ensures appreciable reduction in hairiness and significant increase in yarn strength with enhanced yarn appearance, it notes.Macart's S300 self-twist spinning machine
UK-based spinning system manufacturer Macart has launched the new S300 self-twist spinning machine for high bulk (HB) acrylic yarn.
The S300 machine combines roving, spinning, twisting, yarn bulking and take up winding operations in a single process. Producing two fold yarns in the count range from 2/16Nm to 2/42Nm HB acrylic, the machine has the capacity to process synthetic staple fibers, natural fibers and their blends with fiber lengths suitable for worsted spinning.
The self twist yarn is designed for the production of industrial machine knitted garments. Each four-spindle S300 produces four-fold yarns for delivery to four spindles for winding.
The company notes that the machine can produce between 2.5kg and 7kg per hour, and one spindle of a typical twofold HB acrylic yarn will produce 1kg per hour of relaxed high bulk yarn wound on cone ready for knitting. Delivery speeds range from 200m/min to 240m/min, which remain the same for all counts.
Because of the machine's size, several machines can be placed side by side, while up to 15 machines can be connected to an automatic winder of 60 spindles.
Macart stresses that compared with traditional spinning processes, the S300 uses 60% less energy per kilogram of yarn manufactured, and the streamlined technology saves six separate manufacturing processes compared with conventional ring spinning.
Marzoli's CM600N
After a series of studies carried out in cooperation with the Engineering University, Marzoli has reduced the masses of some of the mechanical components and minimized the friction in the driving head. Its lubrication system is revised so high-performance synthetic oils can be used.
Of high impact was the application of low-friction high-performance bearings. Finally, the company replaced the electrical motors with a new high-efficiency generation.
These advancements introduced by Marzoli enable it to reduce the energy consumption for each kilogram of combed sliver by 14% from the previous version of CM600N.
Marzoli's efforts towards greater energy efficiency without compromising performance and quality, have over time progressively reduced energy consumption by over 40% in the last 15 years.
Besides, its Card C701 offers high performances and quality both in the production of cotton and in the processing of the latest and complex fibers. The renewed chute totally integrated, the new pre- and post-carding systems, the new geometry with a wider work area and many other innovations, make the new Marzoli Card able to satisfy all the different and more demanding requirements of the market.
Murata's VORTEX spinning machine
Japanese Murata has developed high-efficient VORTEX spinning which is a technology which uses an air vortex to spin out the yarn. Fibers formed by these air flows claim to possess a unique structure, providing the yarn with a wide range of functionalities.
The company has recently introduced VORTEX 861 with allegedly world's fastest spinning speed of 450m/min. With its ecological energy saving design, the machine contributes profits with better quality conical packages and user-friendly production management system.
The company says that roving, spinning and rewinding can all be combined in the machine, which has lower power consumption with great improvements in floor space productivity.
Oerlikon Schlafhorst's rotor spinning machines
Swiss Oerlikon Schlafhorst's BD 416 rotor spinning machine offers a combination of new and intelligent features that will benefit users on a daily basis. The machine can offer good yarn quality, great efficiency and flexibility in the rotor yarn market.
The company notes that the user-friendly machine has up to 416 spinning positions. It also features a comprehensive aerodynamic concept that optimizes the air flows on the BD 416. The NSB 38 spinbox and all air-guiding components guarantee the optimum fiber orientation and quality; air utilization is also controlled electronically by Electronic Vacuum Adjustment (EVA).
Its Joint Spinning In is an optimized and highly productive mass piecing technology. The technology claims to reach a piecing reliability of 95%.
Besides, with integrated Fancynation technology on all spinning positions, fancy yarns are spun on the BD 416 quickly, efficiently and productively, says the company.
The company's Autocoro S 360 offers top productivity performance and premium quality. It combines proven Autocoro factors of success with an innovative piecing technology: DigiPiecing. The company notes that the rotor spinning machine is designed for highest piecing precision and infinite reproducibility. Spinning position for spinning position, machine for machine. The new piecing process and the digital piecing check ensure piecing with highest perfection even without automation.
The rotor spinning machine is particularly productive with 360 spinning positions, rotor speeds up to 130,000 rpm and take-up speeds up to 230 m/min.
Rieter's new spinning machines
One of the leading spinning systems supplier Rieter has introduced new spinning machines.
The new J 20 air-jet machine with maximal productivity at minimal space requirement. With this new spinning process, Rieter now offers 4 spinning technologies from one source.
The new RSB-D 45 draw frame with unique "mouse-free" sliver coiling, improved operation and a further increase in quality.
High quality and productivity at delivery speeds of up to 1,100m/min- that is what the new RSB-D 45 autoleveler draw frame and the SB-D 45 draw frame without autoleveling offer. A frequency-controlled main drive and the unique CLEANtube device for clean sliver coiling enhance customer benefits.
The new R 60 automatic rotor spinning machine, that achieves a productivity rise with a new spin box. The R 60 fully automatic rotor spinning machine sets new standards with innovative spinning technology and low energy consumption. It offers up to 5% higher production than other machines and an increased flexibility with up to 540 positions and optionally independent sides.
Savio's spinning solutions
Italian Savio has launched its Flexirotors 3000 automatic rotor spinning frame, which is specifically designed to meet the most different needs of flexibility in the Open End processing line.
Besides, Savio's Polar E is an automatic winder with automatic bobbin feeding and automatic package doffing. Ring spinning frame bobbins are loaded into the hopper tank and then placed on the Flexitray (peg) to be transferred to the preparation station.
Each bobbin placed on Flexitray is automatically moved to the "yarn finder station". This station prepares the bobbing for the following winding process, and all the above mentioned operations are automatically made and "operator-free", says the company.
SSM's PS8-W DIGICONE preciflex winding machine
Swiss supplier of winding machines, Schärer Schweiter Mettler AG (SSM) has introduced its latest PS8-W DIGICONE preciflex winding machine.
The PS8-W is a true high performance precision package winder for dye packages and rewinding operations. The PS8-W concept is for winding short staple yarns.
The process costs can be cut by approx. 20% with PS8-W precision cones. Other significant advantages are the improved reproducibility, adjustable blades for different winding length (statically in step of +/- 5 mm), fewer off-shade dyeing and finally the enhanced quality and improved image as dyer.
The decisive success factor of the PS8-W cone winder is its thread laying by means of counter-rotating blades, which has established itself as the thread laying system that is kindest to the yarn. Further important features of the rotary motions are almost wear-and-tear-free and low-cost operation. In order to increase the speed, SSM has developed the new tensiso, a special balloon optimising system for supply packages. Tensiso is a fully automated system and requires no specific manipulation by the operator. By controlling the unwinding tension the tensiso system offers higher winding speed, fewer yarn breaks, decreased yarn stress and so reduced hairiness as well as a significantly better yarn unwinding efficiency.
Trützschler Spinning's Card TC 7
The elements of Trützschler Card TC 7 have been completely optimised for high production applications in cotton processing, with focus on additional operational safety, reliability and durability.
The company notes that Trützschler Card TC 7 features Integral Feed Tray SENSOFEED for perfect clamping and very precise short-term leveling, fully-integrated Tuft Feeder DIRECTFEED with built-in air volume separator and segmented feed tray, Precision Flat Setting System (PFS) and Flat Measuring System Flatcontrol TC-FCT.
It is also equipped with Magnet Flat System MAGNOTOP, Nep Sensor NEPCONTROL TC-NCT, and Precision Knife Setting System (PMS).
[ATA Journal for Asia on Textile & Apparel - Oct 2011 Issue]
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