link

The customer magazine of Rieter Spun Yarn SystemsNo. 63 / 2013 / EN

03 RIETER INSIDE Innovation by Rieter – implementing ideas and inspiring customers 08 MARKETS & TRENDS Manufacturing linen yarn on Rieter rotor spinning machines – a field report 16 PARTS ECOrized suction tubes – the winners 19 RIETER GLOBAL The 1st Rieter Com4® Yarn Seminar China – Satisfactory Result

2 LINK 63 /2013

CONTENTS

Cover:Those attending the Com4® yarn seminar in China made very good use of the opportunity to feel and compare end products made from the four Com4® yarns. Read more on page 19.

Publisher: Rieter Spun Yarn Systems

Editor-in chief: Anja Knick Marketing Spun Yarn Systems

Copyright: © 2013 Rieter Machine Works Ltd. Klosterstrasse 20, CH-8406 Winterthur, www.rieter.com, rieter-link@rieter.comReprints permitted, subject to prior ap-proval; specimen copies requested.

Design and production:Marketing Rieter CZ s.r.o.

Volume: Year 25

RIETER INSIDE 03 Innovation by Rieter – implementing ideas and inspiring customers

PRODUCT NEWS 05 F 16 / F 36 roving frames – high-quality roving

MARKETS & TRENDS 08 Manufacturing linen yarn on Rieter rotor spinning machines – a field report

10 Convincing Reliability of R 60

TECHNOLOGY 12 SB-D 22 – Double-head drawframe in mill operation

14 New technological findings with air-jet-spun yarns

PARTS 16 ECOrized suction tubes – the winners

18 CLEANtube – perfect, clean coiling

RIETER GLOBAL 19 The 1st Rieter Com4® yarn seminar China – satisfactory result

20 What makes a Com4® yarn so successful

OUR CUSTOMERS 22 New Com4® licensees – the community is growing

23 From our customers’ point of view

3LINK 63 /2013

Innovation by Rieter – implementing ideas and inspiring customersNo-one will claim that textiles are a greenfield industry. From the beginning of the Industrial Revolution, i.e. for more than 200 years, numerous fine minds have been inventing and improving textile machinery. This has resulted in an extremely thoroughly developed product range. However, development is far from finished. Time and again new ideas succeed in optimizing the state of the art and thus customer benefits.

Fig. 1 Flow simulations help to understand and optimize aerodynamic conditions. Open ECOrized suction tube.

Fig. 2 Closed ECOrized suction tube.

Rieter employs the latest technologies and sharp brains to translate new ideas into successful inno-vations. As if following a red thread, successful in-novations always pass through the following phases:•clear definition of the task;•plowing through the field of ideas;•flash of inspiration due to intensive study of the

problem;•assiduous implementation through to release for

sale.

The new power-saving ECOrized suction tube for Rieter ring spinning machines successfully followed exactly this path from idea to finished product.

Why waste energy and money?The impetus for developing a power-saving suction tube was provided by the global rise in energy prices and the realization that suction at the spinning po-sition on the ring spinning machine is designed for the “worst case”. Significantly reduced suction power would suffice for stable machine operation more than 99 % of the time. Halving the power could save costs of some 5 000 US dollars per machine annually.

An inspiring ideaIn the initial phase of development an idea patent-ed 100 years ago was taken up. In this a metal flap was intended to reduce the size of the air aperture of the suction tube at the spinning position. Tentative initial trials quickly revealed the expected dynamic inertia and the adverse effect on yarn quality. This was probably the reason for the failure of this patent. However, the use of modern technologies such as 3D printing and flow simulation (Fig. 1, 2 & 3) enabled the experimental models to be refined further until finally one observation brought the breakthrough: the lightweight plastic flap floats in the air current in the extraction system without touching the yarn (Fig. 4). This blew away the problems of the old pat-ent, so to speak, and opened the way to practical im-plementation.

RIETER INSIDE

4 LINK 63 /2013

5

3 4

RIETER INSIDE

Tools for innovative productsTo enable innovations to come to fruition, Rieter successfully utilizes “soft” aids as well as technical expertise and know-how:•A positive culture with regard to acknowledging

faults helps to eliminate idea killers, to identify serious problems early and resolve them.

•Ideas are tried out immediately, which time after time yields new discoveries. An in-house 3D printer is used to obtain a rapid “grasp” of possible new approaches to a solution (Fig. 4).

•In early concept phases the scope of the search for ideas is deliberately wide.

Fig. 3 Final injectionmolded flap – models from the 3D printer provide in-depth findings and help to “grasp” possible solutions instantly.

Fig. 4 Ideas are sketched out on the whiteboard – the floating flap.

Fig. 5 The energy saving ECOrized suction tube is already in use worldwide.

•There is a vigorous exchange of ideas with ex-ternal partners.

•The idea’s sponsors are motivated to pursue its im-plementation with determination and – if necessary – tenacity.

Reliable operation – satisfied customersThe ECOrized suction tube has been systematically developed and extensively tested using the above-mentioned aids (Fig. 5). Over a period of about two years experience has been gathered on 30 000 spin-dles and further improvements have been made. The initial hopes of annual energy savings of some 5 000 US dollars per machine have been confirmed by various enthusiastic customers (refer also to the article entitled “ECOrized suction tubes” in this is-sue). The global market launch is in full swing.

Ongoing innovationThe further development of Rieter machines is being pursued on a wide front. The K 46 compact spinning machine alone features various innovations, for example:•a new suction tube which improves performance

in terms of soiling and blockage;•a completely revised compacting unit with im-

proved maintenance properties;•a display unit which detects very rarely occurring

obstructions in the compacting unit and makes them visible for operating personnel.

13-301 •

Gabriel Schneider

Head Fundamental Development Ring Spinning, Winterthurgabriel.schneider@rieter.com

5LINK 63 /2013

1 2

PRODUCT NEWS

F 16 / F 36 roving frames – high-quality rovingHigh yarn quality presupposes good spinning preparation. With a new drive concept and individual roving monitoring the new generation of roving frames produces roving featuring high quality consistency at low cost.

Modern drive concepts reduce the energy consump-tion of the F 16 / F 36 roving frame models. The new double-section bobbin drive enables the installed power to be optimally adapted to machine length. The necessary motor power is reduced to a minimum. Direct drive of the bobbins via toothed belts reduces friction losses and improves the energy balance.

Economical production with assured quality due to the new drive conceptAccurate package build on the roving frame ensures high productivity on the ring spinning machine, since faultlessly unwinding bobbins cause fewer ends down. Roving tension is kept constant through-out package build with ROJ roving tension control (Fig. 1) and the new machine control system.

Fig. 2 Individual roving monitoring enables badly running spindles to be identified quickly.

Fig. 1 Roving tension control ensures uniform package build.

Uniform tension ensures homogeneous package build. Since no tension peaks occur, the roving frame operates through roving breakages almost without any stoppages. This is the basis for economical pro-duction of quality bobbins.

At the same time high roving uniformity is thus achieved between the different bobbins and also within the individual package layers. High roving uniformity is the basis for consistently high yarn quality on the ring spinning machine.

Energy saving due to the elimination of extraction Individual roving monitoring on the F 16 / F 36 gen-eration of roving frames ensures that the machine is reliably brought to a standstill in the event of a roving breakage. The roving extraction system can therefore be dispensed with. The elimination of the extraction system reduces installed power by 4 kW and savings of up to 3 kWh can be made, a further step in reducing yarn manufacturing costs. Since no exhaust air is generated, no floor penetrations or ex-haust air ducts to the air conditioning system are necessary. Expenditure on infrastructure and air ex-traction is reduced.

6 LINK 63 /2013

PRODUCT NEWS

Quality assurance with individual roving monitoringThe individual roving monitoring system is connect-ed to a central analysis unit in the machine control system. Badly running spindles can be identified on the machine’s display panel and systematically ex-amined, and the production of “problem bobbins” stopped promptly (Fig. 2). This enables roving qual-ity to be monitored and a high quality level to be ensured. High efficiency is also ensured by system-atic fault analysis and correction, since unnecessary false stoppages are prevented.

High efficiency due to short doffing times, irrespective of spindle numbersThe doffing concept of the fully automated F 36 roving frame enables doffing times of less than 3 minutes to be achieved (Fig. 3). This ensures high machine productivity, even with coarse rovings and

frequent doffing. Since the full bobbins are conveyed away outside the spinning positions, long machines can also be doffed in an equally short time. In the case of long machines this means doffing times ap-prox. 50 % shorter than other doffing systems. The machine starts producing again immediately after the full bobbins are removed and the empty tubes are fitted. There is no waiting time dependent on spindle numbers. This is an important contribution toward ensuring high efficiency levels even on long machines.

Fast, ergonomic and quality-preserving doffing on the F 16The crucial advantage of the F 16 roving frame with manual doffing is the ergonomic positioning of the bobbin rail during doffing. The bobbin rail is tilted forward for doffing (Fig. 4). The bobbins in the front and back rows are therefore easily accessible. The

Fig. 3 The roving frame is doffed and ready for production again within 3 minutes.

7LINK 63 /2013

4 55

Roland Fraas

Product Management Ring SpinningWinterthurroland.fraas@rieter.com

PRODUCT NEWS

full bobbins can easily be removed by the machine operator by grasping the tube. The wound bobbin is therefore undamaged. Package quality is preserved and ensures trouble-free unwinding on the ring spin-ning machine.

The empty tubes can also already be brought into po-sition in a tube hopper while the machine is running. This speeds up doffing.

Reduced eff ort due to easy machine settingThe machine can be specifically adapted to any ma-terial at the new display panel. Graphic display of the separate processes simplifies fine adjustment at startup or batch change. In the event of malfunctions the faults are displayed on the panel. Rapid elimina-tion of faults is assured. The machine control system can store up to 50 sets of batch data, thus provid-ing rapid access to different compositions. The data can be effortlessly transferred from one machine to the next by means of USB. Identical machine settings and thus the same roving quality can therefore be ensured. This is another important contribution to quality assurance on ring spinning machines.

Quality-assured, economical package transportRoving bobbins are a delicate intermediate product, since the outer package layers are unprotected and can easily be damaged. The SERVOtrail transport system provides the safest means of transport and

suitable interim storage of the bobbins (Fig. 5). This prevents any contact with the roving, thus ruling out any loss of quality.

The SERVOtrail system with its open track provides for individual solutions (Fig. 6). Both a simple, man-ually operated system and a fully automated sys-tem are possible. Different levels can also easily be linked. 13-202 •

Fig. 4 The bobbin rail is swung out for easy manual doffing on the F 16. The tubes can already be placed in position in advance.

Fig. 5 The roving bobbins can be transported and stored with assured quality by the SERVOtrail system.

Fig. 6 This is how the “Flexible A” SERVOtrail version operates.

http://bit.ly/18DFkDs

8 LINK 63 /2013

MARKETS & TRENDS

Manufacturing linen yarn on Rieter rotor spinning machines – a field report

A production line for manufacturing spinnable linen fibers and a down-stream rotor spinning mill were installed under Rieter’s leadership in 2009 at the “Orsha Linen Mill Group” in Belarus. This provides financial benefits and potential for new products.

The local availability of fiber raw material (flax) was the prime consideration in the customer’s decision to realize this project. The linen fiber extracted from flax is regarded as an ecological product. Flax can be cultivated without irrigation, fertilizers or the use of pesticides. Furthermore, in the agricultural context flax cultivation serves to regenerate the soil.

Subdivision of the production lineThe production facility can essentially be divided into two mutually independent processing stages – the cottonizing line for extracting the fibers and the rotor spinning line for manufacturing the linen yarn.

Cottonizing line for fiber extraction In cooperation with the TEMAFA company, technolo-gist Dr. Mehdi Azarschab and the Tongor company, a production line has been assembled which enables linen fibers to be extracted; these can then be pro-cessed into yarn by a cotton spinning process.

The special and unique feature of this is that the raw fibers (flax tow) which are fed in can be prepared here for the spinning process without having to be cut. Furthermore, the processing operation results in cleaning and separation of the flax fibers. Together with the fiber recovery line which has also been in-stalled, a fiber yield of up to 75 % can be achieved.

The rather large quantity of dust and stalk residue that is separated out is conveyed to a briquetting press and thus has a further use as heating material.

At the end of the fiber extraction process the linen material is compressed into bales which are fed to the rotor spinning line (Fig. 1).

Rotor spinning for linenThe entire rotor spinning mill at Orsha was sup-plied by Rieter. The Rieter rotor spinning machine is the only rotor spinning machine which can produce 100 % linen yarn (Fig. 2). The reason for this is the technologically fully developed design of the rotor spinning box. In addition to pure linen yarn, various blends of linen with cotton or manmade fibers can also be produced.

The special method of fiber extraction, combined with the specific design of the Rieter rotor spinning box, enables pure linen yarn to be spun out to counts of up to Ne 6 (Nm 10).

The “tapered” ends of the fibers (compared to cut fiber ends) can be incorporated more effectively in the fiber bundle. This results in a smoother, visually more uniform yarn with relatively high yarn strength, so that the addition of a carrier fiber such as viscose can be dispensed with.

Fig. 1 The process of extracting linen fibers is concluded in a baling press.

9LINK 63 /2013

MARKETS & TRENDS

The yarn spun using the economically very attractive rotor spinning process is suitable as warp and weft yarn especially for use in denim manufacture and for workwear and leisurewear (Fig. 3). The yarn is also used in the field of household linen and furnishings instead of expensively produced conventional ring-spun yarns.

Production capacity and utilization Depending on weather conditions, 15 000 tonnes of linen fiber are produced annually in Belarus. The Orsha Linen Group processes approx. 80 % (12 000 tonnes) of this national output of fiber, of which 1 500 tonnes are processed on the cottonizing line supplied by Rieter. With an output of 350 kg/h of spinnable linen fibers, this line operates year-round at the limits of its capacity. Half of the output is then supplied as feed material to the in-house rotor spin-ning mill. Cotton or manmade fibers can also be add-ed there, depending on production needs. The other half is exported to Western Europe via the trade as a sought-after raw material.

In summary Experience with the production facility at the Orsha Group can be described as a success story. The abili-ty created here to manufacture pure linen yarn using the rotor spinning process opens up opportunities for developing new products.

In addition, the financial advantage offered by the rotor spinning process over the otherwise customary ring spinning process is a further benefit. Rieter has also demonstrated its comprehensive technical ex-pertise in the realization of this complex installation for processing linen. 13-303 •

Fig. 2 The Rieter rotor spinning machine is the only one that can manufacture 100 % linen yarn.

Fig. 3 Rotor-spun yarn made from linen is especially suitable for denim manufacture.

Bernhard Paffe

Sales Manager Eastern Europe and RussiaWinterthurbernhard.paffe@rieter.com

10 LINK 63 /2013

Convincing reliability of R 60

More than 350 type R 60 machines have been sold meanwhile to 19 countries. Before deciding, the spinning mills deliberately compare the alternatives.

Here mills are willing to share their practical expe-rience in daily spinning which can provide valuable arguments for other decision-makers.

Rotor spinning with R 60 is extremely energy efficientThe R 60 needs about 5 % less energy than the earli-er R 40 model and 10 % less than competitors’ latest machines. Rieter provides exact figures for consump-tion of electrical power and compressed air for the individual applications, which can prove this advan-tage. Mills can rely on those figures for their calcu-lations.

MARKETS & TRENDS

“The new R 60 needs 20-22 % less en-ergy than the older R 20. The promised savings are 100  % fulfilled. On top of that, we can spin Ne 24 cotton weaving yarns at 9  % higher speed – and still have better yarn strength. We are very interested in buying more R  60 ma-chines of the longest version”

Mr. T. Karagozian, Chairman, Hilado S.A., Argentina

“With the introduction of the new S 60 spin box in the R  60, Rieter has rede-fined the rotor spinning process. The new geometry of components in the spin box ensures not only better spin-nability and quality but also higher speed and efficiency. The design of the S 60 spin box is, as well, user friendly as it also reduces the maintenance and downtime. Combination of higher pro-ductivity, better yarn quality and lower power consumption has made the R 60 stand high in its class.”

Mr. Rajesh Dhingra, Vice President, Nahar Spinning, India

11LINK 63 /2013

R 60 is a simple and very reliable rotor spinning machineThe R 60 has been designed as a sturdy machine for easy operation, access and maintenance. The powerful units for drives, main fan and electronics are centralized to the machine ends. All automation including the unique VARIOclean rotor cleaning is concentrated in the fast robots. This concept pays off in higher reliability and needs less maintenance compared to decentralized concepts, where a lot of small units along the machine can fail and therefore need constant supervision.

R 60 wins with higher productivityThe new spin box S 60 of the R 60 provides a better spinning stability. This allows the use of a huge va-riety of raw materials, including blends with short fibers. Some customers made their own one-to-one comparison to the latest competitor model. They proved the typically higher yarn strength from the R 60, allowing application of less twist or higher ro-tor speed. Downstream mills reported better running with this yarn. Higher productivity with the R 60 of 5 % and more are achieved. Lower twist additionally reduces energy consumption.

Big spinning mills choose R 60The references about technological advantages, low energy consumption and reliability have been the main reasons for big spinning mills in the U.S., China, Argentina, Brazil and Turkey to choose the R 60 for their investments of 10 and more machines. All of them had previously compared it with the latest com-petitor machine. 13-305 •

Stephan Weidner-Bohnenberger

Head Product Management RotorIngolstadt stephan.weidner-bohnenberger@rieter.com

MARKETS & TRENDS

"The future for this R 60 Rieter machine is very good because of its very good advanced technology. This gives us big advantages in con-stant quality for every yarn count and every cotton mixing we are us-ing. Rieter is a reliable brand in China"

Mr. Xie Yimei, Chairman, Pyramid, P.R. of China

“The R 60 is a very re-liable machine. Espe-cially rotor cleaning with VARIOclean is a big advantage for yarn quality. CV value and yarn strength are more stable and reliable then with other machines.”

Mr. Ciao, Mill Manager, Amin Wuyi,

P.R. of China

“The R 60 is a technological milestone in the rotor spinning systems. It has enabled us to yield higher productivity levels by ensuring quality yarns and higher rotor speeds. The R 60’s design ensures optimum con-sumption of electrical power and compressed air. This can be directly translated into profits. Moreover, integration of human factor science in its design has led to lower and safer maintenance operations as well as greater operator satisfaction.”

Mr. Makhan Lal, Managing Director, Rama Krishna Spinning, India

12 LINK 63 /2013

SB-D 22 – Double-head draw-frame in mill operation The SB-D 22 double-head drawframe without autoleveling guarantees maximum machine efficiency with a unique can changer for cans up to 1  000 mm in diameter. It reduces personnel and energy costs. News of the positive results in mill operation is already spreading among customers.

A year after the new SB-D 22 double-head draw-frame was released for sale 350 of these machines have already been sold, that’s a total of 700 drafting heads. This big sales success and the positive feed-back from customers (Fig. 1) clearly demonstrate the advantages of the SB-D 22.

Consistent quality, even at maximum delivery speed of 1 100 m/minThe SB-D 22 is proving its high productivity potential in mill operation. For example, a ring spinning mill conducted a comparison at different delivery speeds using carded cotton with a fiber length of 29  mm. Speeds of 500, 850 and 1  100 m/min were com-pared on the SB-D 22. This was followed by an RSB autoleveler drawframe operating at 850 m/min. The final spun yarn count was Ne 30.

Marginally higher irregularity was measurable in the sliver only at maximum speed, but was no longer de-tectable in the yarn (Fig. 2). The other yarn values, especially the important disturbing Classimat de-fects, were also at the same level at all three delivery speeds. This is certainly also attributable to effective extraction in the drafting system featuring automati-cally lifting cleaning lips on the top rollers.

Drawframes only rarely operate continuously at maximum speed, of course. However, the test results described above show that the SB-D 22 offers the po-tential to increase productivity substantially in the short term without jeopardizing yarn quality. This machine therefore also enables a spinning mill to re-spond more flexibly if additional quantities of sliver are required for a rapid batch change or for coarser yarn counts.

With conventional breaker drawframes this always entails compromises on yarn quality. Apart from this, it can be observed that with these models the maximum speed that can be achieved in practice fre-quently differs significantly from the speed quoted in the corresponding sales literature.

High efficiency and personnel savings with the 1 000 mm can changer The unique automatic can changer for cans up to 1 000 mm in diameter is also proving its worth in mill operation. Spinning mills using large-format cans benefit from the reduced personnel require-ments. These can changers permit longer intervals between operator interventions. More machines can therefore be allocated to each operator compared to conventional double-head drawframes without chan-gers. For example, in mill operation up to six SB-D 22 machines have been allocated to an operator instead of only four conventional double-head drawframes.

The can changer also enables short-term gaps in the availability of personnel to be filled. Since can chang-es on conventional drawframes are dependent on the availability of the operator, productivity slumps of up to 10 % and more can occur. In mill operations with carded cotton the SB-D 22 produces three to six tonnes more sliver per day than conventional double-head drawframes.

TECHNOLOGY

Fig. 1 Mill mechanics appreciate the easy accessibility on the SB-D 22 – here when servicing the central lubricating rail.

13LINK 63 /2013

100

80

60

40

20

0

2 3

Jürgen Müller

Head Product Management Drawframe Ingolstadt juergen.mueller@rieter.com

TECHNOLOGY

Annual energy savings of 1 400 US dollars due to efficient drive technology The energy consumption of the SB-D 22 in comparison to a conventional double-head drawframe was meas-ured in a ring spinning mill processing combed cot-ton yarns (Fig. 3). At a delivery speed of 650 m/min the energy consumption of the SB-D 22 is 25 % lower. This is where the shorter drive train of the SB-D 22, featuring correspondingly fewer belts, wheels and bearings, and the highly efficient motor design, prove their worth.

This results in annual savings of more than 1 400 US dollars per drawframe based on energy costs of 9 US cents per kWh. Numerous blockages occurred in the drawframe delivery zone at 850 m/min on the con-ventional double-head drawframe. It was therefore impossible to make a comparison in continuous op-eration at this delivery speed. However, this result also shows that the SB-D 22 nevertheless still con-sumes slightly less energy at 850 m/min – i.e. at a delivery speed more than 30 % higher – than the conventional double-head drawframe at 650 m/min.

Combining the SB-D 22 with the RSB-D 22 saves 50 % space The SB-D 22 also stands out in mill operation with re-gard to space requirements. It appears that custom-ers like to combine the SB-D 22 with the RSB-D 22 double-head autoleveler drawframe. This setup occu-pies only 50 % of the space needed for two single-head drawframe lines supplied by competitors and set up extremely compactly. The space-saving 3-row can arrangement for 1 000 mm cans in particular is very popular and is unique. Whether double-head or single-head drawframes, with or without autoleveling – Rieter is the only manufacturer to offer the ideal drawframe to meet all requirements. 13-304 •

Fig. 2 Consistent qual-ity even at maximum delivery speed.

Fig. 3 Low energy consumption with the SB-D 22 due to the well-conceived drive concept.

60

50

40

30

20

10

0

5,0

4,5

4,0

3,5

3,0

2,5

2,0

1,5

1,0

0,5

0

Sliver and yarn quality100 % Cotton, carded Energy saving

SB-D 22 sliver1. passage

Ring yarn, Ne 30

500 m/min 850 m/min Competitor1 100 m/min SB-D 22

Uster CVm [%]

Uster CVm [%] Delivery speed [m/min]

Ener

gy co

nsum

ptio

n pe

r kilo

sliv

er [%

]

650

- 1 400 USD/Jahr

850IPI [x10]

Strength [cN/tex]

Elongation [%]

Disturbing Classimat

faults

97 %

not p

ossi

ble

with

com

petit

ion

100 %

3,4

3,2

15,0

14,6

5,2

39,7

37,6

39,2

5,2

5,2

56,7

14,9

15,0

56,5

14,7

14,9

56,4

3,7 75 %

14 LINK 63 /2013

Influence on Yarn Unevenness due to Spinning SystemModal, Cotton Modal Blend, Viscose, Viscose Polyester Blend, Ne 30

CVm

[%]

100 % CMD 100 % CV50 % CO 11/8" / 50 % CMD 33 % CV / 67 % PES

Ring yarn Air-jet yarn Rotor yarn

TECHNOLOGY

New technological findings with air-jet-spun yarns

Rieter has conducted an extensive study under mill conditions in co-operation with Lenzing and an Indonesian spinning mill. Air-jet-spun yarns in different counts and made from different raw materials and blends were compared with ring-spun and rotor-spun yarns. In addi-tion to yarn properties, their influence on the properties of knitted and woven fabrics was also studied.

The three spinning processes – ring, rotor and air-jet spinning – produce yarns with different structures, from which the physical yarn properties can be de-duced, irrespective of the raw material used and the yarn count.

The proportion of covering fibers increases in air-jet-spun yarns as the yarn count becomes finer. However, it was also apparent that the raw material influences the proportion of covering fibers. The increasing pro-portion of covering fibers does not therefore always result in higher strength, but can affect the hand of the knitted or woven fabric.

Fig. 1 In the short-staple range (staple length 1 cm) the regu-larity of the air-jet-spun yarn lies between that of ring-spun and rotor-spun yarn.

Effect of the spinning process on yarn regularityIt is generally the case that regularity in the short yarn staple length range is lower than long-staple regularity. In the short-staple range the regularity of air-jet-spun yarn lies between that of ring-spun and rotor-spun yarn (Fig. 1). The air-jet-spun yarn per-forms best in terms of long-staple regularity (Fig. 2). Regularity in long yarn staple lengths has a signifi-cant influence on the uniformity of knitted and wo-ven fabrics.

Effect of the raw material and the spinning process on yarn strength and elongationWith the same yarn count and raw material this study also confirmed that ring-spun yarns display the best strength properties compared to rotor-spun and air-jet-spun yarns.

In air-jet spinning the correct choice of raw mate-rial can expand the sphere of application. For exam-ple, blends of cotton with Modal have much the same yarn strength as 100 % viscose.

The elongation properties of all three types of yarn can be at a similar level, depending on raw material and yarn count. For predicting whether trouble-free downstream processing is possible, therefore, par-ticular attention must be paid to the variation range of strength and elongation as well as the strength and elongation of the rare weak zones.

Effect of the raw material and the spinning process on yarn hairiness and abrasionHairiness and abrasion are affected mainly by the spinning process. The raw material also has an influ-ence, of course, especially a high short-fiber content in yarns made from cotton.

Rotor-spun and air-jet-spun yarns display generally lower hairiness and abrasion due to their structure, i.e. fiber incorporation in the yarn bundle.

15,0

14,5

14,0

13,5

13,0

12,5

12,0

11,5

11,0

10,5

10,0

9,5

15LINK 63 /2013

0 1 2 3 4 5 6 7 8 9 10 11

Harald Schwippl

Head Technology Spun Yarn Systems Winterthur harald.schwippl@rieter.com

TECHNOLOGY

Fig. 2 Air-jet-spun yarn performed best in terms of regularity in the long-staple range (staple length ≥ 1 cm).

Fig. 3 Fabrics made from air-jet-spun yarn display the best results in terms of pilling and washing behavior.

Properties in the textile fabricThis study also confirmed that under otherwise iden-tical conditions the fabric hand in the case of air-jet-spun yarn is somewhat harder than ring-spun yarn, but softer than rotor-spun yarn. This is true both for knitted fabrics and for woven fabrics. The hand can also be affected by the choice of raw material.

The spinning process affects yarn diameter under otherwise identical conditions. Diameter and yarn structure affect pile density in knitted and woven fabrics. If knitted fabrics are plated, the differ ences between the various spinning processes are re-duced. The characteristic “longitudinal stripiness” of ring-spun yarn cannot be replicated by either ro-tor-spun or air-jet-spun yarn.

The advantages of air-jet-spun yarn are most clear-ly apparent in the pilling behavior of knitted and woven fabrics. Irrespective of fabric structure and raw material, fabrics made from air-jet-spun yarn are most resistant to fiber sloughing and pilling. The advantages are especially obvious after fre-quent washing, which is clearly illustrated by strik-ing photographs (Fig. 3).

The complete study has been published in an offprint. This can be ordered via marketing.sys@rieter.com, quoting reference “Offprint – air-jet-spun yarns – No. 2559”. 13-306 •

5,0

4,5

4,0

3,5

3,0

2,5

2,0

1,5

1,0

0,5

0

Influence on Yarn Unevenness due to Cut Length100 % Viscose, Ne 30

Woven Fabric – Pilling Test100 % Viscose, 38 mm, 1.3 dtex, Ne 30 Fabric after 2 000 cycles with Martindale test instrument

CVm

1, 3

, 10

m [%

]

Ring yarn Rotor yarnAir-jet yarn

Cut lenght [m]

Ring-spun yarn

Air-jet-spun yarn

16 LINK 63 /2013

PARTS

ECOrized suction tubes – the winnersRieter started the market launch of the energy-saving ECOrized suction tube in mid-April 2013. This was accompanied by the opportunity to take part in a worldwide competition. Rieter ring spinning customers could win a retrofit kit for a complete machine. The 5 winners have now been announced.

Ring spinning customers who requested a quota-tion for retrofitting Rieter ring spinning machines during the months of May and June were able to take part in the competition and win the equipment to retrofit a complete machine with ECOrized suc-tion tubes (Fig. 1). The winners were drawn in Win-terthur in mid-July. Edda Walraf, Head Technology & Marketing, and Kurt Frei, Head Parts & Service, drew the five lucky winners from among the many entrants in the competition (Fig. 2). Equipment for retrofitting a complete ring spinning machine with ECOrized suction tubes is awarded to the following companies:

Fig. 1 Lasting savings can be made in ring spinning with the ECOrized suction tube.

Tipoiti SA Corrientes, Argentina

PT Mulia Spindo Mills Jakarta-Serang, Indonesia

Eveready Spg Mills Pvt Ltd. Thadicombu, India

Almer Tekstil San ve Tic AS Kayseri, Turkey

UZTEX Tashkent JV LLC Tashkent, Uzbekistan

AND THE WINNER IS…

17LINK 63 /2013

PARTS

The official presentations were made on the custom-ers’ premises in formal ceremonies in September and October.

Sustainable use of energyThe economical use of energy is an important con-cern for Rieter. Rieter helps its customers to make the spinning process more energy-efficient with in-novative solutions and products. Energy expenses are significant cost drivers in yarn manufacturing. Any energy saving, however small, has a positive im-pact on production costs. The ECOrized suction tube is just one of these innovative products for energy saving. It reduces the power consumed for extraction on the machine by 50 % and thus lowers energy con-sumption by up to 10 %. This results in significant cost savings.

Retrofit kitsRieter Parts offers retrofit kits for ring spinning ma-chines. The conversion kits for the G 35, G 33 and G 32 ring spinning machines are very simply de-signed so that customers can perform the retrofit themselves with their own qualified personnel. The attractive pricing of the retrofit kits ensures rapid amortization of the investment. Customers’ experi-

Urs Tschanz

Head Sales Support PartsWinterthur urs.tschanz@rieter.com

Fig. 2 Drawing the winners of the ECOrized suction tube competition in Winterthur. Left to right: Edda Walraf, Head Technology & Marketing, and Kurt Frei, Head Parts & Service.

Fig. 3 See the energy-saving potential of the ECOrized suction tube for yourself on the Rieter website.

www.rieter.com/ecorized

ence shows that an investment in the ECOrized suc-tion tube pays off within a few months, resulting in lasting savings in energy and thus lower costs. Rieter customer Baris in Turkey offered to share its expe-rience with the ECOrized suction tube. It is already saving up to 10 % energy and 66 600 US dollars an-nually on its 14 retrofitted ring spinning machines. See for yourself – view the video of comments by Mahmut Kilinç, spinning mill manager at Baris (Fig.  3).

Why not be a winner yourself? Request more informa-tion today from Urs Tschanz at urs.tschanz@rieter.com and start saving money tomorrow. 13-307 •

18 LINK 63 /2013

PARTS

Jörg Feigl

Project Manager Parts Ingolstadt joerg.feigl@rieter.com

CLEANtube – perfect, clean coilingThe optional CLEANtube device on Rieter drawframes enables sliver coiling to be performed without accumulations of trash and short fibers. It was first introduced on the RSB-D 45. Now CLEANtube can also be ret-rofitted on the SB-D 15 and SB-D 40 drawframes without autoleveling and on the RSB-D 35 and RSB-D 40 autoleveler drawframes.

The following effect can occur on the drawframe when cotton or its blends with manmade fibers are being processed: particles of dirt and short cot-ton fibers accumulate in the sliver tube of the coil-er while cans are being filled. The drawframe stops when the can is filled to capacity, and this accumu-lation of material, also known in the industry as the “mouse”, then comes to rest on the top layer of sliv-ers. The larger the trash or short fiber content of the cotton, the larger the mouse (Fig. 1).

If the “mouse” is removed manually, this results in more sliver waste and additional annual working hours.

If the “mouse” is left on the sliver, loss of output and quality in the downstream process are inevitable.

The advantages of CLEANtubeCLEANtube prevents soiling of the sliver coil with ac-cumulations of trash and short fibers, and thus offers the following advantages:

•clean sliver coiling without “mouse” •consistent sliver and yarn quality •up to 300 fewer working hours and approx. 0.6 %

less sliver waste annually per drawframe •improved production efficiency in the downstream

process due to fewer ends down and fewer clear-er cuts

Operation of CLEANtubeCLEANtube provides intelligent control of the coiler which prevents trash particles and short fibers from accumulating in the sliver tube (Fig. 2). It is advisa-ble to convert the entire drafting passage at the same time in order to ensure sliver quality along the whole line. This is an update that pays off. The conversion kit includes various components, such as a coupling unit and a sensor with a magnetic ring, as well as the ap-propriate control software. Conversion takes no more than four hours per drawframe and can be performed by customers’ own qualified personnel. 13-308 •

Fig. 1 Coiling with and without the CLEANtube device.

Fig. 2 This is how CLEANtube works.

http://bit.ly/1fC8ZSb

19LINK 63 /2013

Grace Wu

Supervisor Marketing Communication Shanghai grace.wu@rieter.com

RIETER GLOBAL

The 1st Rieter Com4® yarn seminar China – satisfactory resultThe Rieter Com4® yarn seminar for yarn traders, buyers and sellers took place from June 14 - 15th at Rieter’s Changzhou plant. It was the first Com4® yarn seminar to be held in China following the positive experi-ence made with the global pilot seminar last November in Winterthur (Switzerland).

The seminar focused on the 4 different Com4® yarns, their behavior in further processing as well as typi-cal areas of application and end products. The par-ticipants benefited from Rieter’s leading knowledge in the spinning industry which they can apply in their daily yarn trading business activities.

Useful information for the yarn trading businessThe participants have gained detailed technologi-cal knowledge and practical experience of the 4 yarn spinning systems in the two-day Rieter Com4® yarn seminar China. Their background knowledge of re-spective yarn package design, properties and their influence on the downstream process were widened. They also had the opportunity to see, feel and under-stand the properties of the 4 Com4® yarn final prod-ucts.

The visit to Rieter’s new plant in Changzhou aroused great interest and impressed the participants with “Quality made by Rieter”. The positive feedback from the participants confirms the requirement for a fur-ther such training event. The professional organiza-tion, highly-motivated experts, and well-structured content were highly appreciated. This seminar addi-tionally offered participants the opportunity of social networking in their industry.

Further Com4® yarn seminars are being planned, in Winterthur as well as in India and China.

Fig. 1 Hands-on training at the rotor spinning machine to better understand the major features of Com4®rotor yarn.

Fig. 2 Participants compared fabrics made from 4 different Com4® yarns

Customer statements:“I have learned a lot in this yarn seminar. The pres-entations, especially the animations were very effec-tive and engaged the audience.”

“Thank you for a great seminar. The presenta-tions were well prepared and related to our day-to-day business. I am looking forward to applying the knowledge gained and strengthening the success of the team. A very informative seminar!” 13-309 •

20 LINK 63 /2013

RIETER GLOBAL

What makes a Com4® yarnso successfulIt is crucial to use the right yarn for a specific application. Weavers and knitters can benefit from advantages in the converting process. Positive properties in the end product can be defined in advance. High-quality Com4® yarn coupled with textile know-how automatically results in success.

What matters for the successful textile manufactur-er are the properties provided by the yarn. Com4® yarns have to be considered separately in order to describe the differences between them, and also in comparison to competitors.

Comparing Com4® yarns with each otherThe comparison is divided into yarn properties and properties in downstream processing as well as the appearance of the end product (Fig. 2).

Com4® yarns are way ahead of the competitionA Com4®ring yarn stands out in particular for the consistency and high reproducibility of the yarn quality. The high consistency from spinning position to spinning position and between machines of the same type throughout the service life of the machine gives yarn salespeople and buyers the assurance of dealing in constant yarn quality. This creates confi-dence in follow-up orders.

Com4®compact is characterized by consistent com-pacting results over long periods of use. The long service lives of the compacting elements provide the basis for this. Consistently higher strength values compared to competitors are confirmed in mill op-erations. This is achieved by precise fiber guidance during the compacting process. The know-how and the experience accumulated over decades by Rieter are systematically passed on to customers.

Com4®rotor yarn has great potential for reducing the twist factor, which is a basic precondition for manufacturing textiles with a soft hand. R 60 spin-ning box technology enables yarns to be produced with low yarn twist while at the same time maintain-ing yarn strength and imperfection levels. A small number of piecings is a further distinguishing fea-ture compared to competitors. The optimal running characteristics of the Rieter spinning box result in low ends down frequencies during spinning, which in addition to high efficiency levels in the spinning mill also results in low numbers of ends down and thus high efficiency in downstream processing. The easy implementation of the ideal setting for opti-mized piecings, in terms of both appearance and strength – achieved by intelligent piecing technolo-gy – guarantees yarn-like piecings. The consequence is invisible piecings in the textile fabric compared to competitors’ yarns.

The differing hairiness properties of Com4®jet yarn compared to competitors is due to the different fiber guidance in the spinning process. Fabrics made from Com4®jet yarn display a lower pilling tendency. The major and crucial difference is the piecing process.

Fig. 1 Knowing the correct yarn to use for the required application is a key to success.

21LINK 63 /2013

RIETER GLOBAL

Iris Biermann

Senior Marketing Manager Winterthur iris.biermann@rieter.com

* Depending on yarn count and fiber materialas more “+” as more positiveFig. 2 The different

aspects help to find the most suitable yarn for a specific application. Piecings such as those in Com4®jet can be adjusted

much more easily and precisely in terms of appear-ance and strength. This results in fewer ends down in downstream processing. The yarn splices are invis-ible in the end products.

The complete “Rieter Com4® Yarn” offprint can be ordered via info@rieter.com under the heading of “Com4® off print No. 2562” or downloaded from the Rieter website. 13-309 •

Com4®ring Com4®compact Com4®rotor Com4®jet

Yarn properties

High tenacity +++ ++++ + ++

High work capacity +++ ++++ + ++

Low variation in tenacity* +++ ++++ +++ ++

Reduced long hairiness (S3)* + +++ ++ ++++

High mass evenness* +++ ++++ ++ +++

High optical evenness ++ ++ +++ +++

High volume ++ + ++++ +++

Low tendency for fiber fly + +++ ++ +++

Downstream Effects

Low consumption of size ++ ++++ +++ ++++

Low clinging tendency + ++++ +++ +++

Low dust during processing ++ ++++ +++ ++++

Low yarn breaks during weaving ++ ++++ +++ ++

High weaving insertion speeds +++ ++++ ++ ++

High dye staff utilisation ++ +++ +++ ++++

High strength after finishing processes +++ ++++ + ++

Fabric Appearance

Uniform fabric appearance ++ +++ ++++ ++++

Clear structures (striping, printing) ++ ++++ +++ ++++

Low pilling tendency ++ +++ +++ ++++

High opacity and volume +++ + ++ ++

Soft hand ++++ +++ ++ +++

Good raising behaviors ++ + +++ ++

High water absorption +++ ++ ++++ ++++

High abrasion resistance* +++ ++++ ++++ +++

Reduced spirality ++ + +++ ++++

High fabric strength +++ ++++ + ++

Good luster on fabric surface ++ ++++ + +++

22 LINK 63 /2013

OUR CUSTOMERS

New Com4® licensees – the community is growingThe new Com4® brand for yarns produced on Rieter final spinning ma-chines has been in existence for almost two years. Awareness of Com4® yarns in the global marketplace is growing. New licensees are con-tinuously being added.

Two years ago Rieter decided to launch a new brand concept for the yarns spun on Rieter’s four final spinning machines. The Com4® brand now forms the basis for all four yarns:•Com4®ring – for yarns spun on Rieter ring

spinning machines;•Com4®compact – for yarns spun on Rieter

compact spinning machines;•Com4®rotor – for yarns spun on fully automated

Rieter rotor spinning machines;•Com4®jet – for yarns spun on Rieter air-jet

spinning machines.

The adapted brand strategy ensures a high recogni-tion effect.

Boosting the popularity of the Com4® brand furtherIn the meantime the Com4® brand has a presence in media such as the Internet, trade journals, sym-posia and trade shows. Specific seminars are also conducted, at which Rieter specialists provide sys-tematic training for yarn traders, weavers and knit-ters on the subject of Com4® yarns. These seminars are held in Switzerland, India and China. Licensees

who wish to hold an equivalent seminar themselves on-site with their yarn customers can obtain the as-sistance of specialists from Rieter.

New licenseesLicenses are granted worldwide and in all yarn seg-ments. New licensees joining the Com4® community in recent months include the following:•Adama Development PLC

Ethiopia, Com4®ring;•Arikan Mensucat San ve Tic AS

Turkey, Com4®ring, Com4®compact, Com4®rotor;•Brastex SA

Brazil, Com4®ring, Com4®compact;•Hongyang Holding Group Co. Ltd.

China, Com4®rotor;•Karsu Tekstil Sanayi ve Ticaret AS

Turkey, Com4®jet;•Qingdao St. Meer Group

China, Com4®rotor (Fig. 1);•Shijiazhuang Changshan Textile Co. Ltd.

China, Com4®compact.

All licensees and their contact data are listed in Rieter’s “Licensees and Reference Customers” bro-chure, which is actively distributed at trade shows and symposia, and can also be found on the Rieter website. This is updated at least twice a year.

Easy to joinRieter customers producing yarn with the appropri-ate final spinning machines have the opportunity to conclude a licensing agreement with Rieter. Enquir-ies can be addressed to the relevant sales manager or directly via the Rieter website (Fig. 2). 13-311 •

Fig. 1 Formal presen-tation of the Rieter Com4®rotor certificate in China. Left to right: He Jie, Deputy Director Administration, St. Meer International Industry & Trade Co., Ltd.; Michael Daniels-son, Head Sales Rieter China.

Fig. 2 Applications for Com4® licenses can be submitted via the Rieter website.

http://bit.ly/170URvX

Anja Knick

Senior Marketing ManagerWinterthuranja.knick@rieter.com

23LINK 63 /2013

OUR CUSTOMERS

From our customers’ point of viewRieter customers worldwide spin high-quality yarn. Read here what our customers have to say about it.

“The outstanding properties of Com4®compact yarns, such as high tenacity and low hairiness re-sult in trouble-free down-stream processing.”

M. Hanefi OksuzCEO Kipaş Holding

Kipaş Holding, consisting of 16 companies (Kahramanmaraş İplik Pamuk A.Ş, Kipaş Mensuc-at, Bozkurt Konfeksiyon, Kipaş Denim İşletmeleri, Kahramanmaraş Cimento ve Madencilik, Mipsan Tek-stil, Teksan Tekstil, Keaş, Kipaş Tarım, Kipaş Ozel

“The outstanding piecings of the Rieter Com4®rotor yarns guarantee success – in my own weaving mill and in the weaving mills of my customers.”

Mario Lisandro BertoniFounder and owner of Maliber Ind. e Com. Textil Ltda

Maliber commenced business in March 1977. The company is engaged in spinning, weaving and fin-ishing. Over the years Maliber has become a signifi-cant factor in the Brazilian textile industry. Founder and owner Mario Lisandro Bertoni explains that it is

Eğitim, Karen Enerji, Toymar, Kipaş Pazarlama ve Kipaş Sigorta) enjoys 25 years experience in various fields of industry. As its main mission, Kipaş Holding strives to maintain quality in production, customer satisfac-tion at all stages, respect for the environment and dynamism with innovative investments in advanced technology. As a result, it has become one of the most prestigious groups in Turkey with its companies engag-ing in the fields of textiles, readymade clothing, energy, cement, agriculture and education. 13-312 •

www.kipas.com.tr

only possible to survive in today’s markets with top-class equipment and sound finances. Maliber has a capacitiy to process 950 tons of raw material per month. The yarn count range is from Ne 8 to Ne 30. Most of the material spun is cotton, together with also a small number of viscose and polyester/ cot-ton blends. Maliber consumes 20 % and sells 80 % of its yarn production. Half of which is supplied to weaving mills, the other half is sold to the knitting sector. 13-313 •

www.maliber.com.br

www.rieter.com

Rieter Machine Works Ltd.Klosterstrasse 20CH-8406 WinterthurT +41 52 208 7171F +41 52 208 8320sales.sys@rieter.comparts.sys@rieter.com

Rieter India Private Ltd.Gat No 134/1, Off Pune Nagar RoadKoregaon BhimaTaluka Shirur, District PuneIN-Maharashtra 412216T +91 2137 308 500F +91 2137 308 426

Rieter (China)Textile Instruments Co., Ltd.Shanghai BranchUnit B-1, 6F, Building A,Synnex International Park1068 West Tianshan RoadCN-Shanghai 200335T +86 21 6037 3333F +86 21 6037 3399

Rieter’s customer Baris in Turkey saves 6 kW/hour per ring spinning machine, equivalent to US$ 66 600/year for its entire installation, with the ECOrized suction tube. Read more on page 16.