New "Total Testing" approach to ensure predictable profits

Quality control is no easy feat, especially amid the unrelenting cost challenge. To help textile manufacturers optimize production efficiency and reduce costs, Uster has developed the new Quantum 3 yarn quality assurance system, as well as its new "Total Testing" approach, which ATA Journalhad a glimpse at the company's stand at the recent ITMA 2011 exhibition in Barcelona, Spain.

Quantum 3: smart clearing technology

The Quantum 3 is Uster's latest clearer system that measures, analyzes and proposes how the yarn on the winding machines can be tailored to the spinner's quality and productivity needs, hence allowing textile manufacturers to optimize production efficiency and reduce costs. Equipped with new capacitive, optical and foreign matter sensors and powerful processing electronics, the system shows, for the first time ever, the full yarn body, that is, normal yarn with its set of expected tolerable natural variations. The new foreign matter sensor has multiple light sources to detect new colored foreign fibers and to help separation of colored foreign fibers from mostly non-disturbing vegetable matter. The contamination package of the product is completed by a brand new polypropylene clearing option.

Uster stressed that Quantum 3 can learn everything it needs to know about the running yarn in just two minutes. Then, drawing on its built-in Uster know-how, it proposes suitable clearing limits to achieve the required quality level, enabling Quantum 3 to forecast exactly how many cuts will need to be made to reach quality goals.

Sivakumar Narayanan, Uster's Product Manager for Online and Data System Products and Head of Marketing China

"We have integrated our know-how into the clearer, and customers can now only press one button to find the optimal setting to reach a good balance between quality and productivity," said Sivakumar Narayanan, the company's Product Manager for Online and Data System Products and Head of Marketing China, during Uster's press conference at the show. "This was a very complicated process before, but now based on the Uster's built-in know-how, the clearer will learn the yarn first, and then come up with the optimal setting for customers."

Total Testing: from uncertain results to predictable profits

Uster's Total Testing approach was developed to meet textile manufacturers' need to strike a balance between minimizing costs and consistently achieving the required quality through proper control of yarn quality. Combining laboratory testing, process monitoring and know-how, it comprises four key elements to help textile companies to transform their business from uncertain results to predictable profits, the company noted.





Element 1: From sampling to continuous testing

According to Uster, yarn producers need the capability to optimize their process in terms of speed and machine set-up. Combining continuous testing with laboratory tests does exactly that. Laboratory sample testing with Uster's HVI 1000 and Tester 5 enables producers to control raw material and define initial machine settings, while at the same time benchmarking and certifying the quality of their finished yarn.

Reine Wasner, Uster's Vice President of Marketing and Business Development

With the new Quantum 3 yarn clearer, 100% of the produced yarn can be tested for key quality parameters, said Reine Wasner, Uster's Vice President of Marketing and Business Development. "This identifies production problems for further machine setting optimization, while on the other hand it prevents faults in the final product by removing any remaining disturbing defects. In addition, it allows for constant monitoring of production to ensure that the final product is of consistent quality within defined limits - any 'outliers' from these limits caused by defective bobbins are identified and corrective action can be taken."

Element 2: From varying to consistent quality

Consistent quality depends on managing available resources in accordance with quality and cost parameters and making decisions based on facts, data and know-how. Uster claimed to be the only company to provide both the application know-how and a complete range of laboratory testing and process monitoring instruments to minimize waste and cost, while at the same time reproducing an article to a specified quality time after time.

Quality parameters based on tests conducted in the laboratory, together with the results from clearing (Quantum 3), give clear indications on how to choose the right mix of raw material and set the machine correctly for consistent quality, explained Mr Wasner, adding that any quality exceptions - such as uneven yarn or wrong counts or contaminants - are monitored 24 hours a day and removed at the winding machine, assuring stable quality for customers.

Element 3: From subjective to objective quality

More than 50 years ago, Uster established the first quality standard specifically for textiles, Uster Statistics, providing quality references for the classification of fibers, slivers, roving, and all kinds of yarns (cotton, synthetic and cellulosic) based on data from producers around the world. According to the company, Uster Statistics have become the trusted benchmarks across the entire textile value chain, acting as a basis for trading, for benchmarking and certification. In the cotton trade, quality tags from its HVI 1000 are essential for a fair price and good deal and they are supported by national cotton classification offices in, say, the US, China, Uzbekistan and Pakistan. Spinners use Uster Statistics to set quality targets, to benchmark performance against competition and to certify the quality of finished articles.

Element 4: From fiber to fabric

Dr Geoffrey Scott, Uster's CEO

Uster explained that quality starts at the very beginning - with the raw material and producing the right quality yarn. By using the single fiber test instrument, Uster AFIS PRO2, optimal settings can be defined for each step of the mill process to minimize waste. Mr Wasner noted that there is a series of corresponding instruments, namely : USG PRO for sliver quality monitoring (cards and draw frames); Tester 5 for sliver, roving and yarn analysis; Tensorapid / Tensojet strength testers for sliver, roving and yarn testing (staple / cotton and continuous / filament); Zweigle HL400 hairiness tester; and Quantum 3 yarn clearer. He stressed that Uster is the only company able to supply a complete spectrum of instruments for cotton classing, yarn testing and monitoring. 

Continued investment

At the press conference, the company also reported that it successfully handled the challenges arising from the financial crisis and textile crisis, adding that it maintained profitability throughout the crisis, acquired Zweigle products, and had Toyata Industries as its new major shareholder.

"Most important of all, we have continued our investment in the future so that we will have new products introduced to the market," noted Dr Geoffrey Scott, Chief Executive Officer of Uster. He also highlighted the crucial need to understand customers' needs in processing and operations. [ATA Journal]